Multiple stage pyrolysis of recycled PVB of varying compositions

Abstract

It has been discovered that high volumes of valuable recycled content products may be directly derived from waste PVB-containing compositions, such as interlayers, via a chemical recycling system using multiple pyrolysis treatments. More particularly, waste PVB-containing compositions may be subjected to an initial mild pyrolysis step and a subsequent pyrolysis step to thereby yield a variety of desirable recycled content products. Consequently, one can optimize recovery and utilization of recycled content products from waste PVB-containing compositions.

Description

MULTIPLE STAGE PYROLYSIS OF RECYCLED PVB OF VARYING COMPOSITIONSBACKGROUND

[0001] Poly(vinyl butyral) (“PVB”) is commonly used in the manufacture of polymer sheets that can be used as interlayers in light-transmitting laminates, such as safety glass or polymeric laminates. For example, safety glass often refers to a transparent laminate comprising a PVB sheet, or interlayer, disposed between two sheets of glass. Safety glass often is used in automotive and architectural applications as its main function is to absorb energy, such as that caused by a blow from an object, without allowing penetration through the opening or the dispersion of shards of glass, thus minimizing damage or injury to the objects or persons near the glass. Safety glass can also be used to provide other beneficial effects, such as the reduction of ultraviolet (UV) and / or infrared (IR) light transmission, or the enhancement of the appearance and aesthetic appeals of window openings.

[0002] Unfortunately, the widespread use of PVB-containing interlayers has resulted in an overabundance of PVB-containing waste interlayer materials. Due to their non-biodegradable nature, waste interlayer materials can negatively impact the environment when disposed of in landfills. Thus, from an environmental standpoint, it has been desirable to physically recycle as much of these waste interlayer materials as possible.

[0003] Generally, conventional recycling technologies for waste interlayer materials focus on physical recycling techniques that physically separate the glass from the PVB resin, thereby yielding recycled glass and a recycled PVB resin. However, these physical recycling processes are not always economically feasible and / or yield undesirable waste streams that must be disposed of or otherwise handled. Furthermore, these conventional physical recycling processes may suffer operational inefficiencies that do not allow for the efficient recycling of the PVB resins, and the additional materials found therein. Moreover, these conventional recycling processescan require high operation costs, specifically in terms of energy consumption, that may offset any financial benefit of utilizing waste interlayers as a feedstock. Thus, there exists a need for an efficient and economical chemical recycling method for breaking down waste PVB- containing interlayers into desirable recycled content end products.SUMMARY

[0004] In one aspect, the present technology concerns a process of recycling poly(vinyl butyral) (PVB)-containing composition. Generally, the process concerns: (a) pyrolyzing at least a portion of a feedstock comprising a PVB-containing composition in an initial pyrolysis stage to thereby provide an initial pyrolysis effluent and a liquid reaction medium; and (b) pyrolyzing at least a portion of the liquid reaction medium in a subsequent pyrolysis stage to thereby form a subsequent pyrolysis effluent.BRIEF DESCRIPTION OF THE FIGURES

[0005] Embodiments of the present invention are described herein with reference to the following drawing figures, wherein:

[0006] FIG. 1 is a block flow diagram illustrating the main steps of a process and facility for chemically recycling a PVB-containing composition according to embodiments of the present technology; and

[0007] FIG. 2 is a block flow diagram illustrating the main steps of a process and facility for recovering desirable recycled content products from the pyrolysis effluent according to embodiments of the present technology.

[0008] FIG. 3 is a laboratory equipment configuration diagram.DETAILED DESCRIPTION

[0009] We have discovered that PVB-containing waste interlayer materials with varying chemical formulations may be consistently chemically recycled via a pyrolysis process to thereby form valuable recycled content products, which may be recovered from the pyrolysis effluent. More particularly, we have discovered that one or more valuable recycled content products canbe recovered from the pyrolysis of the PVB in waste interlayer materials. Consequently, by utilizing the pyrolysis methods described herein, we can optimize recovery and utilization of recycled content products from PVB- containing waste interlayer materials. Therefore, the waste pyrolysis configuration and process disclosed herein can achieve process efficiencies and logistical simplicity not obtainable in previous recycling iterations for PVB-containing waste interlayer materials.

[0010] Furthermore, we have discovered that the reliance on additional chemical processing facilities upstream of a waste pyrolysis facility may better facilitate the downstream pyrolysis reactions and increase the yield of desired recycled content products from the PVB-containing waste interlayer materials. For example, we have discovered that the incorporation of a mild pyrolysis system upstream of the primary pyrolysis reactor may enhance the yield of desired recycled content products from the PVB-containing waste interlayer materials.

[0011] FIG. 1 depicts an exemplary chemical recycling facility 10 comprising a pyrolysis facility. The chemical recycling facility described herein can effectively pyrolyze a PVB-containing composition into various recycled content products. It should be understood that FIG. 1 depicts one exemplary embodiment of the present technology. Certain features depicted in FIG. 1 may be omitted and / or additional features described elsewhere herein may be added to the system depicted in FIG. 1 . The various process steps are described below in greater detail.Overall Chemical Recycling Facility

[0012] Turning now to FIG. 1 , the main steps of a process for chemically recycling PVB-containing compositions in a chemical recycling facility 10 are shown. Chemical recycling processes and facilities as described herein may be used to convert PVB-containing compositions to recycled content products or chemical intermediates used to form a variety of end use materials. The PVB-containing compositions fed to the chemical recycling facility can be post-consumer PVB-containing compositions,post-industrial PVB-containing compositions, or a combination of two or more thereof. A post-consumer chemical recycling feedstock refers to nonvirgin plastics, polymers, materials, or articles that have been previously introduced into the consumer market. A post-consumer material chemical recycling feedstock has been used at least once for its intended application for any duration of time regardless of wear, or has been sold to an end use customer, or which is discarded into a recycle bin by any person or entity other than a manufacturer or business engaged in the manufacture or sale of the material. A post-industrial chemical recycling feedstock is one which has been manufactured and has not been used for its intended application or has not been sold to the end use customer, or is a material discarded by a manufacturer or any other entity engaged in the sale of the material. Examples of post-industrial materials include rework, regrind, scrap, trim, out of specification materials, and finished materials transferred from a manufacturer to any downstream customer (e.g. manufacturer to wholesaler to distributor) but not yet used or sold to the end use customer. A post-consumer or post-industrial PVB containing feedstock is one which contains PVB polymer.

[0013] In an embodiment or in combination with any embodiment mentioned herein, the chemical recycling facility may be a commercial-scale facility capable of processing significant volumes of PVB-containing compositions. As used herein, the term “commercial scale facility” refers to a facility having an average annual feed rate of at least 500 pounds per hour, averaged over one year.

[0014] In an embodiment or in combination with any embodiment mentioned herein, two or more of the facilities of the chemical recycling facility, such as the liquification facility, the pyrolysis facility, and the feedstock source, may be co-located with one another. As used herein, the term “co-located” refers to facilities in which at least a portion of the process streams and / or supporting equipment or services are shared between the two facilities. When two or more of the facilities are co-located, the facilities may meet at least one of the following criteria (i) through (v): (i) the facilities share at leastone non-residential utility service; (ii) the facilities share at least one service group; (iii) the facilities are owned and / or operated by parties that share at least one property boundary; (iv) the facilities are connected by at least one conduit configured to carry at least one process material (e.g., solid, liquid and / or gas fed to, used by, or generated in a facility) from one facility to another; and (v) the facilities are within 40, within 35, within 30, within 20, within 15, within 12, within 10, within 8, within 5, within 2, or within 1 mile of one another, measured from their geographical center. At least one, at least two, at least three, at least four, or all of the above statements (i) through (v) may be true.

[0015] Regarding (i), examples of suitable utility services include, but are not limited to, steam systems (co-generation and distribution systems), cooling water systems, heat transfer fluid systems, plant or instrument air systems, nitrogen systems, hydrogen systems, non-residential electrical generation and distribution, including distribution above 6900V, non- residential wastewater / sewer systems, storage facilities, transport lines, flare systems, and combinations thereof.

[0016] Regarding (ii), examples of service groups and facilities include, but are not limited to, emergency services personnel (fire and / or medical), a third-party vendor, a state or local government oversight group, and combinations thereof. Government oversight groups can include, for example, regulatory or environmental agencies, as well as municipal and taxation agencies at the city, county, and state level.

[0017] Regarding (iii), the boundary may be, for example, a fence line, a property line, a gate, or common boundaries with at least one boundary of a third-party owned land or facility.

[0018] Regarding (iv), the conduit may be a fluid conduit that carries a gas, a liquid, a solid / liquid mixture (e.g., slurry), a solid / gas mixture (e.g., pneumatic conveyance), a solid / liquid / gas mixture, or a solid (e.g., belt conveyance). In some cases, two units may share one or more conduits selected from the above list.

[0019] Turning again to FIG. 1 , a chemical recycling feedstock comprising one or more PVB-containing compositions may be introduced into the chemical recycling facility from a feedstock source. As used herein, the term “PVB-containing compositions” refer to used, scrap, and / or discarded PVB- containing compositions and articles in any form, such as waste PVB- containing compositions typically sent to a landfill, including post-consumer and post-industrial PVB. The PVB-containing compositions may be pretreated prior to pyrolysis. The pre-treatment of feedstock may be conducted at the pyrolysis facility, or at a supplier’s facility or by the supplier and supplied by the supplier to the pyrolysis facility as a pre-treated or pre-sorted feedstock.

[0020] The chemical recycling feedstock fed to the chemical recycling facility may include unprocessed or partially processed PVB-containing compositions. As used herein, the term “unprocessed PVB-containing composition” means PVB-containing compositions that have not be subjected to any automated or mechanized sorting, washing, or comminuting. Partially processed PVB-containing compositions may originate from, for example, reclaimers. In an embodiment or in combination with any embodiment mentioned herein, the PVB-containing compositions may comprise a post-industrial PVB-containing composition and / or a postconsumer PVB-containing composition.

[0021] In an embodiment or in combination with any embodiment mentioned herein, all or a portion of the PVB-containing composition in the chemical recycling feedstock can originate from a reclaimer facility that recovers glass from discarded and scrap glass laminates containing PVB interlayers.

[0022] As used herein, the term “chemical recycling feedstock” refers to the total feedstock fed into the chemical recycling facility and encompasses all feedstock streams that are introduced into the chemical recycling facility.

[0023] As shown in FIG. 1 , the chemical recycling facility 10 may contain a feed system 12 for introducing the chemical recycling feedstock comprising a PVB-containing composition, such as a solid PVB resin, into the facility.The feed system 12 can be any conventional feed system for handling a solid particulate feed, such as a screw feeder or a belt conveyance system.

[0024] In an embodiment or in combination with any embodiment mentioned herein, the chemical recycling feedstock fed into the chemical recycling facility and / or the pyrolysis reactor may comprise a PVB-containing composition in an amount of at least 25, at least 50, at least 60, at least 65, at least 70, at least 75, at least 80, at least 85, at least 90, at least 95, or at least 99 weight percent, based on the total weight of the chemical recycling feedstock. Additionally, or in the alternative, the chemical recycling feedstock fed into the pyrolysis reactor may comprise less than 99, less than 95, less than 90, less than 85, less than 80, less than 75, or less than 70 weight percent PVB-containing compositions, based on the total weight of the chemical recycling feedstock stream.

[0025] In an embodiment or in combination with any embodiment mentioned herein, the chemical recycling feedstock fed into the chemical recycling facility consists essentially of or consists of at least 1 , 2, 3, 4, 5, 6, or 7 different PVB -containing compositions. The differences between the PVB-containing compositions can be in the amount or type of plasticizer, the degree of total substitution, or the degree of -OH, -acetaldehyde moieties, butyraldehyde moieties, or metal content.

[0026] In an embodiment or in combination with any embodiment mentioned herein, the chemical recycling feedstock fed into the pyrolysis reactor comprises at least 3 different PVB-containing compositions.

[0027] In an embodiment or in combination with any embodiment mentioned herein, the chemical recycling feedstock fed to the pyrolysis reactor comprises less than 10, less than 5, less than 2, less than 1 , less than 0.5, or less than 0.1 weight percent of glass, based on the total weight of the stream. However, an advantage of the chemical recycling facility of the invention over a mechanical recycling process is the capability of the pyrolysis reactor to tolerate a chemical recycling feedstock containing glass. Accordingly, on one embodiment, the chemical recycling feedstock contains at least 0.1 wt.%, or at least 0.5 wt.%, or at least 1 wt.%, or at least 1 .5 wt.%,or at least 2 wt.%, or at least 2.5 wt.%, or at least 3 wt.%, or at least 4 wt.%, or at least 5 wt.% glass, based on the weight of the feedstock stream(s) fed to the pyrolysis reactor.

[0028] In an embodiment or in combination with any embodiment mentioned herein, the chemical recycling feedstock comprises less than 10, less than 5, less than 2, less than 1 , less than 0.5, or less than 0.1 weight percent of halogenated plastics, such as polyvinyl chloride, based on the total weight of the feedstock stream(s) fed to the pyrolysis reactor.

[0029] In an embodiment or in combination with any embodiment mentioned herein, the chemical recycling feedstock comprises less than 10, less than 5, less than 2, less than 1 , less than 0.5, or less than 0.1 weight percent of a polyolefin (e.g., polypropylene and / or polyethylene) and / or a polyester (e.g., polyethylene terephthalate), based on the total weight of the feedstock stream(s) fed to the pyrolysis reactor.

[0030] In an embodiment or in combination with any embodiment mentioned herein, the chemical recycling facility does not include, or is not preceded by, a co-located plastic sortation facility that separates PVB from polyolefins, nylons, and polyesters and that produces a PVB rich stream containing at least 60 wt.% PVB.

[0031] In one embodiment or in combination with any of the mentioned embodiments, the chemical recycling feedstock comprises not more than 20, not more than 15, not more than 12, not more than 10, not more than 8, not more than 6, not more than 5, not more than 4, not more than 3, not more than 2, or not more than 1 weight percent of biowaste materials, based on the total weight of the stream. As used herein, the term “biowaste” refers to material derived from living organisms. Exemplary biowaste materials include, but are not limited to, cotton, wood, saw dust, food scraps, animals and animal parts, plants and plant parts, and manure.

[0032] In an embodiment or in combination with any embodiment mentioned herein, the PVB-containing composition may comprise one or more thermoplastic polymers in addition to the PVB or instead of the PVB. Examples of suitable thermoplastic polymers can include, but are not limitedto, polyesters such as polyethylene terephthalate (PET), optionally modified with modifiers such as DEG and IPA and copolyesters containing terephthalyl moieties, aliphatic based polyesters, poly(vinyl acetal) resins, polyurethanes (PU), poly(ethylene-co-vinylacetate) (EVA), polyvinyl chlorides (PVC), poly(vinylchloride-co-methacrylate), polyethylenes, polyolefins, ethylene acrylate ester copolymers, poly(ethylene-co-butyl acrylate), silicone elastomers, epoxy resins, acid copolymers (e.g., ethylene / carboxylic acid copolymers and ionomers thereof), or combinations thereof.

[0033] When the PVB-containing compositions described herein include PVB resins, the PVB resins can be formed according to any suitable method. PVB resins can be formed by acetalization of polyvinyl alcohol with one or more aldehydes in the presence of an acid catalyst. The resulting resin can then be separated, stabilized, and dried according to known methods such as, for example, those described in U.S. Patent Nos. 2,282,057 and 2,282,026, as well as Wade, B. 2016, Vinyl Acetal Polymers, Encyclopedia of Polymer Science and Technology. 1 -22 (online, copyright 2016 John Wiley & Sons, Inc.), the disclosures of which are incorporated herein by reference in their entireties. The resulting PVB resins may have a total percent acetalization of at least 50, at least 60, at least 70, at least 75, at least 80, or at least 85 weight percent, as measured according to ASTM D-1396, unless otherwise noted. The total amount of aldehyde residues in the PVB resin can be collectively referred to as the acetal component, with the balance of the PVB resin being residual vinyl alcohol (hydroxyl) and residual acetate groups, which will be discussed in further detail below.

