Process for utilizing alkyl (meth-)acrylate production waste streams
The process converts alkyl (meth-)acrylate production waste streams into synthesis gas using gasifiers, addressing CO2 emissions and waste utilization challenges, providing a sustainable feedstock for chemical production.
Patent Information
- Application Number
- PCT/EP2025/066346
- Authority / Receiving Office
- WO · WO
- Patent Type
- Applications
- Current Assignee / Owner
- Priority Date
- 2024-06-21
- Filing Date
- 2025-06-12
- Publication Date
- 2025-12-26
AI Technical Summary
Current methods for treating alkyl (meth-)acrylate production waste streams, such as incineration, result in undesired CO2 emissions and are not suitable for converting waste into feedstocks for the chemical industry.
A process that converts alkyl (meth-)acrylate production waste streams into synthesis gas using an entrained flow or plasma gasifier, integrated with a production plant, reducing CO2 emissions and enabling the waste streams to be used as feedstocks for chemical production.
The process reduces CO2 emissions and carbon footprint while providing a more environmentally friendly method for waste stream utilization, converting waste into synthesis gas suitable for chemical production.
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Abstract
Description
Process for utilizing alkyl (meth-)acrylate production waste streamsTechnical areaThe present invention relates to a process utilizing alkyl (meth-)acrylate production waste streams, an alkyl (methacrylate production plant comprising an integrated production waste streams treatment facility and the use of said plant for said process.Background of the inventionAlkyl (meth-)acrylates are important commodities in the chemical industry. Accordingly, large amounts of waste streams are formed during production of alkyl (meth-)acrylates.Alkyl (meth-)acrylates are manufactured from (meth-)acrylic acid and an aliphatic alcohol in a reaction unit which can be a single reactor or a reactor cascade. The crude alkyl (meth-)acrylates are then purified in an upgrading unit and the purified alkyl (meth-)acrylates are used as such or subjected to a polymerization reaction. Unreacted (meth- jacrylic acid is separated from volatile reaction products in an educt recovery unit and then transferred back into the reaction unit. A waste stream, also referred to as "heavy residue”, is either purged from the reaction unit or the upgrading unit, depending on the particular alkyl (meth-)acrylate production process. Optional further waste streams, also referred to as "light residue”, may be purged from the educt recovery unit and / or the upgrading unit depending on the particular alkyl (meth-)acrylate production process.A standard method for treatment of waste streams from alkyl (meth-)acrylate production is incineration of said waste streams for example in a boiler in which steam can be produced. Thereby, undesired CO2 is formed.W02004 / 069082A1 relates to a method for producing (meth-)acry lie acid based on the use of two distillation columns, a dehydration column followed by a finishing column). A cracking residue derived from the bottom of the dehydration column is utilized by hydrothermal gasification at 350 to 450 °C and 25 MPa resulting in a mixture of methane, hydrogene, CO2 and minor amounts of solid residues and water. Heavy residues derived from (methacrylic acid and heavy residues derived from methyl acrylate or ethyl acrylate production are combined in ratios from 9:1 to 1 :9 and cracked together at 180 to 220 °C under atmospheric pressure for 0.5 to 3 hours. The is not suited as a feedstock for producing chemicals such as methanol and Fischer-Tropsch liquids which require pure mixtures of CO and H2 ("syngas”).US2003 / 0143143A1 relates to a process for treating waste discharged from an acrylic acid production process and a consecutive polyacrylic acid production process in which at least one waste stream derived from said two processes are combusted simultaneously. Combustion of waste streams from chemical production results in undesired formation of CO2.DE102005006305A1 relates to process for generating fuel- and or synthesis gas from biomass by gasification in an entrained flow gasifier at a temperature below 1200 °C. Waste streams from acrylate production plants are not "biomass” and, in addition, have a different composition, e.g., are based on ligno-cellulosic material.It is the objective of the present invention to utilize the alkyl (meth-)acrylate production waste streams described above in a more environmentally friendly way than incineration