[0034] In an embodiment or in combination with any embodiment mentioned herein, the PVB resin in the PVB-containing composition can be a poly(vinyl n-butyral) resin that mainly comprises residues of butyraldehyde, and may, for example, include not more than 50, not more than 40, not more than 30, not more than 20, not more than 10, not more than 5, or not more than about 2 weight percent of residues of an aldehyde other than butyraldehyde, based on the total weight of all aldehyde residues of the resin.

[0035] In an embodiment or in combination with any embodiment mentioned herein, the molecular weight of the PVB resins in the PVB-containing composition can be at least 50,000, at least 70,000, or at least 100,000 Daltons and / or not more than 800,000, not more than 550,000, not more than 500,000, not more than 450,000, or not more than 425,000 Daltons, as measured by size exclusion chromatography using low angle laser light scattering (SEC / LALLS) method of Cotts and Ouano. As used herein, the term “molecular weight” refers to weight average molecular weight (Mw). The molecular weight of the PVB resin can be in the range of from about 50,000 to about 600,000, about 70,000 to about 450,000, or about 100,000 to about 425,000 Daltons.

[0036] In an embodiment or in combination with any embodiment mentioned herein, the PVB-containing composition in the chemical recycling feedstock may comprise at least 1 , at least 5, at least 10, at least 25, at least 50, at least 60, at least 70, at least 80, at least 85, at least 90, at least 95, or at least 98 weight percent of a PVB resin, based on the total weight of the PVB-containing composition.

[0037] In an embodiment or in combination with any embodiment mentioned herein, the chemical recycling feedstock may comprise at least two different PVB-containing compositions including at least a first PVB-containing composition and a second PVB-containing composition, with the first PVB- containing composition having a different PVB content relative to the second PVB-containing composition. For example, the difference between the PVB content of the first PVB-containing composition and the second PVB- containing composition may be at least 2, at least 5, at least 10, at least 12, at least 15, at least 20, or at least 30 weight percent. As used herein, the term “weight percent different” or “the difference . . . is at least . . . weight percent” refers to a difference between two given weight percentages, calculated by subtracting the one number from the other.

[0038] In an embodiment or in combination with any embodiment mentioned herein, the PVB-containing composition may comprise two or more PVB resins having different compositions. For example, in some embodiments,one or both of the outer skin layers of an interlayer forming the PVB- containing composition may be formed from a first PVB resin, while the core or inner layer can be formed from a second PVB resin. In such embodiments, the first PVB resin used to form the outer layers can have a residual polyvinyl alcohol content and / or residual acetate content that is at least 2, at least 3, at least 4, at least 5, at least 6, or at least 8 weight percent higher or lower than the residual polyvinyl alcohol content and / or residual acetate content of the second PVB resin used to form the inner layer.

[0039] As used herein, the terms “residual polyvinyl alcohol content” and “residual acetate content” refer to the amount of hydroxyl and acetate groups, respectively, that remain on a resin after processing is complete. For example, polyvinyl n-butyral can be produced by hydrolyzing polyvinyl acetate to polyvinyl alcohol, and then acetalizing the polyvinyl alcohol (“PVOH”) with butyraldehyde to form polyvinyl n-butyral. In the process of hydrolyzing the polyvinyl acetate, not all of the acetate groups are converted to hydroxyl groups, and residual acetate groups remain on the resin. Similarly, in the process of acetalizing the polyvinyl alcohol, not all of the hydroxyl groups are converted to acetal groups, which also leaves residual hydroxyl groups on the resin. As a result, most poly(vinyl acetal) resins include both residual PVOH groups (as vinyl hydroxyl groups) and residual acetate groups (as vinyl acetate groups) as part of the polymer chain. The residual PVOH content and residual acetate content are expressed in weight percent, based on the weight of the polymer resin, and are measured according to ASTM D-1396, unless otherwise noted.

[0040] In an embodiment or in combination with any embodiment mentioned herein, the PVB-containing composition may comprise a percent residual polyvinyl alcohol (PVOH) content of at least 8, at least 9, at least 9.5, at least 10, at least 10.5, at least 11 , at least 11 .5, at least 12, at least 12.5, at least13, at least 13.5, at least 14, at least 14.5, at least 15, at least 15.5, at least16, at least 16.5, at least 17, at least 17.5, at least 18, at least 18.5, at least19, at least 19.5, at least 20, at least 25, at least 26, at least 30, at least 32, at least 35, at least 40, at least 50, at least 60, at least 70, at least 80, or atleast 90 percent and / or not more than 100, not more than 90, not more than 80, not more than 70, not more than 60, not more than 50, not more than40, not more than 35, not more than 32, not more than 30, not more than25, not more than 22, not more than 20, not more than 19, not more than18, not more than 17, not more than 16, not more than 15, not more than14, not more than 13, not more than 12, not more than 1 1 , not more than10, not more than 9, or not more than 8 percent. For example, the PVB- containing composition may comprise a percent residual polyvinyl alcohol (PVOH) content in the range of from about 14 to about 45, about 16 to about 30, about 18 to about 25, about 18.5 to about 20, or about 19.5 to about 21 weight percent.

[0041] In an embodiment or in combination with any embodiment mentioned herein, the chemical recycling feedstock may comprise at least two different PVB-containing compositions including at least a first PVB-containing composition and a second PVB-containing composition, with the first PVB- containing composition having a different residual PVOH content relative to the second PVB-containing composition. For example, the difference between the residual PVOH content of the first PVB-containing composition and the second PVB-containing composition may be at least 2, at least 5, at least 10, at least 12, at least 15, at least 20, or at least 30 weight percent.

[0042] In an embodiment or in combination with any embodiment mentioned herein, the PVB-containing composition may comprise a residual acetate content of at least 5, at least 8, at least 10, at least 12, at least 14, at least16, at least 18, at least 20, or at least 30 weight percent and / or less than 90, less than 80, less than 70, or less than 60 weight percent.

[0043] In an embodiment or in combination with any embodiment mentioned herein, the chemical recycling feedstock may comprise at least two different PVB-containing compositions including at least a first PVB-containing composition and a second PVB-containing composition, with the first PVB- containing composition having a different residual acetate content relative to the second PVB-containing composition. For example, the difference between the residual acetate content of the first PVB-containingcomposition and the second PVB-containing composition may be at least 2, at least 5, at least 10, at least 12, at least 15, at least 20, or at least 30 weight percent and / or not more than 15, not more than 13, not more than 1 1 , not more than 9, not more than 8, not more than 6, not more than 5, not more than 4, not more than 3, not more than 2, not more than 1 , or not more than 0.5 weight percent.

[0044] In an embodiment or in combination with any embodiment mentioned herein, the PVB-containing composition may comprise at least one plasticizer. For example, the PVB-containing composition may comprise at least 1 , at least 5, at least 10, at least 15, at least 20, at least 25, at least 30, at least 35, at least 40, at least 45, at least 50, at least 55, at least 60, at least 65, at least 70, at least 75, at least 80, at least 85, or at least 90 phr and / or not more than 100, not more than 90, not more than 85, not more than 80, not more than 75, not more than 70, not more than 65, not more than 60, not more than 55, not more than 50, not more than 45, not more than 40, not more than 35, not more than 30, not more than 25, not more than 20, not more than 15, not more than 10 phr, not more than 5, not more than 4, not more than 3, not more than 2, not more than 1 , not more than 0.5, or not more than 0.1 of at least one plasticizer. As used herein, the term “parts per hundred parts of resin” or “phr” refers to the amount of plasticizer present as compared to one hundred parts of resin, on a weight basis.

[0045] In an embodiment or in combination with any embodiment mentioned herein, the chemical recycling feedstock may comprise at least two different PVB-containing compositions including at least a first PVB-containing composition and a second PVB-containing composition, with the first PVB- containing composition having a different plasticizer content relative to the second PVB-containing composition. For example, the difference between the plasticizer content of the first PVB-containing composition and the second PVB-containing composition may be at least 2, at least 5, at least 10, at least 12, at least 15, at least 20, or at least 30 phr and / or not more than 15, not more than 13, not more than 1 1 , not more than 9, not more than8, not more than 6, not more than 5, not more than 4, not more than 3, not more than 2, not more than 1 , not more than 0.5, or not more than 0.1 phr.

[0046] In an embodiment or in combination with any embodiment mentioned herein, the plasticizer can be triethylene glycol bis (2-ethylhexanoate) (“TEG-EH”), triethyleneglycol-di-2ethylbutyrate, triethylene glycol diheptanoate, tetraethylene glycol diheptanoate, tetraethylene glycol di-(2- ethylhexanoate) (“4GEH”), dioctyl adipate, hexyl cyclohexyladipate, diisononyl adipate, heptylnonyl adipate, di(butoxyethyl) adipate, dihexyladipate, dibutylsebacate, triethylene glycol di-(2-ethylhexanoate) (“3GEH”), dioctyl sebacate, bis-(methoxyethyl)terephthalate, bis-(butoxyethyl)terephthalate, bis-(butoxyethoxyethyl)terephthalate, bis-(ethoxyethyl)terephthalate, bis-(ethoxyethoxyethyl)terephthalate, bis-(2- ethylhexyloxyethyl)terephthalate, bis-(2-ethylhexyl)iso-phthalate, ethoxyethoxyethyl benzoate, butoxyethoxyethyl benzoate, butoxyethoxyethoxyethyl benzoate, dipropylene glycol di-o-toluate, or a combination of two or more thereof.

[0047] In an embodiment or in combination with any embodiment mentioned herein, the chemical recycling feedstock may comprise at least two different PVB-containing compositions including at least a first PVB-containing composition and a second PVB-containing composition, with the first PVB- containing composition having a different plasticizer relative to the second PVB-containing composition. Alternatively, the first PVB-containing composition and the second PVB-containing composition may have the same plasticizer.

[0048] In an embodiment or in combination with any embodiment mentioned herein, the PVB-containing composition may comprise less than 10, less than 5, less than 4, less than 3, less than 2, less than 1 , or less than 0.5 weight percent of glass, frit, UV stabilizers, pigments, adhesion control agents, antioxidants, rubber, silicates, or a combination of two or more thereof, based on the total weight of the PVB-containing composition.

[0049] In an embodiment or in combination with any embodiment mentioned herein, the PVB-containing composition may comprise at least 0.01 , at least0.1 , or at least 0.5 and / or less than 10, less than 5, less than 4, less than 3, less than 2, or less than 1 weight percent of glass, based on the total weight of the PVB-containing composition.

[0050] Generally, at least a portion of the glass (e.g., glass particles) may be at least partially embedded and / or adhered to the PVB resin.

[0051] Generally, the concentration of solid contaminants in the PVB- containing composition can be measured via an alcohol dissolution test where the PVB resin and plasticizer will dissolve in the designated alcohol, while the solid contaminants will not dissolve. In an embodiment or in combination with any embodiment mentioned herein, the PVB-containing composition may comprise at least 0.01 , at least 0.1 , at least 0.2, at least 0.3, at least 0.4, at least 0.5, at least 1 , at least 1 .5, at least 2, at least 2.5, at least 3, at least 3.5, at least 4, at least 4.5, or at least 5 weight percent of one or more substantially non-soluble components that are not substantially soluble in an alcohol, based on the total weight of the PVB-containing composition. Additionally, or in the alternative, the PVB-containing composition may comprise less than 50, less than 40, less than 30, less than 25, less than 20, less than 15, less than 10, less than 9, less than 8, less than 7, less than 6, less than 5, less than 4, less than 3, less than 2, or less than 1 weight percent of one or more substantially non-soluble components that are not substantially soluble in an alcohol, based on the total weight of the PVB-containing composition. Generally, the alcohol can be ethanol.

[0052] In an embodiment or in combination with any embodiment mentioned herein, the substantially non-soluble components are not soluble in ethanol and may comprise glass, metal, a polymer, a salt, a silicate, calcium, a calcium derivative, a sodium derivative, or combinations thereof.

[0053] Generally, in one or more embodiments, the non-soluble components may comprise at least one polymer, such as polyolefin, a polyester, a rubber, a polyamide, a polystyrene, or a combination of two or more thereof. In an embodiment or in combination with any embodiment mentioned herein, the PVB-containing composition may comprise at least0.01 , at least 0.1 , at least 0.2, at least 0.3, at least 0.4, at least 0.5, at least 1 , at least 1 .5, at least 2, at least 2.5, at least 3, at least 3.5, at least 4, at least 4.5, or at least 5 weight percent of at least one non-soluble polymer. Additionally, or in the alternative, the PVB-containing composition may comprise less than 50, less than 40, less than 30, less than 25, less than 20, less than 15, less than 10, less than 9, less than 8, less than 7, less than 6, less than 5, less than 4, less than 3, less than 2, or less than 1 weight percent of at least one non-soluble polymer. The polymers that are substantially non-soluble in alcohol (e.g., ethanol) may be derived from packaging materials, recycled windshields, and / or mounting materials.

[0054] In an embodiment or in combination with any embodiment mentioned herein, the PVB-containing composition may comprise at least 0.01 , at least 0.1 , at least 0.2, at least 0.3, at least 0.4, at least 0.5, at least 1 , at least 1 .5, at least 2, at least 2.5, at least 3, at least 3.5, at least 4, at least 4.5, or at least 5 weight percent of rubber. Additionally, or in the alternative, the PVB- containing composition may comprise less than 50, less than 40, less than 30, less than 25, less than 20, less than 15, less than 10, less than 9, less than 8, less than 7, less than 6, less than 5, less than 4, less than 3, less than 2, or less than 1 weight percent of rubber.

[0055] In an embodiment or in combination with any embodiment mentioned herein, the PVB-containing composition may comprise at least 0.01 , at least 0.1 , at least 0.2, at least 0.3, at least 0.4, at least 0.5, at least 1 , at least 1 .5, at least 2, at least 2.5, at least 3, at least 3.5, at least 4, at least 4.5, or at least 5 weight percent of glass, metal, a salt, a silicate, calcium, a calcium derivative, a sodium derivative, or combinations thereof. Additionally, or in the alternative, the PVB-containing composition may comprise less than 50, less than 40, less than 30, less than 25, less than 20, less than 15, less than 10, less than 9, less than 8, less than 7, less than 6, less than 5, less than 4, less than 3, less than 2, or less than 1 weight percent of glass, metal, a salt, a silicate, calcium, a calcium derivative, a sodium derivative, or combinations thereof.

[0056] In an embodiment or in combination with any embodiment mentioned herein, the PVB-containing composition may comprise less than 10, less than 5, less than 4, less than 3, less than 2, or less than 1 weight percent of glass, based on the total weight of the PVB-containing composition.

[0057] The amount of non-soluble components in the PVB-containing composition may be measured by combining 20 grams of the PVB- containing composition with 200 mL of 190 proof ethanol in a stirred vessel at room temperature (~23°C) and subjecting the mixture to stirring for four hours. The resulting solution is then screened with a strainer (25 to 30 mesh). The varnish allowed to dry via evaporation in a ventilated hood until no weight loss is detectable. Subsequently, the material is further dried in an oven at 50°C for two hours. The dry material is analyzed using a ICP- OES analysis.

[0058] Additionally or alternatively, the amount of solid contaminants may also be measured by ascertaining the ash content of the PVB-containing compositions via ASTM E1534-93 (2019).

[0059] The analysis of the carbon residue can be performed according to ASTM D4530 - Micro Carbon Residue Test.

[0060] In an embodiment or in combination with any embodiment mentioned herein, the PVB-containing composition may comprise at least 0.01 , at least 0.1 , at least 0.2, at least 0.3, at least 0.4, at least 0.5, at least 1 , at least 1 .5, at least 2, at least 2.5, at least 3, at least 3.5, at least 4, at least 4.5, or at least 5 weight percent of ash content as measured according to ASTM D5630-13, based on the total weight of the PVB-containing composition. Additionally, or in the alternative, the PVB-containing composition may comprise less than 50, less than 40, less than 30, less than 25, less than 20, less than 15, less than 10, less than 9, less than 8, less than 7, less than 6, less than 5, less than 4, less than 3, less than 2, less than 1 , or less than 0.5 weight percent of ash content as measured according to ASTM D5630- 13, based on the total weight of the PVB-containing composition.

[0061] Examples of suitable PVB-containing compositions for use in the chemical recycling facility described herein can include, but are not limitedto, post-industrial PVB-containing scrap and / or post-consumer PVB- containing size reduced flakes, particles, shreds, or comminuted PVB obtained from used consumer applications, including but not limited to transportation (e.g. windshield, side and rear windows), architectural, photovoltaics, LED’s, artistic expressions, and skylights. Exemplary postindustrial PVB-containing compositions can include, for example, PVB scrap, cracked laminated glass, off-grade PVB resin, over-sized material from PVB production, or a combination of two or more thereof. The PVB- containing compositions, whether post-consumer or post-industrial or both, may also include metals and other polymers, such as a polymer film (e.g. polyester) having a spectrally-selective metallic coating, such as obtained from solar controlled post-consumer glass having a polymer film with a spectrally-selective metallic coating either encapsulated between layers of PVB, between the PVB film and the glass, or applied as an outer surface layer to glass. The PVB-containing compositions may also include glazing and colorants. Such materials can be obtained from glass panels that contain PVB coated or infused with glazing for solar absorbing, thermal control, sound damping, or coloring applications. The PVB-containing compositions may also include UV absorbing compounds and polymers.

[0062] Specific embodiments of PVB-containing compositions (in the form of interlayers) are described in detail in PCT Patent Application Publication No. WO 2021 / 127206 and U.S. Patent Application Publication No. 2017 / 0285339, the entireties of which are incorporated herein by reference to the extent not inconsistent with the present disclosure.

[0063] Generally, the formulation of the PVB-containing composition may vary over time depending on the source of the PVB-containing composition. For example, the amount of the PVB resin, the plasticizer, and / or the solid contaminants (e.g., glass, rubber, etc.) may vary with each PVB-containing composition introduced into the chemical recycling facility.

[0064] In an embodiment or in combination with any embodiment mentioned herein, one or more of the following criteria may be applicable to the PVB- containing composition being introduced into the chemical recycling facility:(i) the amount of the PVB resin in the PVB-containing composition varies by at least 2 weight percent over time, (ii) the amount of the plasticizer in the PVB-containing composition varies by at least 2 phr over time, (iii) the amount of the solid contaminants in the PVB-containing composition varies by at least 2 weight percent over time, or (iv) the ratio of the PVB resin to the plasticizer varies by at least 2 percent by weight over time. In many cases, at least two, at least three, or all four of the criteria are met. This can be due to the variance of the source that the PVB-containing composition is derived from.

[0065] As discussed above, the composition of the PVB-containing composition being fed into the chemical recycling facility may vary depending on its source. However, the chemical recycling facility may be designed with sufficiently broad flexibility to accommodate this variance.

[0066] In an embodiment or in combination with any embodiment mentioned herein, the amount of the PVB resin in the PVB-containing composition varies by at least 2, at least 3, at least 4, at least 5, at least 6, at least 7, at least 8, at least 9, at least 10, at least 1 1 , at least 12, at least 13, at least 14, or at least 15 weight percent and / or less than 25 weight percent over a time period of 1 hour, 6 hours, 12 hours, 18 hours, 1 day, 2 days, 3 days, 4 days, or one week. As noted above, this difference can be calculated based on the difference between two given weight percentages at the designated time period, calculated by subtracting one number from the other.

[0067] In an embodiment or in combination with any embodiment mentioned herein, the amount of the plasticizer in the PVB-containing composition varies by at least 2, at least 3, at least 4, at least 5, at least 6, at least 7, at least 8, at least 9, at least 10, at least 1 1 , at least 12, at least 13, at least 14, or at least 15 phr and / or less than 25 phr over a time period of 1 hour, 6 hours, 12 hours, 18 hours, 1 day, 2 days, 3 days, 4 days, or one week. As noted above, this difference can be calculated based on the difference between two given phr values at the designated time period, calculated by subtracting one number from the other.

[0068] In an embodiment or in combination with any embodiment mentioned herein, the amount of the solid contaminants in the PVB-containing composition varies by at least 2, at least 3, at least 4, at least 5, at least 6, at least 7, at least 8, at least 9, at least 10, at least 1 1 , at least 12, at least 13, at least 14, or at least 15 weight percent and / or less than 25 weight percent over a time period of 1 hour, 6 hours, 12 hours, 18 hours, 1 day, 2 days, 3 days, 4 days, or one week. As noted above, this difference can be calculated based on the difference between two given weight percentages at the designated time period, calculated by subtracting one number from the other.

[0069] In an embodiment or in combination with any embodiment mentioned herein, the ratio of the PVB resin to the plasticizer in the PVB-containing composition varies by at least 2, at least 3, at least 4, at least 5, at least 6, at least 7, at least 8, at least 9, at least 10, at least 1 1 , at least 12, at least 13, at least 14, or at least 15 percent and / or less than 25 percent over a time period of 1 hour, 6 hours, 12 hours, 18 hours, 1 day, 2 days, 3 days, 4 days, or one week. As noted above, this difference can be calculated based on the difference between two given ratio values at the designated time period, calculated by subtracting one number from the other.

[0070] The above variance measurements can be measured by sampling the PVB-containing composition at the designated time periods (e.g., at one week). To create consistent measurements, a 20-gram sample of the PVB- containing composition may be obtained and tested as discussed above via the solubility analysis.Optional Feedstock Preprocessing

[0071] Although not depicted in FIG. 1 , the chemical recycling facility 10 may include an optional preprocessing facility that can prepare the PVB- containing composition for the downstream recycling processes. While in the optional preprocessing facility, the PVB-containing composition may undergo one or more preprocessing steps to prepare it for chemical recycling. As used herein, the term “preprocessing facility” refers to a facilitythat includes all equipment, lines, and controls necessary to carry out the preprocessing of the PVB-containing composition. Preprocessing facilities as described herein may employ any suitable method for carrying out the preparation of the PVB-containing composition for chemical recycling using one or more of following steps, which are described in further detail below. Alternatively, in certain embodiments, the chemical recycling facility may not contain a preprocessing facility and the chemical recycling feedstock is not subjected to any preprocessing before any of the downstream chemical recycling steps described herein.

[0072] While in the preprocessing facility, the chemical recycling feedstock may undergo one or more processing steps to prepare it for chemical recycling. As used herein, the term “preprocessing” refers to preparing the PVB-containing composition for chemical recycling using one or more of the following steps: (i) comminuting; (ii) particulating; (iii) washing; (iv) drying; and (v) separation. “Pre-processing” does not refer to a plastic sortation facility for separating mixed plastic waste into a PVB rich stream and other streams concentrated in one or more of polyolefins, nylons, or polyester polymers. The chemical recycling feedstock and the PVB-containing feedstock may be fed to the pyrolysis reactor as solid particles, dried or wet, or as a slurry, or as a liquid, molten or solvated in a solvent.

[0073] In an embodiment or in combination with any embodiment mentioned herein, at least a portion of the PVB-containing composition may undergo a size-reduction treatment while in the preprocessing facility. For instance, the feedstock may be subjected to a mechanical size reduction operation, such as grinding / granulating, shredding, guillotining, chopping, or other comminuting process to provide PVB-containing composition particles having a reduced size. Such mechanical size reduction operations can include a size reduction step other than crushing and / or compacting.

[0074] In an embodiment or in combination with any embodiment mentioned herein, after the size-reduction treatment, the PVB-containing composition may comprise solid particles having a D90 diameter of at least 0.01 , at least 0.05, at least 0.1 , at least 0.2, at least 0.3, at least 0.4, at least 0.5, at least1 , or at least 2 inches and / or not more than 5, not more than 4, not more than 3, not more than 2, or not more than 1 inches. As used herein, the term “D90” refers to a specified diameter where ninety percent of a distribution of particles has a smaller diameter than the specified diameter and ten percent has a larger diameter than the specified diameter. To ensure that a representative D90 value is obtained, the sample size of the particles should be at least one pound. To determine a D90 for particles in a continuous process, testing should be performed on at least 5 samples that are taken at equal time intervals over at least 24 hours. Testing for D90 is performed using high-speed photography and computer algorithms to generate a particle size distribution. One suitable particle size analyzer for determining D90 values is the Model CPA 4-1 Computerized Particle Analyzer from W.S Tyler of Mentor, Ohio.Liquification System (Dehydration, Liquification, and Pyrolysis)

[0075] As shown in FIG. 1 , the chemical recycling feedstock may be introduced into a liquification system 14 prior to being introduced into the pyrolysis reactor 16, where it can be at least partially subjected to dehydration, liquification, and pyrolysis. As used herein, “dehydration” refers to chemical processing in which at least a portion of the water present in the PVB-containing composition is removed. As used herein, the term “liquification” refers to chemical processing in which at least a portion of the incoming stream is liquefied. The step of liquefying the PVB-containing composition can include dehydration, chemical liquification, physical liquification, or combinations thereof. Exemplary methods of liquefying the PVB-containing composition introduced in the liquification system can include: (i) heating / melting (thereby forming a “molten” stream); (ii) dissolving in a solvent; (iii) depolymerizing; (iv) plasticizing; and combinations thereof. Additionally, one or more of options (i) through (iv) may also be accompanied by the addition of a blending or liquification agent to help facilitate the liquification (reduction of viscosity) of the polymer material. As such, a variety of rheology modification agents (e.g., solvents,depolymerization agents, plasticizers, and blending agents) can be used the enhance the flow and / or dispersibility of the liquified PVB-containing composition.

[0076] When added to the liquification system, at least 50, at least 55, at least 60, at least 65, at least 70, at least 75, at least 80, at least 85, at least 90, at least 95, or at least 99 weight percent of the PVB resin originally present in the chemical recycling feedstock undergoes a reduction in viscosity. In some cases, the reduction in viscosity can be facilitated by heating (e.g., addition of steam directly or indirectly contacting the PVB- containing composition), while, in other cases, it can be facilitated by combining the PVB-containing composition with a solvent capable of at least partially dissolving it. Examples of suitable solvents can include, but are not limited to, alcohols such as methanol or ethanol, glycols such as ethylene glycol, diethylene glycol, triethylene glycol, neopentyl glycol, cyclohexanedimethanol, glycerin, pyrolysis oil, motor oil, water, vinyl chloride monomer, vinyl acetate, polyvinyl acetate, vinyl alcohol, polyvinyl alcohol, butyraldehyde, TEG-EH, triethyleneglycol-di-2ethylbutyrate, triethylene glycol diheptanoate, tetraethylene glycol diheptanoate, tetraethylene glycol di-(2-ethylhexanoate) (“4GEH”), dioctyl adipate, hexyl cyclohexyladipate, diisononyl adipate, heptylnonyl adipate, di(butoxyethyl) adipate, dihexyladipate, dibutylsebacate, triethylene glycol di-(2- ethylhexanoate) (“3GEH”), dioctyl sebacate, bis- (methoxyethyl)terephthalate, bis-(butoxyethyl)terephthalate, bis- (butoxyethoxyethyl)terephthalate, bis-(ethoxyethyl)terephthalate, bis- (ethoxyethoxyethyl)terephthalate, bis-(2-ethylhexyloxyethyl)terephthalate, bis-(2-ethylhexyl)iso-phthalate, ethoxyethoxyethyl benzoate, butoxyethoxyethyl benzoate, butoxyethoxyethoxyethyl benzoate, and / or dipropylene glycol di-o-toluate. This dissolution solvent can be added directly to the liquification vessel in the liquification system, or it can be previously combined with one or more streams fed to the liquification system, including chemical recycling feedstock.

[0077] In an embodiment or in combination with any embodiment mentioned herein, the dissolution solvent can comprise a stream withdrawn from one or more other facilities within the chemical recycling facility. For example, the solvent can comprise a stream withdrawn from the pyrolysis reactor. In certain embodiments, the dissolution solvent can be or comprise pyrolysis oil.

[0078] In some cases, at least a portion of the PVB resins in the PVB- containing composition can be depolymerized such that, for example, the number average chain length of the resin is reduced by contact with a depolymerization agent. In an embodiment or in combination with any embodiment mentioned herein, at least one of the previously-listed solvents may be used as a depolymerization agent, while, in one or more other embodiments, the depolymerization agent can include an organic acid (e.g., acetic acid, citric acid, butyric acid, formic acid, lactic acid, oleic acid, oxalic, stearic acid, tartaric acid, and / or uric acid) or inorganic acid such as sulfuric acid (for polyolefins) or hydrochloric acid. The depolymerization agent may reduce the melting point and / or viscosity of the polymer by reducing its number average chain length.

[0079] Further, one or more of the methods of liquefying the chemical recycling feedstock can also include adding at least one blending agent to the stream before, during, or after the liquification process in the liquification system. Such blending agents may include for example, emulsifiers and / or surfactants. When used, the blending agent may be present in an amount of at least 0.1 , at least 0.5, at least 1 , at least 2, or at least 5 weight percent and / or not more than 10, not more than 8, not more than 5, not more than 3, not more than 2, or not more than 1 weight percent, based on the total weight of the chemical recycling feedstock, or it can be in a range of from 0.1 to 10 weight percent, 0.5 to 8 weight percent, or 1 to 5 weight percent, based on the total weight of the chemical recycling feedstock.

[0080] In an embodiment or in combination with any embodiment mentioned herein, the liquified chemical recycling feedstock formed within the liquification system can have a viscosity of less than 3,000, less than 2,500,less than 2,000, less than 1 ,500, less than 1 ,000, less than 800, less than 750, less than 700, less than 650, less than 600, less than 550, less than 500, less than 450, less than 400, less than 350, less than 300, less than 250, less than 150, less than 100, less than 75, less than 50, less than 25, less than 10, less than 5, or less than 1 poise, as measured using a Brookfield R / S rheometer with a V80-40 vane spindle operating at a shear rate of 10 rad / s and a temperature of 350°C.

[0081] In an embodiment or in combination with any embodiment mentioned herein, the liquification system may comprise at least one, at least two, at least three, or at least four liquification vessels to facilitate the liquefying and / or pyrolysis of the PVB-containing composition prior to the pyrolysis reactor. In various embodiments, the liquification vessels can include at least one melt tank and / or at least one extruder to facilitate the liquification and / or pyrolysis of the PVB-containing composition.

[0082] In an embodiment or in combination with any embodiment mentioned herein, the melt tanks can include one or more continuously stirred tanks. When one or more rheology modification agents (e.g., solvents, depolymerization agents, plasticizers, and blending agents) are used in the liquification system, such rheology modification agents can be added to and / or mixed with the chemical recycling feedstock in or prior to introduction into the melt tank(s).

[0083] In an embodiment or in combination with any embodiment mentioned herein, the liquification vessel(s), such as the melt tanks and / or the extruders, may receive the chemical recycling feedstock and heat the PVB- containing composition via heating mechanisms in the melt tank and / or via the extrusion process in the extruder.

[0084] In an embodiment or in combination with any embodiment mentioned herein, the interior space of the liquification vessel, where the PVB- containing composition is dehydrated and / or liquefied, or the PVB- containing compositions, may be brought to or maintained at a temperature of at least 75, at least 100, at least 125, at least 150, at least 175, at least 200, at least 210, or at least 225 °C. Additionally, or in the alternative, theinterior space of the first liquification vessel, or the PVB containing composition, may be brought to or maintained at a temperature of not more than 400, not more than 375, not more than 350, not more than 325, not more than 300, not more than 275, not more than 250, not more than 225, or not more than 200 °C. For example, the interior space of the liquification vessel, where the PVB-containing composition is dehydrated and / or liquefied, or the PVB-containing compositions, may be brought to or maintained at a temperature in the range of 75 to 250 °C, 100 to 225 °C, or 100 to 200 °C.