and the above-described process comprising four steps.It is a further objective of the present invention to provide a process for manufacture of alkyl (meth-)acrylate production having a reduced product carbon footprint (PCF).It is a further objective of the present invention to provide a process and an alkyl (meth-)acrylate production plant which convert at least a portion of the waste streams into feedstocks for the chemical industry.Summary of the inventionThese problems are solved by a process for utilizing at least one waste stream from an alkyl (meth-)acrylate production plant, wherein the alkyl (meth-)acrylate production plant comprises a) a reaction unit RU, b) an educt recovery unit ERU, and c) an acrylate upgrading unit UU, the process comprising the steps(oi) feeding (meth-)acrylic acid (M)AA, an alkanol and an acid catalyst into said reaction unit RU which comprises at least one reactor and preferably consists of a cascade of two or more reactors,(i) providing a first waste stream W1, wherein the first waste stream W1 is separated from the reaction unit RU or the acrylate upgrading unit UU,(ii) optionally providing a second waste stream W2, wherein the optional second waste stream W2 is separated from the educt recovery unit ERU and / or a third waste stream W3, wherein the optional third waste stream W3 is separated from the acrylate upgrading unit UU,(iii) optionally pretreating the first waste stream W1 and / or the optional second waste stream W2 and / or the optional third waste stream W3,(iv) subjecting the first waste stream W1, optionally after pretreatment in step (iii), and optionally the optional second waste stream W2 and / or the optional third waste stream W3, optionally after pretreatment in step (iii), to a gasification process wherein said gasification process comprises at least one gasifier G, wherein said at least one gasifier G is an entrained flow gasifiers or a plasma gasifier, and thereby forming a gas stream GS1 wherein said gas stream GS1 comprises CO, CO2 and H2.These problems are further solved by an alkyl (meth-)acrylate production plant comprising an integrated waste stream treatment facility wherein said alkyl (meth-)acrylate production plant comprisesa) a reaction unit RU, b) an educt recovery unit ERU downstream and fluidically connected to said reaction unit RU, c) an acrylate upgrading unit UU downstream and fluidically connected to said reaction unit RU, d) at least one gasifier G downstream of and directly or indirectly fluidically connected to said acrylate upgrading unit UU or said reaction unit RU, wherein said educt recovery unit ERU is upstream of and optionally directly or indirectly fluidically connected to said at least one gasifier G.The waste streams purged from an alkyl (meth-)acrylate production plant are converted into synthesis gas. Accordingly, less undesired CO2 is formed in comparison to the incineration of such waste streams which is the current standard procedure for treating said production waste streams. Furthermore, the synthesis gas formed by the process according to the present invention can be directly used as feedstock for the production of chemicals in chemical production plants. Thereby also the product carbon footprint (PCF) of alkyl (meth-)acrylates manufactured by said process is reduced.The alkyl (meth-)acrylate production plant is suited for treating the waste streams from production of alkyl (methacrylates in a more environmentally friendly way by reducing the CO2 emissions.Figure 1 shows the process and the alkyl (meth-)acrylate plant in one aspect of the present invention in which the first waste stream W1 is purged from the upgrading unit UU, dotted lines represent optional waste streams and process units.Figure 2 shows the process and the alkyl (meth-)acrylate plant in another aspect of the invention in which the first waste stream W1 is purged from the upgrading unit UU and a waste stream W2 and / or a waste stream W3 are also fed into the gasifier G, dotted lines represent optional waste streams and process units.Figure 3 shows the process and the alkyl (meth-)acrylate plant in another aspect of present invention in which the first waste stream W1 is purged from the reaction unit RU, dotted lines represent optional waste streams and process units.Figure 4 shows the process and the alkyl (meth-)acrylate plant in another aspect of the invention in which the first waste stream W1 is purged from the reaction unit RU and a waste stream W2 is also fed into the gasifier G, dotted lines represent optional waste streams and process units.Detailed description of the