[0085] In an embodiment or in combination with any embodiment mentioned herein, during the dehydration, liquification, and / or pyrolysis steps, the temperature of the PVB-containing composition may be raised by at least 50°C, at least 75°C, at least 100°C, at least 125°C, at least 150°C, at least 175°C, at least 200°C, at least 225°C, or at least 250°C and / or less than 400°C.

[0086] Although not wishing to be bound by theory, depending on the temperature and environmental conditions within the liquification vessel(s), at least a portion of the PVB-containing composition of the chemical recycling feedstock in the liquification vessel(s) may undergo pyrolysis and thereby produce a pyrolysis effluent. More particularly, if temperatures above 250°C are utilized in the liquification vessel(s), then pyrolytic conditions may be present within the liquification vessel(s). Thus, in such embodiments, the liquefied chemical recycling feedstock formed in the liquification vessel(s) may also undergo a certain amount of pyrolysis and form pyrolysis products (e.g., a pyrolysis gas, a pyrolysis oil, and a pyrolysis residue). Desirably, the temperature of liquification vessel interior or the temperature of the PVB-containing composition is in the range of 75 to 250 °C, 100 to 225 °C, or 100 to 200 °C to avoid any significant cracking of the polymer backbone.

[0087] Generally, the residence times of the chemical recycling feedstock in the liquification vessel(s) can vary depending on the type of the liquification vessel(s). In an embodiment or in combination with any embodimentmentioned herein, the residence times of the chemical recycling feedstock in the liquification vessel(s) can be least 1 , at least 2, at least 3, at least 4, at least 5, at least 6, at least 7, at least 8, at least 9, at least 10, at least 20, at least 30, at least 45, at least 60, at least 75, or at least 90 minutes. Additionally, or alternatively, the residence times of the feedstocks within the liquification vessel(s) can be less than 6, less than 5, less than 4, less than 3, less than 2, less than 1 , or less than 0.5 hours. Additionally, or alternatively, the residence times of the chemical recycling feedstock in the liquification vessel(s) can be less than 100, less than 90, less than 80, less than 70, less than 60, less than 50, less than 40, less than 30, less than 20, less than 10, less than 9, less than 8, less than 7, less than 6, less than 5, less than 4, less than 3, less than 2, or less than 1 minutes. More particularly, the residence times of the feedstocks within the liquification vessel(s) can range from 30 minutes to 4 hours, 30 minutes to 3 hours, 1 hour to 3 hours, or 1 hour to 2 hours.

[0088] As noted above, the liquification vessel(s) may operate under pyrolytic conditions and, therefore, produce pyrolysis products (e.g., pyrolysis gas, pyrolysis oil, and / or pyrolysis residue). Thus, if pyrolytic temperatures and conditions are utilized in the liquification system, a pyrolysis effluent stream may be recovered from the system as shown in FIG. 1. The contents of these possible pyrolysis effluent streams are discussed in greater detail below, in reference to the pyrolysis reactor. Therefore, all of the foregoing ranges and characteristics of the pyrolysis effluent stream from the pyrolysis reactor may also be applicable to the possible pyrolysis effluent streams derived from the liquification vessel(s).

[0089] In an embodiment or in combination with any embodiment mentioned herein, the liquification system can facilitate a mild pyrolysis treatment of the PVB-containing composition. As used herein, “mild pyrolysis” refers to a pyrolysis treatment that occurs at lower pyrolysis temperatures relative to the subsequent treatment occurring in the pyrolysis reactor. As shown in FIG. 1 , this mild pyrolysis step in the liquification system occurs in a different reactor than the subsequent pyrolysis reaction in the pyrolysis reactor.

[0090] In an embodiment or in combination with any embodiment mentioned herein, the pyrolysis effluent stream exiting the liquification system may comprise at least 1 , at least 5, at least 10, at least 15, at least 20, at least 25, at least 30, at least 35, at least 40, at least 45, at least 50, at least 55, at least 60, at least 65, at least 70, or at least 75 weight percent of one or more pyrolysis products, such as pyrolysis gas, pyrolysis oil, and / or pyrolysis residue. Additionally, or in the alternative, the pyrolysis effluent stream exiting the liquification system may comprise not more than 99, not more than 95, not more than 90, not more than 85, not more than 80, not more than 75, not more than 70, not more than 65, not more than 60, not more than 55, not more than 50, not more than 45, not more than 40, not more than 35, not more than 30, not more than 25, not more than 20, not more than 15, or not more than 10 weight percent of one or more pyrolysis products, such as pyrolysis gas, pyrolysis oil, and / or pyrolysis residue.

[0091] In an embodiment or in combination with any embodiment mentioned herein, the pyrolysis effluent stream exiting the liquification system may comprise at least 1 , at least 5, at least 10, at least 15, at least 20, at least 25, at least 30, at least 35, at least 40, at least 45, at least 50, at least 55, at least 60, at least 65, at least 70, or at least 75 weight percent of unreacted(i.e., non-pyrolyzed) liquefied PVB. Additionally, or in the alternative, the pyrolysis effluent stream exiting the liquification system may comprise not more than 99, not more than 95, not more than 90, not more than 85, not more than 80, not more than 75, not more than 70, not more than 65, not more than 60, not more than 55, not more than 50, not more than 45, not more than 40, not more than 35, not more than 30, not more than 25, not more than 20, not more than 15, or not more than 10 weight percent of unreacted (i.e., non-pyrolyzed) liquefied PVB.

[0092] In an embodiment or in combination with any embodiment mentioned herein, the pyrolysis effluent stream from the PVB-containing composition feedstock to the pyrolysis reactor, or through a liquification system may comprise a number of thermal decomposition products in the form of recycled content products, which were directly derived from the PVB-containing composition. For example, the thermal decomposition products may comprise several recycled content products derived from the thermal decomposition of the PVB resin. Additionally, or alternatively, the thermal decomposition products may comprise a plasticizer originally derived from the recycled PVB-containing composition.

[0093] In an embodiment or in combination with any embodiment mentioned herein, the thermal decomposition products in the pyrolysis effluent can comprise recycled content plasticizer, recycled content C2-C4 aldehydes (e.g., recycled content acetaldehyde and / or recycled content butyraldehyde), a recycled content UV stabilizer, a recycled content antioxidant, recycled content CO, recycled content ethylene, recycled content methane, or a combination of two or more thereof, in each case obtained from the PVB-containing composition feedstock.

[0094] In an embodiment or in combination with any embodiment mentioned herein, the pyrolysis effluent stream from the liquification system may comprise at least 0.1 , at least 0.5, at least 1 , or at least 1 .5 weight percent of recycled content carbon monoxide, based on the total weight of the pyrolysis effluent stream. Additionally, or in the alternative, the pyrolysis effluent stream from the liquification system may comprise not more than 15, not more than 10, not more than 8, not more than 7, not more than 6, not more than 5, not more than 4, not more than 3, or not more than 2 weight percent of recycled content carbon monoxide, based on the total weight of the pyrolysis effluent stream. These weight percentages are measured on a dry-basis.

[0095] In an embodiment or in combination with any embodiment mentioned herein, the pyrolysis effluent stream from the liquification system may comprise at least 0.1 , at least 0.5, at least 1 , or at least 1 .5 weight percent of recycled content acetaldehyde, based on the total weight of the pyrolysis effluent stream. Additionally, or in the alternative, the pyrolysis effluent stream from the liquification system may comprise not more than 15, not more than 10, not more than 8, not more than 7, not more than 6, not more than 5, not more than 4, not more than 3, or not more than 2 weight percentof recycled content acetaldehyde, based on the total weight of the pyrolysis effluent stream. These weight percentages are measured on a dry-basis.

[0096] In an embodiment or in combination with any embodiment mentioned herein, the pyrolysis effluent stream from the liquification system may comprise at least 1 , at least 2, at least 3, at least 4, at least 5, at least 6, at least 7, at least 8, at least 9, at least 10, at least 1 1 , at least 12, at least 13, at least 14, at least 15, at least 16, at least 17, at least 18, at least 19, or at least 20 weight percent of recycled content butyraldehyde, based on the total weight of the pyrolysis effluent stream. Additionally, or in the alternative, the pyrolysis effluent stream from the liquification system may comprise not more than 60, not more than 55, not more than 50, not more than 45, not more than 40, not more than 35, not more than 30, or not more than 25 weight percent of recycled content butyraldehyde, based on the total weight of the pyrolysis effluent stream. These weight percentages are measured on a dry-basis.

[0097] In an embodiment or in combination with any embodiment mentioned herein, the pyrolysis effluent stream from the liquification system may comprise at least 1 , at least 5, at least 10, at least 15, at least 20, at least 25, at least 30, at least 35, or at least 40 weight percent of recycled content plasticizer, based on the total weight of the pyrolysis effluent stream. Additionally, or in the alternative, the pyrolysis effluent stream from the liquification system may comprise not more than 80, not more than 75, not more than 70, not more than 65, not more than 60, not more than 55, not more than 50, not more than 45, not more than 40, or not more than 35 weight percent of recycled content plasticizer, based on the total weight of the pyrolysis effluent stream. These weight percentages are measured on a dry-basis.

[0098] In an embodiment or in combination with any embodiment mentioned herein, the pyrolysis effluent stream from the liquification system may comprise at least 0.1 , at least 0.5, at least 1 , or at least 1 .5 weight percent of recycled content ethylene, recycled content propylene, recycled content butadiene, recycled content butane, recycled content pentadiene, recycledcontent cyclopentadiene, recycled content benzene, recycled content toluene, recycled content styrene, recycled content naphthalene, or a combination of two or more thereof, based on the total weight of the pyrolysis effluent stream. Additionally, or in the alternative, the pyrolysis effluent stream from the liquification system may comprise not more than 10, not more than 8, not more than 6, not more than 5, not more than 4, not more than 3, not more than 2, not more than 1 , not more than 0.5, or not more than 0.1 weight percent of recycled content ethylene, recycled content propylene, recycled content butadiene, recycled content butane, recycled content pentadiene, recycled content cyclopentadiene, recycled content benzene, recycled content toluene, recycled content styrene, recycled content naphthalene, or a combination of two or more thereof, based on the total weight of the pyrolysis effluent stream. These weight percentages are measured on a dry-basis.

[0099] In an embodiment or in combination with any embodiment mentioned herein, the pyrolysis effluent stream from the liquification system may comprise not more than 5, not more than 4, not more than 3, not more than 2, not more than 1 , not more than 0.5, or not more than 0.1 weight percent of recycled content C2-C4 hydrocarbons, based on the total weight of the pyrolysis effluent stream.

[0100] In an embodiment or in combination with any embodiment mentioned herein, the pyrolysis effluent stream from the liquification system may comprise not more than 5, not more than 4, not more than 3, not more than 2, not more than 1 , not more than 0.5, or not more than 0.1 weight percent of recycled content aromatics, based on the total weight of the pyrolysis effluent stream. These recycled content aromatics can comprise recycled content benzene, recycled content toluene, recycled content styrene, and / or recycled content naphthalene.

[0101] In an embodiment or in combination with any embodiment mentioned herein, the pyrolysis effluent stream from the liquification system may comprise at least 0.1 , at least 0.5, or at least 1 weight percent of recycled content glass, based on the total weight of the pyrolysis effluent stream.Additionally, or in the alternative, the pyrolysis effluent stream from the liquification system may comprise not more than 50, not more than 25, not more than 10, or not more than 5 weight percent of recycled content glass, based on the total weight of the pyrolysis effluent stream. These weight percentages are measured on a dry-basis. In such embodiments, the glass in the pyrolysis effluent may be in the form of particles and predominantly form the pyrolysis residue.

[0102] After exiting the liquification system, the pyrolysis effluent stream may be separated into a recycled content pyrolysis oil stream, a recycled content pyrolysis residue stream, and a recycled content pyrolysis gas stream in a separation system. Additionally, or in the alternative, one or more thermal decomposition products may be recovered from at least a portion of the pyrolysis effluent, pyrolysis oil, pyrolysis gas, and / or pyrolysis residue. The separation systems may include various types of equipment including, but not limited to a filter system, a multistage separator, a vacuum separator, a condensation system, a distillation column, and / or a quench tower.

[0103] In an embodiment or in combination with any embodiment mentioned herein, the liquification vessel(s), such as the melt tank and / or the extruder, may be at least partially heated by an electrical heat source (e.g., one or more electrical heaters) and / or a combustion heat system comprising a plurality of burners that combust a combustion fuel and air. The combustion fuel may comprise a conventional fossil fuel and / or a recycled content fuel, such as recycled content carbon monoxide, recycled content acetaldehyde, and / or recycled content ethylene, which may be derived from the pyrolysis effluent streams of the chemical recycling facility. For example, a recycled content combustion fuel may be at least partially derived from the pyrolysis effluent streams from the chemical recycling facility.

[0104] In an embodiment or in combination with any embodiment mentioned herein, the combustion heat system may heat a heat transfer fluid, such as water, steam, Dowtherm, Therminol, and / or mineral spirits, which can be used to provide indirect heat to the liquification system.

[0105] In an embodiment or in combination with any embodiment mentioned herein, at least a portion of the pyrolysis gas stream derived from the pyrolysis effluent stream may be used as a combustion fuel in a combustion heat system that provides heat energy to the liquification vessel(s).

[0106] As shown in FIG. 1 and described below in greater detail, at least a portion of the liquefied (e.g., molten) chemical recycling feedstock from the liquification system 14 may be introduced into a downstream pyrolysis reactor 16 at a pyrolysis facility to produce a pyrolysis effluent.Pyrolysis

[0107] Turning again to FIG. 1 , the chemical recycling facility 10 may comprise a pyrolysis reactor 16. A “pyrolysis facility” is a facility that includes all equipment, lines, and controls necessary to carry out pyrolysis of the PVB-containing composition and feedstocks derived therefrom. In certain embodiments, the pyrolysis facility can comprise the pyrolysis reactor 16 and the aforementioned liquification system 14.

[0108] As depicted in FIG. 1 , at least a portion of the chemical recycling feedstock from the liquification system 14 may be introduced into a pyrolysis reactor 16 at a pyrolysis facility so as to produce a pyrolysis effluent stream comprising a pyrolysis oil, a pyrolysis gas, and a pyrolysis residue.

[0109] In general, the pyrolysis facility may include the liquification system, the pyrolysis reactor, and separation systems for the pyrolysis effluent, which can separate the pyrolysis effluent into a pyrolysis gas stream, a pyrolysis oil stream, a pyrolysis residue stream, and / or specific recycled content product streams.

[0110] While in the pyrolysis reactor, at least a portion of the chemical recycling feedstock which includes the PVB-containing composition may be subjected to a pyrolysis reaction that produces a pyrolysis effluent stream comprising a pyrolysis oil, a pyrolysis gas, and a pyrolysis residue. Generally, the pyrolysis effluent stream exiting the pyrolysis reactor can be in the form of vapors that comprise the pyrolysis gas and uncondensedpyrolysis oil. As used herein, “pyrolysis vapor” refers to the uncondensed pyrolysis effluent.

[0111] Pyrolysis is a process that involves the chemical and thermal decomposition of the introduced feed in the substantial absence of oxygen. The. pyrolysis processes may be generally characterized as the thermal decomposition of a substance (e.g. polymer) in the presence of an inert or non-combustible atmosphere. While steam or water can be present in a pyrolysis zone, typically, the pyrolysis reaction is conducted in the absence of added free oxygen.

[0112] In an embodiment or in combination with any embodiment mentioned herein, the pyrolysis reactor can be, for example, a film reactor, a screw extruder, a tubular reactor, a tank, a stirred tank reactor, a riser reactor, a fixed bed reactor, a fluidized bed reactor, a rotary kiln, a vacuum reactor, a microwave reactor, or an autoclave.

[0113] In an embodiment or in combination with any embodiment mentioned herein, an optional lift gas and / or a feed gas may be used to introduce the feedstock into the pyrolysis reactor and / or facilitate various reactions within the pyrolysis reactor. For instance, the lift gas and / or the feed gas may comprise, consist essentially of, or consist of nitrogen, carbon dioxide, and / or steam. The lift gas and / or feed gas may be added with the chemical recycling feedstock prior to introduction into the pyrolysis reactor and / or may be added directly to the pyrolysis reactor. The lift gas and / or feed gas can include steam and / or a reducing gas such as hydrogen, carbon monoxide, and combinations thereof.

[0114] In an embodiment or in combination with any embodiment mentioned herein, the lift gas and / or the feed gas may comprise steam. Alternatively, in certain embodiments, no steam is added to the pyrolysis reactor.

[0115] Furthermore, the temperature in the pyrolysis reactor can be adjusted so as to facilitate the production of certain end products. In an embodiment or in combination with any embodiment mentioned herein, the pyrolysis temperature in the pyrolysis reactor can be at least 200, at least 225, at least 250, or at least 275 °Cor at least 300, or at least 325, or at least350, or at least 375, or at least 400, or at least 425, or at least 440, or at least 450, or at least 465, or at least 475°C. Additionally, or in the alternative, the pyrolysis temperature in the pyrolysis reactor can be not more than 600, or not more than 550, not more than 530, not more than 510, nor more than 500, not more than 490, not more than 480, not more than 475, not more than 450, not more than 425, or not more than 400 °C.

[0116] In an embodiment or in combination with any embodiment mentioned herein, the pyrolysis temperature in the pyrolysis reactor can range from 200 to 550 °C, 250 to 550 °C, 300 to 550 °C, 325 to 550 °C, 350 to 550 °C, 375 to 550 °C, 400 to 550 °C, 425 to 550 °C, 440 to 550 °C, 450 to 550 °C, 465 to 550 °C, 475 to 550 °C, 300 to 525 °C, 325 to 525 °C, 350 to 525 °C, 375 to 525 °C, 400 to 525 °C, 425 to 525 °C, 440 to 525 °C, 450 to 525 °C, 465 to 525 °C, 475 to 525 °C, 300 to 500 °C, 325 to 500 °C, 350 to 500 °C, 375 to 500 °C, 400 to 500 °C, 425 to 500 °C, 440 to 500 °C, 450 to 500 °C, 465 to 500 °C, 475 to 500 °C, 300 to 490 °C, 325 to 490 °C, 350 to 490 °C, 375 to 490 °C, 400 to 490 °C, 425 to 490 °C, 440 to 490 °C, or 450 to 490 °C. We have found that high yields can be produced when the temperature in the pyrolysis reaction zone ranges from 400°C to 500°C, and particularly from more than 425°C to 500°C. Temperatures within the pyrolysis reactor from 440°C to 500°C, or from 440°C to 490°C, or from 450°C to 500°C, or from 450°C to 490°C would produce good yields across the combination of two or more recovered components (e.g. acetaldehyde, butyraldehyde, plasticizer) without expending unnecessary energy. However, we have also discovered that butyraldehyde can be recovered in high yields at lower temperatures, from 350°C to 400°C. If one desire to optimize the process for recovery of butyraldehyde and tolerate lower yields on other components, the pyrolysis reaction temperature can be further lowered to the above stated range. These pyrolysis temperatures may be measured at a feed inlet of the pyrolysis reactor and / or at a pyrolysis effluent outlet of the pyrolysis reactor.

[0117] In an embodiment or in combination with any embodiment mentioned herein, the pyrolysis reactor maintains an internal temperature within 15, 10,or 5 percent of the pyrolysis temperature ranges noted above, as measured at a feed inlet of the pyrolysis reactor and / or at a pyrolysis effluent outlet of the pyrolysis reactor.

[0118] In an embodiment or in combination with any embodiment mentioned herein, the pyrolysis temperature within the pyrolysis reactor is higher than the temperature conditions in the liquification system. Thus, the pyrolysis reaction in the pyrolysis reactor may occur at more severe conditions (e.g., higher temperature) relative to the mild pyrolysis treatment in the liquification system.

[0119] Although not depicted in FIG. 1 , it is envisioned that the mild pyrolysis step discussed above and the subsequent severe pyrolysis step may also occur in separate stages / zones of the same reactor. For example, the mild pyrolysis step discussed above in the liquification system (including the aforementioned operating temperatures and residence times) may actually be carried out and occur in a stage or zone in the pyrolysis reactor that is separate from the stage / zone where the subsequent severe pyrolysis is carried out. Exemplary pyrolysis reactors in this case could be multi-staged film reactors, multistage tubular reactors, or extruders with distinction sections.

[0120] In an embodiment or in combination with any embodiment mentioned herein, the residence times of the feedstocks within the pyrolysis reactor can be at least 0.1 , at least 0.2, at least 0.3, at least 0.5, at least 1 , at least 1 .2, at least 1 .3, at least 2, at least 3, or at least 4 seconds. Alternatively, the residence times of the feedstocks within the pyrolysis reactor can be at least 1 , at least 2, at least 3, at least 4, at least 5, at least 6, at least 7, at least 8, at least 9, at least 10, at least 20, at least 30, at least 45, at least 60, at least 75, or at least 90 minutes. Additionally, or alternatively, the residence times of the feedstocks within the pyrolysis reactor can be less than 6, less than 5, less than 4, less than 3, less than 2, less than 1 , or less than 0.5 hours, less than 20 minutes, less than 15 minutes, less than 10 minutes, or 5 minutes or less. Furthermore, the residence times of the feedstocks within the pyrolysis reactor can be less than 100, less than 90,less than 80, less than 70, less than 60, less than 50, less than 40, less than 30, less than 20, less than 10, less than 9, less than 8, less than 7, less than 6, less than 5, less than 4, less than 3, less than 2, or less than 1 seconds. More particularly, the residence times of the feedstocks within the pyrolysis reactor can range from 15 seconds to 30 minutes, or 30 seconds to 20 minutes, or 30 seconds to 10 minutes, or 30 seconds to 5 minutes, or 0.5 seconds to 4 hours, 1 second to 4 hours, 10 seconds to 2 hours, 10 seconds to 30 minutes, 0.5 to 30 seconds, 1 to 15 seconds, or 2 to 8 seconds. The residence time can be shortened if the chemical recycling feedstock is preheated in a liquification zone and fed to the pyrolysis reactor at a temperature of 100°C or more, or 200°C or more.

[0121] In an embodiment or in combination with any embodiment mentioned herein, the pressure within the pyrolysis reactor can be maintained at atmospheric pressure or within the range of 0.05 to 100 bar, or 0.05 to 60 bar, or 0.1 to 30 bar, or 0.1 to 10 bar, 0.2 to 1.5 bar, or 0.3 to 1.1 bar. As used herein, the term “bar” refers to gauge pressure, unless otherwise noted. Alternatively, the pressure within the pyrolysis reactor can be maintained at a vacuum.

[0122] In an embodiment or in combination with any embodiment mentioned herein, a pyrolysis catalyst may be introduced into the chemical recycling feedstock prior to introduction into the pyrolysis reactor and / or introduced directly into the pyrolysis reactor. The catalyst can be homogenous or heterogeneous and may include, for example, certain types of zeolites and other mesostructured catalysts.

[0123] In an embodiment or in combination with any embodiment mentioned herein, the pyrolysis reaction may not be catalyzed (e.g., carried out in the absence of a pyrolysis catalyst), but may include a non-catalytic, heatretaining inert additive, such as sand and / or glass, in the reactor in order to facilitate the heat transfer. Such catalyst-free pyrolysis processes may be referred to as “thermal pyrolysis.”

[0124] After exiting the pyrolysis reactor, the pyrolysis effluent may be separated into the pyrolysis oil stream and the pyrolysis gas stream in aseparation system, such as a condenser. This condenser can include various types of equipment including, but not limited to, a filter system, a multistage separator, a condensation zone, and / or a quench tower. While the in the condenser, the pyrolysis effluent, such as the pyrolysis vapors, may be cooled to condense the pyrolysis oil fraction originally present in the pyrolysis effluent stream.

[0125] In an embodiment or in combination with any embodiment mentioned herein, the pyrolysis effluent or pyrolysis vapors from the pyrolysis reactor may comprise pyrolysis oil in an amount of at least 50, at least 60, at least 75, at least 80, at least 85, at least 90, at least 95, at least 98, at least 99, at least 99.5, at least 99.9 weight percent, based on the total weight of the pyrolysis effluent or pyrolysis vapors. Additionally, or alternatively, the pyrolysis effluent or pyrolysis vapors may comprise pyrolysis oil in an amount of not more than 99.9, not more than 99.5, not more than 99, not more than 98, not more than 97, not more than 95, not more than 90, not more than 85, not more than 80, not more than 75, weight percent, based on the total weight of the pyrolysis effluent or pyrolysis vapors. As discussed above, the pyrolysis oil may be in the form of uncondensed vapors in the pyrolysis effluent upon exiting the heated reactor; however, these vapors may be subsequently condensed into the resulting pyrolysis oil. The pyrolysis effluent or pyrolysis vapors may comprise pyrolysis oil in the range of 70 to 99.9 weight percent, 80 to 99.9 weight percent, 90 to 99.9 weight percent, 90 to 99 weight percent, 85 to 98 weight percent, 95 to 99.5 weight percent, 95 to 99 weigh, or 95 to 98 weight percent, based on the total weight of the pyrolysis effluent or pyrolysis vapors.

[0126] In an embodiment or in combination with any embodiment mentioned herein, the pyrolysis effluent or pyrolysis vapors from the pyrolysis reactor may comprise pyrolysis gas in an amount of at least 0.01 , at least 0.1 , at least 0.5, at least 1 , at least 1 .5, or at least 2weight percent, based on the total weight of the pyrolysis vapors. Additionally, or alternatively, the pyrolysis vapors may comprise pyrolysis gas in an amount of not more than 20, not more than 15, not more than 10, not more than 8, not more than 5,not more than 4, not more than 3, not more than 2, or not more than 1 weight percent, based on the total weight of the pyrolysis vapors. The pyrolysis effluent may comprise pyrolysis gas in an amount of 0.01 to 20 weight percent, 0.01 to 10 weight percent, 0.01 to 5 weight percent, 0.01 to 4 weight percent, 0.01 to 3 weight percent, 0.1 to 5 weight percent, 0.5 to 5 weight percent, 1 to 5 weight percent, 1.5 to 5 weight percent, or 1.5 to 4 weight percent, based on the total weight of the pyrolysis vapors In an embodiment or in combination with any embodiment mentioned herein, the pyrolysis effluent or from the pyrolysis reactor may comprise pyrolysis residue in an amount of at least 0.5, at least 1 , at least 2, at least 3, at least 4, at least 5, at least 6, at least 7, at least 8, at least 9, or at least 10 weight percent, based on the total weight of the pyrolysis effluent or pyrolysis vapors. Additionally, or alternatively, the pyrolysis effluent may comprise pyrolysis residue in an amount of not more than 15, not more than 10, not more than 9, not more than 8, not more than 7, not more than 6, not more than 5, not more than 4, or not more than 3 weight percent, based on the total weight of the pyrolysis effluent or pyrolysis vapors. The pyrolysis effluent may comprise pyrolysis residue present in an amount within a range of 0.1 to 20 weight percent, 0.5 to 10 weight percent, 1 to 5 weight percent, or 1 to 3 weight percent pyrolysis residue, based on the total weight of the pyrolysis effluent or pyrolysis vapors. This pyrolysis residue may be removed from the pyrolysis reactor (where it may form) and / or separated from the pyrolysis effluent in a downstream separator, such as the condenser, or both.

[0127] We have also found that pyrolysis oil may be recovered in high yield from the PVB-containing composition. In an embodiment or in combination with any embodiment mentioned herein, the yield of pyrolysis oil, based on the weight of the PVB-containing composition in the chemical recycling feedstock, or alternatively based on the weight of the chemical recycling feedstock, fed to the pyrolysis reactor, is at least 70 wt.%, or at least 75 wt.%, or at least 80 wt.%, or at least 85 wt.%, or at least 87 wt.%, or at least 88 wt.%, or at least 90 wt.%, or at least 85 wt.%.

[0128] In an embodiment or in combination with any embodiment mentioned herein, the yield of pyrolysis gas can be low, which is desirable particularly in combination with a high yield of pyrolysis oil. The yield of pyrolysis gas, based on the weight of the PVB-containing composition in the chemical recycling feedstock, or alternatively based on the weight of the chemical recycling feedstock, fed to the pyrolysis reactor, can be not more than 20 wt.%, or not more than 10 wt.%, or not more than 5 wt.%, or not more than 4 wt.%, or not more than 3 wt.%, or not more than 2 wt.%.

[0129] In an embodiment or in combination with any embodiment mentioned herein, the yield of pyrolysis residue can be low, which is desirable particularly in combination with a high yield of pyrolysis oil. The yield of pyrolysis residue, based on the weight of the PVB-containing composition in the chemical recycling feedstock, or alternatively based on the weight of the chemical recycling feedstock, fed to the pyrolysis reactor can be not more than 20 wt.%, or not more than 10 wt.%, or not more than 5 wt.%, or not more than 4 wt.%, or not more than 3 wt.%. The amount of pyrolysis residue can be at least 0.5 wt.%, or at least 1 wt.%, or at least 1 .5 wt.%, on the same basis.

[0130] We have also found that butyraldehyde may be recovered in good yield from the PVB-containing composition. In an embodiment or in combination with any embodiment mentioned herein, the yield of butyraldehyde, based on the weight of the PVB-containing composition in the chemical recycling feedstock, or alternatively based on the weight of the chemical recycling feedstock, fed to the pyrolysis reactor is at least 10 wt.%, or at least 15 wt.%, or at least 18 wt.%, or at least 20 wt.%, or at least 21 wt.%, or at least 22 wt.%, or at least 23 wt.%, or at least 24 wt.%.

[0131] The recovery of butyraldehyde noted above is based on the weight of the PVB-containing composition in the chemical recycling feedstock, or alternatively based on the weight of the chemical recycling feedstock, fed to the pyrolysis reactor. We have found that we can achieve high yields of recovered butyraldehyde based on the amount of butyraldehyde available for recovery in the PVB feedstock. Based on the butyraldehyde content inPVB fed to the pyrolysis reactor, the yield of recovered butyraldehyde is at least 70 wt.%, or at least 72 wt.%, or at least 75 wt.%, or at least 77 wt.%, or at least 80 wt.% (determined as kg butyraldehyde recovered per kg of butyraldehyde moiety content in the PVB fed to the pyrolysis reactor x 100).

[0132] We have also found that acetaldehyde may be recovered in good yield from the PVB-containing composition. In an embodiment or in combination with any embodiment mentioned herein, the yield of acetaldehyde, based on the weight of the PVB-containing composition in the chemical recycling feedstock, or alternatively based on the weight of the chemical recycling feedstock, fed to the pyrolysis reactor is at least 1 wt.%, or at least 1.5 wt.%, or at least 2 wt.%, or at least 2.5 wt.%, or at least 3 wt.%.

[0133] We have also found that plasticizer may be recovered in good yield from the PVB-containing composition. In an embodiment or in combination with any embodiment mentioned herein, the yield of plasticizer, based on the weight of the PVB-containing composition in the chemical recycling feedstock, or alternatively based on the weight of the chemical recycling feedstock, fed to the pyrolysis reactor is at least 10 wt.%, or at least 15 wt.%, or at least 18 wt.%, or at least 19 wt.%, or at least 20 wt.%, or at least 21 wt.%.

[0134] The recovery of plasticizer noted above is based on the weight of the PVB-containing composition in the chemical recycling feedstock, or alternatively based on the weight of the chemical recycling feedstock, fed to the pyrolysis reactor. We have found that we can achieve high yields of recovered plasticizer based on the amount of plasticizer available for recovery in the PVB feedstock. Based on the plasticizer content in PVB fed to the pyrolysis reactor, the yield of recovered plasticizer is at least 65 wt.%, or at least 68 wt.%, or at least 70 wt.%, or at least 72 wt.%, or at least 74 wt.% (determined as kg plasticizer recovered per kg of plasticizer content in the PVB fed to the pyrolysis reactor x 100).