inventionThe present invention is further described below with reference to the aspects, but the present invention is not limited to these aspects, and any modifications of these aspects, combinations of these aspects or substitutions within the basic spirit of the present invention are still within the scope of the present invention as claimed.Definitions:In the context of the present description and the accompanying claims, the term "about” preferably means a deviation of the thus described value of ±10 %. In the context of the present invention, the term “combinations thereof' is inclusive of one or more of the recited elements. In the context of the present invention, the term “mixture thereof” is inclusive of one or more of the recited elements.“Refuse-derived fuel” (RDF) is defined herein as a fuel produced form various types of waste such as municipal solid waste (MSW), industrial waste or commercial waste. RDF consists largely of combustible components of such waste, as non-recyclable plastics (not including PVC), paper cardboard, labels, and other corrugated materials. These fractions are separated by different processing steps, such as screening, air classification, ballistic separation, separation of ferrous and non-ferrous materials, glass, stones, and other foreign materials and shredding into a uniform grain size, or also pelletized to produce a homogeneous material which can be used as a feedstock for gasification processes (Y. Yang et al., Gasification of refuse-derived fuel from municipal solid waste for energy production: a review, Environmental Chemistry Letters (2021) 19, 2127-2140 (https: / / doi.org / 10.1007 / s10311-020- 01177-5).The term “downstream of” is defined herein in respect to a succession of unit operations as located next to on the side which is in the flow direction of fluids passing said succession of unit operations.The term “fluidically connected to” in respect to two or more units is defined herein that a fluid such as a particulate solid, liquids, gases, and mixtures thereof can flow from one of such unit to the other such unit and flow through and / or along such an analytical unit. Two units “fluidically connected to” each other are for example connected by “direct” connection means such as one or more pipes or by “indirect” connection means such as a truck, a train or a pipeline transporting the first waste stream W1 and the optional second waste stream W2 and / or the third waste stream W3 from the unit form which it / they are purged to the gasifier G and / or an optional unit in which the first waste stream W1 and optional second waste stream W2 and / or third waste stream W3 is / are pretreated before fed into said gasifier G.The process for utilizing waste streams from an alkyl (meth-)acrylate production plant according to the present invention is schematically shown in Figures 1 to 4 and is described below in detail. Additional aspects of the present invention utilizing in addition a gasifier GO which is upstream of and fluidically connected to the at least one gasifier G are not shown in Figures 1 to 4 but described further below.Several processes to produce alkyl (meth-)acrylates are known und commercially used. In general, such processes utilize an alkyl (meth-)acrylate production plant which comprises a reaction unit RU, an educt recovery unit ERU and an upgrading unit UU.Alkyl esters of (meth-)acrylic acid ("alkyl (meth-)acylates”) are formed by reacting (meth-)acrylic acid with alkanols, preferably with alkanols having from 1 to 8 carbon atoms in a homogeneous, liquid, solvent-free phase at elevated temperature and in the presence of an acid esterification catalyst in an acrylate production plant.(Meth-)acrylic acid (M)AA, the alkanol and the acid catalyst are fed into a reaction unit RU which comprises at least one reactor and preferably consists of a cascade of two or more reactors (step oi).A crude product CP which comprises the desired alkyl (meth-)acrylate is formed in the reaction unit RU and then discharged from the reaction unit RU and conveyed into an upgrading unit UU in which the desired alkyl (methacrylate is separated from the crude product CP. Furthermore, a first waste stream W1 is separated from the crude product CP in said upgrading unit UU or directly from the reaction unit RU.The volatile reaction products VRP formed in the reaction unit RU are separated from unreacted educts in an educt recovery unit ERU from which unreacted (meth-)acrylic acid (M)AA' is fed into the reaction unit RU. Optionally, a second waste stream W2 is separated from the educt recovery unit ERU and