[0135] In an embodiment or in combination with any embodiment mentioned herein, the pyrolysis effluent stream from the pyrolysis reactor may comprisea number of thermal decomposition products in the form of recycled content products, which were directly derived from the PVB-containing composition. For example, the thermal decomposition products may comprise several recycled content products derived from the thermal decomposition of the PVB resin. Additionally, or alternatively, the thermal decomposition products may comprise a plasticizer originally derived from the recycled PVB- containing composition.

[0136] In an embodiment or in combination with any embodiment mentioned herein, the thermal decomposition products in the pyrolysis effluent can comprise recycled content plasticizer, recycled content C2-C4 aldehydes (e.g., recycled content acetaldehyde and / or recycled content butyraldehyde), a recycled content UV stabilizer, a recycled content antioxidant, recycled content CO, recycled content ethylene, recycled content methane, or a combination of two or more thereof.

[0137] In an embodiment or in combination with any embodiment mentioned herein, the pyrolysis effluent stream from the pyrolysis reactor may comprise at least 0.1 , at least 0.5, at least 1 , or at least 1 .5 weight percent of recycled content carbon monoxide, based on the total weight of the pyrolysis effluent stream. Additionally, or in the alternative, the pyrolysis effluent stream from the pyrolysis reactor may comprise not more than 15, not more than 10, not more than 8, not more than 7, not more than 6, not more than 5, not more than 4, not more than 3, or not more than 2 weight percent of recycled content carbon monoxide, based on the total weight of the pyrolysis effluent stream. These weight percentages are measured on a dry-basis.

[0138] In an embodiment or in combination with any embodiment mentioned herein, the pyrolysis effluent stream from the pyrolysis reactor may comprise at least 0.1 , at least 0.5, at least 1 , or at least 1 .5 weight percent of recycled content acetaldehyde, based on the total weight of the pyrolysis effluent stream. Additionally, or in the alternative, the pyrolysis effluent stream from the pyrolysis reactor may comprise not more than 15, not more than 10, not more than 8, not more than 7, not more than 6, not more than 5, not more than 4, not more than 3, or not more than 2 weight percent of recycledcontent acetaldehyde, based on the total weight of the pyrolysis effluent stream. These weight percentages are measured on a dry-basis.

[0139] In an embodiment or in combination with any embodiment mentioned herein, the pyrolysis effluent stream from the pyrolysis reactor may comprise at least 1 , at least 2, at least 3, at least 4, at least 5, at least 6, at least 7, at least 8, at least 9, at least 10, at least 1 1 , at least 12, at least 13, at least 14, at least 15, at least 16, at least 17, at least 18, at least 19, or at least 20 weight percent of recycled content butyraldehyde, based on the total weight of the pyrolysis effluent stream. Additionally, or in the alternative, the pyrolysis effluent stream from the pyrolysis reactor may comprise not more than 60, not more than 55, not more than 50, not more than 45, not more than 40, not more than 35, not more than 30, or not more than 25 weight percent of recycled content butyraldehyde, based on the total weight of the pyrolysis effluent stream. These weight percentages are measured on a dry-basis.

[0140] In an embodiment or in combination with any embodiment mentioned herein, the pyrolysis effluent stream from the pyrolysis reactor may comprise at least 1 , at least 5, at least 10, at least 15, at least 20, at least 25, at least 30, at least 35, or at least 40 weight percent of recycled content plasticizer, based on the total weight of the pyrolysis effluent stream. Additionally, or in the alternative, the pyrolysis effluent stream from the pyrolysis reactor may comprise not more than 80, not more than 75, not more than 70, not more than 65, not more than 60, not more than 55, not more than 50, not more than 45, not more than 40, or not more than 35 weight percent of recycled content plasticizer, based on the total weight of the pyrolysis effluent stream. These weight percentages are measured on a dry-basis.

[0141] In an embodiment or in combination with any embodiment mentioned herein, the pyrolysis effluent stream from the pyrolysis reactor may comprise at least 0.1 , at least 0.5, at least 1 , or at least 1 .5 weight percent of recycled content ethylene, recycled content propylene, recycled content butadiene, recycled content butane, recycled content pentadiene, recycled content cyclopentadiene, recycled content benzene, recycled content toluene,recycled content styrene, recycled content naphthalene, or a combination of two or more thereof, based on the total weight of the pyrolysis effluent stream. Additionally, or in the alternative, the pyrolysis effluent stream from the pyrolysis reactor may comprise not more than 10, not more than 8, not more than 6, not more than 5, not more than 4, not more than 3, not more than 2, not more than 1 , not more than 0.5, or not more than 0.1 weight percent of recycled content ethylene, recycled content propylene, recycled content butadiene, recycled content butane, recycled content pentadiene, recycled content cyclopentadiene, recycled content benzene, recycled content toluene, recycled content styrene, recycled content naphthalene, or a combination of two or more thereof, based on the total weight of the pyrolysis effluent stream. These weight percentages are measured on a dry-basis.

[0142] In an embodiment or in combination with any embodiment mentioned herein, the pyrolysis effluent stream from the pyrolysis reactor may comprise not more than 5, not more than 4, not more than 3, not more than 2, not more than 1 , not more than 0.5, or not more than 0.1 weight percent of recycled content C2-C4 hydrocarbons, based on the total weight of the pyrolysis effluent stream.

[0143] In an embodiment or in combination with any embodiment mentioned herein, the pyrolysis effluent stream from the pyrolysis reactor may comprise not more than 5, not more than 4, not more than 3, not more than 2, not more than 1 , not more than 0.5, or not more than 0.1 weight percent of recycled content aromatics, based on the total weight of the pyrolysis effluent stream. These recycled content aromatics can comprise recycled content benzene, recycled content toluene, recycled content styrene, and / or recycled content naphthalene.

[0144] In an embodiment or in combination with any embodiment mentioned herein, the pyrolysis effluent stream from the pyrolysis reactor may comprise at least 0.1 , at least 0.5, or at least 1 weight percent of recycled content glass, based on the total weight of the pyrolysis effluent stream. Additionally, or in the alternative, the pyrolysis effluent stream from thepyrolysis reactor may comprise not more than 50, not more than 25, not more than 10, or not more than 5 weight percent of recycled content glass, based on the total weight of the pyrolysis effluent stream. These weight percentages are measured on a dry-basis. In such embodiments, the glass in the pyrolysis effluent may be in the form of particles and predominantly form the pyrolysis residue.

[0145] In such embodiments, the glass in the pyrolysis effluent may be in the form of particles and predominantly form the pyrolysis residue.

[0146] As discussed below in greater detail, after exiting the pyrolysis reactor, the pyrolysis effluent stream may be separated into a recycled content pyrolysis oil stream, a recycled content pyrolysis residue stream, and a recycled content pyrolysis gas stream in a separation system. Additionally, or in the alternative, one or more thermal decomposition products may be recovered from at least a portion of the pyrolysis effluent, pyrolysis oil, pyrolysis gas, and / or pyrolysis residue. The separation systems may include various types of equipment including, but not limited to, a filter system, a multistage separator, a vacuum separator, a condensation system, a distillation column, and / or a quench tower.

[0147] In an embodiment or in combination with any embodiment mentioned herein, at least a portion of the pyrolysis effluent may be routed to a separation system to thereby recover a recycled content plasticizer stream, a recycled content acetaldehyde stream, and / or a recycled content butyraldehyde stream.

[0148] FIG. 2 depicts a chemical recycling facility 10 containing downstream separation systems for recovering one or more thermal decomposition products from the pyrolysis effluent coming out of the pyrolysis reactor.

[0149] As shown in FIG. 2, at least a portion of the pyrolysis effluent 18 may be routed to a first separation system 20 to thereby recover one or more thermal decomposition products, unconverted PVB resin, and / or other byproducts (e.g., recycled content glass) from the pyrolysis effluent. This first separation system 20 can include various types of equipment including, but not limited to, a filter system, a multistage separator, a vacuumseparator, a condensation system, a distillation column, and / or a quench tower.

[0150] In an embodiment or in combination with any embodiment mentioned herein, at least a portion of the pyrolysis effluent 18 may be routed to a first separation system 20 to thereby form a first depleted effluent stream 22 and a first recycled content product stream comprising a recycled content plasticizer, recycled content acetaldehyde, and / or recycled content butyraldehyde.

[0151] In an embodiment or in combination with any embodiment mentioned herein, the first recycled content product stream may comprise at least 1 , at least 5, at least 10, at least 15, at least 20, at least 25, at least 30, at least 35, at least 40, at least 45, at least 50, at least 55, at least 60, at least 65, at least 70, at least 75, at least 80, at least 85, at least 90, or at least 95 weight percent of recycled content plasticizer, recycled content acetaldehyde, and / or recycled content butyraldehyde, based on the total weight of the stream. Additionally, or in the alternative, the recycled content product stream may comprise not more than 99, not more than 95, not more than 90, not more than 85, not more than 80, not more than 75, not more than 70, not more than 65, not more than 60, not more than 55, not more than 50, not more than 45, not more than 40, or not more than 35 weight percent of recycled content plasticizer, recycled content acetaldehyde, and / or recycled content butyraldehyde, based on the total weight of the stream. These weight percentages are measured on a dry-basis.

[0152] In an embodiment or in combination with any embodiment mentioned herein, the first recycled content product stream may be enriched in one or more plasticizers relative to the pyrolysis effluent stream.

[0153] Additionally, or in the alternative, in an embodiment or in combination with any embodiment mentioned herein, at least a portion of the pyrolysis effluent may be routed to a first separation system to thereby form a first depleted effluent stream and a first recycled content product stream comprising glass particles. In such embodiments, the first recycled contentproduct stream may be enriched in glass relative to the pyrolysis effluent stream.

[0154] T urning again to FIG. 2, at least a portion of the first depleted effluent stream 22 may be introduced into a second separation system 24 to thereby recover one or more additional thermal decomposition products from the first depleted effluent stream 22. This second separation system 24 can include various types of equipment including, but not limited to, a filter system, a multistage separator, a vacuum separator, a condensation system, a distillation column, and / or a quench tower.

[0155] In an embodiment or in combination with any embodiment mentioned herein, at least a portion of the first depleted effluent stream 22 may be routed to a second separation system 24 to thereby form a second depleted effluent stream 26 and a second recycled content product stream comprising a recycled content plasticizer, recycled content acetaldehyde, and / or recycled content butyraldehyde.

[0156] In an embodiment or in combination with any embodiment mentioned herein, the second recycled content product stream may comprise at least 1 , at least 5, at least 10, at least 15, at least 20, at least 25, at least 30, at least 35, at least 40, at least 45, at least 50, at least 55, at least 60, at least 65, at least 70, at least 75, at least 80, at least 85, at least 90, or at least 95 weight percent of recycled content plasticizer, recycled content acetaldehyde, and / or recycled content butyraldehyde, based on the total weight of the stream. Additionally, or in the alternative, the second recycled content product stream may comprise not more than 99, not more than 95, not more than 90, not more than 85, not more than 80, not more than 75, not more than 70, not more than 65, not more than 60, not more than 55, not more than 50, not more than 45, not more than 40, or not more than 35 weight percent of recycled content plasticizer, recycled content acetaldehyde, and / or recycled content butyraldehyde, based on the total weight of the stream. These weight percentages are measured on a drybasis.

[0157] In an embodiment or in combination with any embodiment mentioned herein, the second recycled content product stream may be enriched in one or more aldehydes (e.g., acetaldehyde and / or butyraldehyde) relative to the first depleted effluent stream.

[0158] Additionally, or in the alternative, in an embodiment or in combination with any embodiment mentioned herein, at least a portion of the first depleted effluent stream may be routed to a second separation system to thereby form a second depleted effluent stream and a second recycled content product stream comprising glass particles. In such embodiments, the second recycled content product stream may be enriched in glass relative to the first depleted effluent stream.

[0159] In an embodiment or in combination with any embodiment mentioned herein, the first separation system and / or the second separation system may comprise separation steps and / or systems that occur under vacuum conditions. Additionally, or in the alternative, the first separation system and / or the second separation system may occur under conditions and temperatures that do not chemically modify the unconverted PVB in the pyrolysis effluent and / or the first depleted effluent stream.

[0160] In an embodiment or in combination with any embodiment mentioned herein, the first separation system and / or the second separation system may comprise a quench tower. While in the quench tower, at least a portion of the pyrolysis effluent stream and / or the first depleted stream may be cooled rapidly (e.g., quenched) in order to prevent production of large amounts of undesirable by-products and to minimize fouling in downstream equipment.

[0161] Turning again to FIG. 2, at least a portion of the second depleted effluent stream 26, which may contain some residual amount of unconverted PVB resin, may be routed via a pump 28 back to the pyrolysis reactor 16. As shown in FIG. 2, additional PVB solids may be introduced into the second depleted effluent stream 26 prior to its introduction into the pyrolysis reactor 16. Additionally, one or more lift gases, as previously discussed, may be added to the second depleted effluent stream 26 prior to its introduction intothe pyrolysis reactor 16. Furthermore, in some embodiments, at least a portion of the secondary effluent stream 26 may be further heated via a heat exchanger 30 prior to its introduction into the pyrolysis reactor.

[0162] The resulting pyrolysis oil, the pyrolysis gas, and / or the thermal decomposition products recovered therefrom may be directly used in various downstream applications based on their formulations. As discussed above, individual or combinations of the thermal decomposition products may be recovered from the pyrolysis effluent, the pyrolysis residue, the pyrolysis gas, and / or the pyrolysis oil.

[0163] In an embodiment or in combination with any embodiment mentioned herein, one or more thermal decomposition products may be recovered from the pyrolysis effluent, the pyrolysis residue, the pyrolysis gas, and / or the pyrolysis oil. Subsequently, at least a portion of the recovered thermal decomposition product may be disposed of by: (i) transferring at least a portion of the thermal decomposition product to a third party as a recycled content product; (ii) reacting at least a portion of the thermal decomposition product with one or more additional reactants to thereby produce an additional recycled content product, and / or (iii) combining at least a portion of the thermal decomposition product with another ingredient to thereby produce a secondary recycled content product.

[0164] Examples of additional recycled content products include polyvinyl alcohol, polyvinyl acetate, polyvinyl butyral, cellulose ester butyrate, cellulose ester propionate, and the mono-, di-, and tri- propyl or butyl amines obtained from reducing propionaldehyde or butyraldehyde to propanol and butanol, respectively.

[0165] These products can be made by reacting one or more of the thermal decomposition products with one or more additional reactants to make the desired additional recycled content products. The additional recycled content products can obtain at least a part of their recycle content value derived from the thermal decomposition product.

[0166] Secondary recycled content products can be made by combining, blending, or mixing at least a portion of the thermal decomposition productwith another ingredient to thereby produce a secondary recycled content product. The secondary recycled content product is desirably a blend or mixture of the decomposition product with another polymer. The secondary recycled content products can obtain at least a part of their recycle content value derived from the thermal decomposition product.

[0167] For example, the thermal decomposition product plasticizer can be combined, mixed, or blended with a PVB polymer to make a plasticized or more heavily plasticized PBV interlayer.

[0168] In an embodiment or in combination with any embodiment mentioned herein, at least a portion of the recovered thermal decomposition product may be disposed of by transferring at least a portion of the thermal decomposition product to a third party as a recycled content product. Generally, this transferring may involve the sale of the thermal decomposition product to the third party.

[0169] In an embodiment or in combination with any embodiment mentioned herein, at least a portion of the recovered thermal decomposition product may be disposed of by reacting at least a portion of the thermal decomposition product with one or more additional reactants to thereby produce an additional recycled content product. Generally, in such embodiments, the thermal decomposition product may comprise a C2-C4 aldehyde, which may be used to produce an additional recycled content product, such as a recycled content PVB resin.

[0170] In an embodiment or in combination with any embodiment mentioned herein, at least a portion of the recovered thermal decomposition product may be disposed of by combining at least a portion of the thermal decomposition product with another ingredient to thereby produce a secondary recycled content product. Generally, in such embodiments, the thermal decomposition product may be a recycled content plasticizer, which may be combined with a PVB resin to form a recycled content PVB resin.

[0171] In an embodiment or in combination with any embodiment mentioned herein, at least a portion of the recovered recycled content glass from thepyrolysis effluent may be reused as a bed material and / or an inert heat retention additive in the pyrolysis reactor.

[0172] In an embodiment or in combination with any embodiment mentioned herein, at least a portion of the recovered glass particles from the pyrolysis effluent may have a D90 diameter of less than 2 mm, less than 1 mm, less than 0.5 mm, or less than 0.2 mm.

[0173] In an embodiment or in combination with any embodiment mentioned herein, the pyrolysis reactor may be at least partially heated by an electrical heat source (e.g., one or more electrical heaters) and / or a combustion heat system comprising a plurality of burners that combust a combustion fuel and air. The combustion fuel may comprise a conventional fossil fuel and / or a recycled content fuel, such as recycled content carbon monoxide, recycled content acetaldehyde, and / or recycled content ethylene, which may be derived from the pyrolysis effluent streams of the chemical recycling facility. For example, a recycled content combustion fuel may be at least partially derived from the pyrolysis effluent streams from the chemical recycling facility.

[0174] In an embodiment or in combination with any embodiment mentioned herein, the combustion heat system may heat a heat transfer fluid, such as water, steam, Dowtherm, Therminol, and / or mineral spirits, which can be used to provide indirect heat to the pyrolysis reactor.

[0175] In an embodiment or in combination with any embodiment mentioned herein, at least a portion of the pyrolysis gas stream derived from the pyrolysis effluent stream may be used as a combustion fuel in a combustion heat system that provides heat energy to the pyrolysis reactor.EXAMPLES

[0176] Two different PVB feedstocks were pyrolyzed to demonstrate the recovery of butyraldehyde, acetaldehyde and plasticizer.The PVB Feedstocks:Feedstock 1 : PVB-PIR (Post industrial recycle) were a variety of standard interlayers from Eastman Chemical Company.Feedstock 2: PVB-PCR (Post consumer recycle) were flakes obtained from recycling and processing automotive windshields into PVB flakes containing very little glass (<1 wt.%).

[0177] In Table 1 describes the contribution of different polyene fractions for Feedstock 1 and given that a variety of PVB interlayers were used, the amount of plasticizer Pz, butyraldehyde moiety, acetaldehyde moiety, and or polyenes varied between the listed lows and highs. The values given are in wt.%. Except for the quantity of plasticizer which was measured, the value for all other components of Feedstock 2 were assumed as theoretical, representative of the likely expected composition in a PCR stream containing recycle PVB from a variety of manufacturers.Table 1 - Contribution of different polyene fractions in Feedstock 1 and 2.PVB-PCR Low PzTypical PVB interlayer PVB-PIR High Pz PVB*“Theoretical** PVB“*Pz 27.54““ 30.07 25.00 35.00PVOH (-HC=CH-)* 8.56 8.44 8.68 8.20BUCHO 29.03 27.63 30.42 24.91PVB (-HC=CH-)* 20.96 20.23 21.69 18.81Water 13.19 12.90 13.48 12.34HOAc 0.51 0.51 0.51 0.51PVAc (-HC=CH-)* 0.22 0.22 0.22 0.22* PVB, PVOH and PVAc wt% were calculated based on their respective polyene fractions. "" Assumed PVB-PCR composition for calculating recovery of acetaldehyde, butyraldehyde, and PVB Plasticizer after pyrolysis*** Commercially available PVB materials with different plasticizer content. These are used in the results section to demonstrate potential recoveries of acetaldehyde, butyraldehyde, and PVB Plasticizer after pyrolysis""""The quantity of Pz was measured.The Experimental Setup

[0178] Pyrolysis of PVB Feedstock samples was done in a batch-wise operated fixed-bed reactor. Experiments were done with 150 g PVB material. The schematic of the laboratory equipment setup is shown in Fig.3. A nitrogen cylinder 1 furnished nitrogen to the pyrolysis reactors 7. The nitrogen flow was controlled by a valve 2 coupled to a mass flow meter 3. The flow of nitrogen was pre-heated in the pre-heater (71 cm in length, 2.25 cm internal diameter) 4 made of stainless-steel wrapped with insulated heating tapes. The nitrogen temperature was regulated by measuring the nitrogen temperature with a thermocouple inserted into the preheater and the preheater temperature was regulated by a PIC controller 6. Heated nitrogen at the desired set point flowed into the pyrolysis reactor 7. The pyrolysis reactor 7 consisted of a stainless-steel reactor (50 cm in length, 6 cm internal diameter) that was externally heated by insulated heating tapes. Heating was controlled by the PIC controller 6 coupled to a variety of thermocouple on pyrolysis reactor 7 to measure the pyrolysis reactor temperature. The PID controller 6 enabled the feed to be heated at a heating rate of 10 to 15 °C min-1to the desired final pyrolysis temperature. The pyrolysis reactor 7 was under reflux set at the same temperature as the pyrolysis reactor 7. Cooler 8, through which the pyrolysis effluent flowed (not product off-take from the cooler) was set at -10 °C to capture volatile species such as acetaldehyde (boiling point 20°C). As a cooling medium, a mixture of 50 wt.% glycol and 50 wt.% water was used and circulated through a water circulating heater 9. After the cooler 8, a container was placed to trap the liquid phase (not shown in Fig. 3). The gas phase flows through condenser 11 with a spiral which was cooled to 0°C using an ice bath through which water circulated in water circulating cooler 10. The purpose of condenser 11 was to capture liquid products which were not captured using cooler 8. Gas products 13 from the overhead of condenser 11 were captured for analysis, as were the bottoms oil and waxy products 12.

[0179] Typically, mass balance closures of at least of 95% can be achieved. The carbon bed 14 could be used in the event the mass balance closure was insufficient. Technical checks, safety checks and experiments to adjust the N2 flow rate from cylinder 1 and mass balance closure without carbon bed were carried out. Initial results showed that no C-bed was needed to achieve satisfactory mass balance closure. If needed, the gas stream from the overhead of condenser 11 can flow through a carbon bed 14 to generate a second gas product stream 15.Experimental Procedure

[0180] Weights of clean equipment (reactor, condenser, collection vessel) were recorded. The fixed bed reactor was filled with a pre-weighed amount of the PVB sample. The PVB recycle feedstock was introduced in the pyrolysis reactor 7 as received. Cooling on the cooler 8 and the condenser 1 1 was started. The pyrolysis reactor 7 was purged with N2from cylinder 1 and a leak test was conducted. Nitrogen was used as a product carrier gas, and was pre-heated to 300 °C before entering the fixed-bed pyrolysis reactor 7. The N2flowrate was set at 5 ml min-1. A Tedlar bag of 5 L volume was connected to line 15 for the collection of the second gas stream. The gas bag was changed before it was full, and the gas was analyzed in short time to avoid the condensation of Ce+ products. The gas effluent was sampled at least 3 times per experiment (start-middle-end) for off-line gas analysis in a micro-GC.

[0181] Pyrolysis reactor heating was started and time zero for the experiment was assumed when the bottom thermocouple on the pyrolysis reactor 7 reached the desired temperature. After the desired reaction time, the heaters were turned off and the oil from collection points was collected, weighed, and stored in the freezer. The gas bag was disconnected, and a sample was taken for the analysis purposes. Insulation layer was removed to all equipment to reach ambient temperatures, and subsequently setup was purged with a N2flow of 50 ml min-1for 20 min. Thereafter, equipment(reactor, condenser, collection vessel) were weighed and solid residue was collected and weighed for the mass balance purposes.A variety of pyrolysis run were conducted at different temperatures. The pyrolysis conditions for both Feedstock 1 and 2 PVB samples are reported in Table 2 below.Table 2 - Summary of Experimental ConditionsTest Run No. Feedstock Temperature Time°C h1 PVB-PIR 300 22* PVB-PIR 375 23 PVB-PIR 375 24 PVB-PIR 450 25 PVB-PCR 300 26 PVB-PCR 375 27 PVB-PCR 375 28 PVB-PCR 400 29** PVB-PCR 425 210 PVB-PCR 450 211 PVB-PCR 450 212 PVB-PCR 500 2* Different experimental conditions (Feedstock: 200 g; Cooler temperature: 0 °C) " Water was co-fed with PVB sample in 1:1 weight ratio Liauid / Oil Products Analytical Method

[0182] Quantitative analysis of acetaldehyde, butyraldehyde, and PVB plasticizer in recovered liquid / oil products for each test run was performed by following Test Method A. Quantification of acetaldehyde, butyraldehyde, and PVB plasticizer (S2075) in liquid / oil pyrolysis products was implemented on gas chromatography coupled with a flame ionization detector (GC-FID). In this analysis, the DB1 column (60m x 320 pmx 1 pm)was used with helium as a carrier gas. The amount of acetaldehyde, butyraldehyde, and PVB plasticizer in the samples was calculated based on an external calibration method, while the unknown compounds were quantified with the response factor of butyraldehyde.Solids Analytical Method

[0183] The solids analysis of the PVB Feedstock samples and solid residue obtained from different pyrolysis test runs were subjected to the ICP analysis (Test Method B) to determine the metal content.

[0184] The metal content in PVB feedstocks and solid residues obtained from pyrolysis experiments was determined by inductively coupled plasma- optical emission spectrometry (ICP-OES) technique. Samples were subjected to acid digestion (HNO3 / H2O2) with the support of a Microwave oven before measurement.

[0185] The analysis of the carbon residue was performed according to ASTM D4530 - Micro Carbon Residue Test (MCRT) ~ i.e., Pyrolysis at 500°C.

[0186] The analysis of ash content was determined according to ASTM E1534-93 (2019) by burning away a sample in air atmosphere at 575 °C for 24 hours.Gas Sample Analytical Method

[0187] The gas sample analysis was performed in a Varian 450-GC gas analyzer equipped with two chromatographic columns. The first column was dedicated for separation of H2, CO, CO2, N2and O2, and were quantified by a Thermal Conductivity Detector. The second column was dedicated for identification and quantification of different hydrocarbons (CPU, C2-5 and C6+). Same samples were analyzed three times to ensure the reproducibility.Metal Content Test ResultsCharacterization of both PVB Feedstocks for metals and ash is reported in Table 3. It can be seen that PIR feedstock is low in metal content.Table 3 - Metal content, MCRT and Ash content in Feedstocks PVB-PIR and PVB-PCR

[0188] In Table 4, lumped product yields obtained from pyrolysis of PVB- PIR and PVB-PCR Feedstock are presented as a function of pyrolysis temperature. The yields are reported as a wt.%, calculated as kg recovered product per kg of PVB processed x 100. It can be seen that gas production over temperature range for both feedstocks was limited after the gas stream was cooled in cooler 8 and condenser 11 . With increasing temperature, an increase in oil yield and decreasing solid residue yield was observed. No significant changes in lumped product yields were observed above 450°C for both feedstocks. Water has minimal to no influence on the pyrolysis behavior of PVB-PCR feedstock.Table 4 - Lumped product yield obtained from pyrolysis of PVB feedstockSolid ResidueNo. Feedstock Temperature Liquid / Oil Yield Gas YieldYield# °C kg kg'1PVB kg kg'1PVB kg kg'1PVB1 PVB-PIR 300 16% 83% 0.1%2 PVB-PIR 375 75% 18% 0.5%3 PVB-PIR 375 78% 16% 0.7%4 PVB-PIR 450 92% 1% 0.9%5 PVB-PCR 300 19% 77% 0.1%6 PVB-PCR 375 77% 17% 1%7 PVB-PCR 375 77% 17% 0.9%8 PVB-PCR 400 79% 8% 1.2%9* PVB-PCR 425 86% (93*) 2% 0.9%10 PVB-PCR 450 90% 3% 1.7%11 PVB-PCR 450 87% 2% 1.7%12 PVB-PCR 500 89% 2% 1.7%Liquid / Oil Analysis Results

[0189] Yields of key components, i.e., acetaldehyde, butyraldehyde, plasticizer and other compounds obtained from pyrolysis of PVB-PCR and PVB-PIR at different temperatures were analyzed and the yields are presented in Table 5. The values are reported as a wt.% wt.%, calculated as kg recovered product per kg of PVB processed x 100. An increase in yield of all products was observed with increase in pyrolysis temperature from 300°C to 375°C, whereas above 375°C yields remained fairly constant.Table 5 - Yields of acetaldehyde, butyraldehyde, and plasticizer obtained from pyrolysis of PVB feedstockFeedstock Temperature Acetaldehyde Butyraldehyde Plasticizer Other** No.1 PVB-PIR 300 0.61% 8.22% 0.64% 6.53%2* PVB-PIR 375 - . . .3 PVB-PIR 375 1.56% 23.48% 27.22% 25.74%4 PVB-PIR 450 2.58% 24.20% 25.48% 39.74%5 PVB-PCR 300 0.86% 9.44% 0.21% 8.49%6 PVB-PCR 375 2.16% 24.02% 20.33% 30.49%7 PVB-PCR 375 2.08% 23.41% 21.10% 30.42%8 PVB-PCR 400 2.21% 22.12% 21.09% 33.58%9** PVB-PCR 425 2.58% 22.36% 21.59% 39.47%10 PVB-PCR 450 3.60% 25.29% 22.50% 38.61%11 PVB-PCR 450 3.39% 23.58% 20.71% 39.32%12 PVB-PCR 500 3.56% 23.05% 19.67% 42.72%Key Component Recoveries

[0190] In Table 6, acetaldehyde recovery was estimated based on PVOH, PVB, PVAc and HOAc content in the sample. For both feedstocks, with increase in temperature recovery of acetaldehyde increased. Recovery of acetaldehyde at 450°C for PVB-PCR was higher than that of PVB-PIR.Table 6 - Recovery of acetaldehyde achieved after the pyrolysis of PVB feedstockFeedstoc Temperatur ActualNo. Lower Limit** Higher Limit** k e Recovery# - °C kg kg'1(PVOH+PVB+PVAc+HOAc)1 PVB-PIR 300 2.1 % 2.0% 2.2%2* PVB-PIR 3753 PVB-PIR 375 5.3% 5.0% 5.6%4 PVB-PIR 450 8.8% 8.3% 9.3%5 PVB-PCR 300 2.8% 2.7% 3.1%6 PVB-PCR 375 7.1 % 6.9% 7.8%7 PVB-PCR 375 6.9% 6.7% 7.5%8 PVB-PCR 400 7.3% 7.1% 8.0%9*“ PVB-PCR 425 8.5% 8.3% 9.3%10 PVB-PCR 450 11.9% 11.6% 13.0%11 PVB-PCR 450 11.2% 10.9% 12.2%12 PVB-PCR 500 11.8% 11.4% 12.8%

[0191] In Table 7, butyraldehyde recovery was calculated based on the butyraldehyde content in sample Feedstock, calculated as kg recovered butyraldehyde per kg of butyraldehyde content in PVB processed x 100. For both Feedstocks, recovery of butyraldehyde increased with an increase in temperature up to 375°C, and subsequently remained constant.Table 7 - Recovery of butyraldehyde achieved after the pyrolysis of PVB feedstock* Analysis not performed." Lower and higher potential recoveries calculated based on commercially available PVB materials with different plasticizer content. Refer Table 1.*" Recovery calculated based on dry liquid / oil yield

[0192] In Table 8, plasticizer recovery was calculated based on its content in the sample Feedstock, calculated as kg recovered plasticizer per kg of plasticizer content in PVB processed x 100. For both Feedstocks, recovery of plasticizer increased with an increase in temperature up to 375°C, and subsequently remained constant. In the case of PVB-PIR Feedstock, higher plasticizer recovery was observed compared to PVB-PCR feedstock.Table 8 - Recovery of plasticizer achieved after the pyrolysis of PVB feedstock* Analysis not performed.” Lower and higher potential recoveries calculated based on commercially available PVB materials with different plasticizer content. Refer Table 1. *” Recovery calculated based on dry liquid / oil yield

[0193] In Table 9 the compositional analysis of solid residue is presented. As compared to the feedstock composition (Table 3), the ppm (mg / kg) of metals increased in the solid residue. During pyrolysis, all inorganic species remain non-volatile and end up largely in the solid residue. The content of inorganic material is higher in solid residue of PVB-PCR feedstock than PVB-PIR material. It is important to note that with increasing temperature, the metal concentration present in the solid residue increased for both Feedstocks. Without being bound to a theory, this may be attributed to the inorganic species being deeply embedded within the polymer matrix of each layer. With increase in pyrolysis temperature, the polymer matrix is more thoroughly pyrolyzed and as a result, the concentration of inorganic species present in the remaining residue increases, as a result of increased oil and / or gas yields and decreasing solid yield.Table 9 - Solid Residue AnalysisNo. Feedstock Temp MCRT Ash Al Ca Cr Cu Fe K Mg Na S Si Ti Zn# °C wt.% wt.% ppm ppm ppm ppm ppm ppm ppm ppm ppm ppm ppm ppm1 PVB-PIR 300 2 ± 0.3 <0.1 ± <0.1 15 16 14 20 16 0 62 1 62 PVB-PIR 375 23 ± 1.63 PVB-PIR 375 20 ± 0.2 0.2 ± 0.1 138 232 13 70 317 359 239 102 74 35 81 14 PVB-PIR 450 84 ± 2.2 1.2 ± 0.1 144 872 328 39 1577 2437 1028 226 260 242 363 765 PVB-PCR 300 2 ± 0.2 1 ± 0.26 PVB-PCR 3757 PVB-PCR 375 47 4139 2 149 250 601 1300 68 1672 5 <18 PVB-PCR 400 51 ± 3.6 5.8 ± 0.1 249 >10000 22 339 1243 2257 5857 208 16020 29 62 9 PVB-PCR 425 75 ± 0.9 13.1 ± 0.2 419 >10000 52 28 642 2198 3867 9921 680 16677 46 1010 PVB-PCR 45011 PVB-PCR 450 96 ± 0.3 18.7 ± 0.3 541 >10000 221 130 1463 2590 4587 11717 455 23855 70 7012 PVB-PCR 500 95 ± 0.2 25.1 ± 0.5 759 >10000 228 1089 1740 3732 5987 15725 619 29202 88 103

[0194] From Table 4, the non-condensable pyrolysis gas yield did not exceed 1 wt.% for PVB-PIR samples and 2 wt.% for PVB-PIR samples. The compositional analysis of this minor product stream is presented in Table 10.Table 10 - Gas composition obtained from pyrolysis of PVB FeedstockNo. Feedstock Temperature H2 CO2 CO CH4 C2H6 C2H4# - °C kg kg-1P1 PVB-PIR 300 0.00% 0.04% 0.02% 0.00% 0.00% 0.00% 02 PVB-PIR 3753 PVB-PIR 375 0.00% 0.26% 0.22% 0.02% 0.03% 0.02% 0.06% 0.07% 0.00% 0.00% 0.00% 0.02%4 PVB-PIR 450 0.01 % 0.17% 0.26% 0.08% 0.06% 0.07% 0.09% 0.13% 0.00% 0.00% 0.00% 0.03%5 PVB-PCR 300 0.00% 0.06% 0.02% 0.00% 0.00% 0.00% 0.01 % 0.01 % 0.00% 0.00% 0.00% 0.01 %05016 PVB-PCR 375 0.00% 0.45% 0.29% 0.03% 0.03% 0.02% 0.08% 0.08% 0.00% 0.00% 0.00% 0.03%7 PVB-PCR 3758 PVB-PCR 400 0.00% 0.38% 0.33% 0.07% 0.09% 0.04% 0.12% 0.12% 0.00% 0.00% 0.00% 0.03%9 PVB-PCR 42510 PVB-PCR 450 0.01 % 0.49% 0.48% 0.11 % 0.10% 0.08% 0.15% 0.24% 0.00% 0.00% 0.00% 0.04%11 PVB-PCR 450 0.01 % 0.44% 0.24% 0.16% 0.13% 0.13% 0.20% 0.33% 0.00% 0.00% 0.00% 0.04%12 PVB-PCR 500 0.01 % 0.46% 0.59% 0.07% 0.03% 0.08% 0.13% 0.28% 0.01% 0.00% 0.00% 0.04%Blank cell in above table imply that the value was not determined.

[0195] From both Feedstocks, maximum recovery of acetaldehyde, butyraldehyde, and plasticizer and highest liquid yields can be achieved at about 400°C to 500°C, and more particularly at about 425°C to 475°C. The yields of the compounds dramatically increased until a temperature of 450°C was obtained and thereafter plateaued with only slight improvements and in some instances, the yield started to decrease slightly as the temperature reached 500°C. The high yields were realized within a residence time of only 5 minutes or less in the pyrolysis reactor.

[0196] Maximizing liquid yield consequently lowered the solid residue yield. Low solid residue yields may ensure efficient separation of undesired inorganic species from the polymer matrix. Addition of water / steam during pyrolysis did not affect the yield of organics. With this observation it can be concluded that moisture rich feedstocks can be processed seamlessly through the pyrolysis process without pre-pyrolysis drying step, thereby saving an added energy expense. Moreover, presence of water or steam does not affect the oil, gas and solid yields as well as the recoveries of key components such as plasticizer, acetaldehyde, butyraldehyde.DEFINITIONS

[0197] It should be understood that the following is not intended to be an exclusive list of defined terms. Other definitions may be provided in the foregoing description, such as, for example, when accompanying the use of a defined term in context.

[0198] As used herein, the terms “a,” “an,” and “the” mean one or more.

[0199] As used herein, the term “and / or,” when used in a list of two or more items, means that any one of the listed items can be employed by itself or any combination of two or more of the listed items can be employed. For example, if a composition is described as containing components A, B, and / or C, the composition can contain A alone; B alone; C alone; A and B in combination; A and C in combination, B and C in combination; or A, B, and C in combination.

[0200] As used herein, the phrase “at least a portion” includes at least a portion and up to and including the entire amount or time period.

[0201] As used herein, the term “chemical recycling” refers to a PVB recycling process that includes a step of chemically converting waste PVB into lower molecular weight polymers, oligomers, monomers, and / or non- polymeric molecules (e.g., carbon monoxide, C2-C4 aldehydes, ethylene, and propylene) that are useful by themselves and / or are useful as feedstocks to another chemical production process(es).

[0202] As used herein, the term “co-located” refers to the characteristic of at least two objects being situated on a common physical site, and / or within one mile of each other.

[0203] As used herein, the terms “comprising,” “comprises,” and “comprise” are open-ended transition terms used to transition from a subject recited before the term to one or more elements recited after the term, where the element or elements listed after the transition term are not necessarily the only elements that make up the subject.

[0204] As used herein, the term “depleted” refers to having a concentration (on a dry weight basis) of a specific component that is less than the concentration of that component in a reference material or stream.

[0205] As used herein, the term “diameter” means the maximum chord length of a particle (i.e., its largest dimension), which can be measured with a particle size analyzer, such as the Model CPA 4-1 Computerized Particle Analyzer from W.S Tyler of Mentor, Ohio.

[0206] As used herein, the term “directly derived” refers to having at least one physical component originating from recycled PVB.

[0207] As used herein, the term “enriched” refers to having a concentration (on a dry weight basis) of a specific component that is greater than the concentration of that component in a reference material or stream.

[0208] As used herein, the terms “having,” “has,” and “have” have the same open-ended meaning as “comprising,” “comprises,” and “comprise” provided above.

[0209] As used herein, the terms “including,” “include,” and “included” have the same open-ended meaning as “comprising,” “comprises,” and “comprise” provided above.

[0210] As used herein, the term “interlayer” refers to a single or multiple layer polymer sheet suitable for use with at least one rigid substrate to form a multiple layer panel.

[0211] As used herein, the term “isolated” refers to the characteristic of an object or objects being by itself or themselves and separate from other materials, in motion or static.

[0212] As used herein, a “molten feed” refers to a substantially liquid feed that contains at least one component that is in substantially liquid form and has been heated above its melt temperature and / or glass transition temperature.

[0213] As used herein, the term “predominantly” means more than 50 percent by weight. For example, a predominantly PVB stream, composition, feedstock, or product is a stream, composition, feedstock, or product that contains more than 50 weight percent PVB.

[0214] As used herein, the term “preprocessing” refers to preparing PVB compositions for chemical recycling using one or more of the following steps: (i) comminuting, (ii) particulating, (iii) washing, (iv) drying, and / or (v) separating.

[0215] As used herein, the term “PVB recycling facility” refers to a facility for producing a recycled content product via chemical recycling of PVB.

[0216] As used herein, the term “pyrolysis” refers to thermal decomposition of one or more organic materials at elevated temperatures in an inert (i.e., substantially oxygen free) atmosphere.

[0217] As used herein, the term “pyrolysis char” refers to a carbon- containing composition obtained from pyrolysis that is solid at 200°C and 1 atm.

[0218] As used herein, the terms “pyrolysis gas” and “pygas” refer to a composition obtained from pyrolysis that is gaseous at 25°C at 1 atm.

[0219] As used herein, the terms “pyrolysis oil” or “pyoil” refers to a composition obtained from pyrolysis that is liquid at 25°C and 1 atm. The pyrolysis oil or pyoil may be in vapor or liquid form.

[0220] As used herein, the term “pyrolysis residue” refers to a composition obtained from pyrolysis that is not pyrolysis gas or pyrolysis oil and that comprises predominantly pyrolysis char and pyrolysis heavy waxes. It is solid at 25°C and 1 atm.

[0221] As used herein, the terms “recycled content” and “r-content” refer to being or comprising a composition that is directly and / or indirectly derived from the recycled PVB composition.

[0222] As used herein, the terms “recycled content pyrolysis gas,” “r- pyrolysis gas,” or “r-pygas” refer to being or comprising a pyrolysis gas that is directly and / or indirectly derived from the recycled PVB composition.

[0223] As used herein, the terms “recycled content pyrolysis oil,” “r-pyrolysis oil,” or “r-pyoil” refer to being or comprising a pyrolysis oil that is directly and / or indirectly derived from the recycled PVB composition.

[0224] As used herein, the terms “single-sheet” interlayer and “monolithic” interlayer refer to interlayers formed of one single resin sheet, while the terms “multiple layer” and “multi-layer” interlayer refer to interlayers having two or more resin sheets coextruded, laminated, or otherwise coupled to one another.NUMERICAL RANGES

[0225] When a numerical sequence is indicated, it is to be understood that each number is modified the same as the first number or last number in the numerical sequence or in the sentence, e.g., each number is “at least,” or “up to” or “not more than” as the case may be; and each number is in an “or” relationship. For example, “at least 10, 20, 30, 40, 50, 75 wt.%...” means the same as “at least 10 wt.%, or at least 20 wt.%, or at least 30 wt.%, or at least 40 wt.%, or at least 50 wt.%, or at least 75 wt.%,” etc.; and “not more than 90 wt.%, 85, 70, 60...” means the same as “not more than 90 wt.%, or not more than 85 wt.%, or not more than 70 wt.%..” etc.; and “at least 1 %,2%, 3%, 4%, 5%, 6%, 7%, 8%, 9% or 10% by weight...” means the same as “ at least 1 wt.%, or at least 2 wt.%, or at least 3 wt.% ...” etc.; and “at least 5, 10, 15, 20 and / or not more than 99, 95, 90 weight percent” means the same as “at least 5 wt.%, or at least 10 wt.%, or at least 15 wt.% or at least 20 wt.% and / or not more than 99 wt.%, or not more than 95 wt.%, or not more than 90 weight percent...” etc.

[0226] The present description uses numerical ranges to quantify certain parameters relating to the invention. It should be understood that when numerical ranges are provided, such ranges are to be construed as providing literal support for claim limitations that only recite the lower value of the range as well as claim limitations that only recite the upper value of the range. For example, a disclosed numerical range of 10 to 100 provides literal support for a claim reciting “greater than 10” (with no upper bounds) and a claim reciting “less than 100” (with no lower bounds).CLAIMS NOT LIMITED TO DISCLOSED EMBODIMENTS

[0227] The preferred forms of the invention described above are to be used as illustration only and should not be used in a limiting sense to interpret the scope of the present invention. Modifications to the exemplary embodiments, set forth above, could be readily made by those skilled in the art without departing from the spirit of the present invention.

[0228] The inventors hereby state their intent to rely on the Doctrine of Equivalents to determine and assess the reasonably fair scope of the present invention as it pertains to any apparatus not materially departing from but outside the literal scope of the invention as set forth in the following claims.

Claims

What is claimed is:

1. A process for recycling poly(vinyl butyral) (PVB), the process comprising:(a) pyrolyzing at least a portion of a feedstock comprising a PVB- containing composition in an initial pyrolysis stage to thereby provide an initial pyrolysis effluent and a liquid reaction medium; and(b) pyrolyzing at least a portion of the liquid reaction medium in a subsequent pyrolysis stage to thereby form a subsequent pyrolysis effluent.

2. The process of claim 1 , wherein the initial pyrolysis effluent comprises a recycled content plasticizer.

3. The process of claim 1 , wherein the subsequent pyrolysis effluent comprises recycled content acetaldehyde or recycled content butyraldehyde.

4. The process of claim 1 , wherein the PVB-containing composition comprises post-consumer scrap.

5. The process of claim 1 , wherein the pyrolyzing of step (b) occurs at a higher temperature relative to the pyrolyzing of step (a).

6. The process of claim 1 , wherein the initial pyrolysis stage and the subsequent pyrolysis stage occur in different pyrolysis reactors.

7. The process of claim 1 , wherein the pyrolyzing of step (a) occurs at a pyrolysis temperature in the range of 200 to 450 °C, and pyrolyzing of step (b) occurs at a pyrolysis temperature in the range of 200 to 550 °C.

8. The process of claim 1 , wherein the subsequent pyrolysis effluent comprise 5 to 60 weight percent of recycled content butyraldehyde.

9. The process of claim 1 , wherein the initial pyrolysis effluent comprises 5 to 80 weight percent of a recycled content plasticizer.

10. The process of claim 1 , wherein the initial pyrolysis effluent and / or the subsequent pyrolysis effluent comprise not more than 10 weight percent of recycled content ethene, recycled content propene, recycled content butadiene, recycled content butane, recycled content pentadiene, recycled content cyclopentadiene, recycled content benzene, recycled content toluene, recycled content styrene, recycled content naphthalene, or a combination of two or more thereof, based on the total weight of the pyrolysis effluent.1 1 . The process of claim 1 , wherein the feedstock comprises at least 75 weight percent of the PVB-containing composition.

12. The process of claim 1 , wherein the decomposition product comprises butyraldehyde, and the yield of butyraldehyde, based on the weight of the PVB-containing composition, or alternatively based on the weight of the chemical recycling feedstock, fed to the pyrolysis reactor, is at least 10 wt.%, or at least 15 wt.%, or at least 18 wt.%, or at least 20 wt.%, or at least 21 wt.%, or at least 22 wt.%, or at least 23 wt.%, or at least 24 wt.%.

13. The process of claim 1 , wherein the decomposition product comprises butyraldehyde, and the yield of butyraldehyde, based on the butyraldehyde content in PVB fed to the pyrolysis reactor, is at least 70 wt.%, or at least 72 wt.%, or at least 75 wt.%, or at least 77 wt.%, or at least 80 wt.%.

14. The process of claim 1 , wherein the decomposition product comprises plasticizer, and the yield of plasticizer, based on the weight of the PVB-containing composition, or alternatively based on the weight of the chemical recycling feedstock, fed to the pyrolysis reactor, is at least 10 wt.%, or at least 15 wt.%, or at least 18 wt.%, or at least 19 wt.%, or at least 20 wt.%, or at least 21 wt.%.

15. The process of claim 1 , wherein the decomposition product comprises plasticizer, and the yield of plasticizer, based on the amount of plasticizer in the PVB fed to the pyrolysis reactor, is at least 65 wt.%, or at least68 wt.%, or at least 70 wt.%, or at least 72 wt.%, or at least 74 wt.%.

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