purged therefrom.Optionally, a third waste stream W3 is purged from the upgrading unit UU which is different from the first waste stream W1.The above-described process is the generalized and preferred method which is used to manufacture alkyl (methacrylates from (meth-)acrylic acid (M)AA and alkanols, preferably alkanols having from 1 to 8 carbon atoms. Specific processes utilizing said general and preferred method are for example disclosed in Ullmanns Encyclopedia of Industrial Chemistry, Takahashi Ohara et al., Chapter "Acrylic acid and derivatives”, pages 10 to 12, 2020, Wiley- VCH Verlag GmbH & Co. KGaA, Weinheim (DOI: 10.1002 / 14356007. a01_161.pub4). Such processes produce at least a first waste stream W1 (purged from the upgrading unit UU or the reaction unit RU) and optionally a second waste stream W2 which is purged from the educt recovery unit ERU and / or an optional third waste stream W3 which is purged from the upgrading unit UU.A method for continuous preparation of alkyl esters of (meth-)acrylic acid is disclosed in US 6,072,076. A preferred acrylate production plant type from which a first waste stream W1 and a second waste stream W2 are separated is described therein. The plant and the method disclosed therein is particularly suited for reacting alkanols having 4 to 8 carbon atoms such as n-butanol and 2-ethyl-hexanol with (meth-)acrylic acid in the presence of an organic sulfonic acid such as para-toluenesulfonic acid as acidic catalyst. The upgrading unit UU in US 6,072,076 from which the first waste stream W1 ("viscous residue 40”) is separated comprises the "rectification column IV”. The educt recovery unit ERU in US 6,072,076 A from which the second waste stream W2 ("octens separated off 45”) is separated comprises the "condenser 16 and separator 17”.A method for continuous preparation of alkyl esters of (meth-)acrylic acid is disclosed in US 6,472,554 B1 and another preferred acrylate production plant type from which a first waste stream W1 and a second waste stream W2 are separated is described therein. The plant and the method disclosed therein is particularly suited for reacting alkanols having 4 to 8 carbon atoms such as n-butanol and 2-ethyl-hexanol with (meth-)acrylic acid in the presence of an organic sulfonic acid such as para-toluenesulfonic acid as acidic catalyst. The first waste stream W1 is a high caloric waste stream and is separated from the upgrading unit UU. The second waste stream W2 is purged from the educt recovery unit ERU.A process for preparing alkyl esters of (meth-)acrylic acid and another preferred acrylate production plant type from which a first waste stream W1 is separated is disclosed in US 2006 / 0205973 A1 . The first waste stream W1 is denoted "bottom stream 40 comprising high boilers” and is separated by a "boiler 61” which is part of the upgrading unit UU. The first waste stream W1 is a high caloric waste stream.A process for preparing alkyl esters of (meth-)acrylic acid and another preferred acrylate production plant type from which a first waste stream W1 is separated is disclosed in DE 10144490 A1 . This process is particularly suited for manufacture of methyl- and ethyl-(meth-)acrylates. The first waste stream W1 is a high caloric waste stream and purged in this process from the reaction unit RU.Analytical methods suitable for measuring the calorific value of a first waste stream W1, a second waste stream W2 and a third waste stream W3 comprise combustion of a sample of said waste streams in a bomb calorimeter. Such methods are for example suitable to assess the thermochemical behavior of said waste streams during the gasification reaction and, accordingly, the suitable type of gasifier and gasification process parameters such as temperature, amount, and type of oxidant.Analytical methods suitable for measuring the elemental composition such as the content of chemical elements H, C, O, N, and S of a first waste streams W1, a second waste stream W2 and a third waste stream W3 comprise CHNX analysis by combustion combined with thermal conductivity detection and / or infrared spectroscopy. The ranges for calorific values, carbon content, hydrogen content, oxygen content, nitrogen content and sulfur content for waste streams W1, W2 and W3 disclosed below are obtained when converting acrylic acid and an alkyl alcohol in the presence of an acid catalyst in processes for manufacture of alkyl esters of (meth-)acrylic acid briefly described above and described in detail for example in the references cited above.The first waste stream W1 has at least one, preferably all the following properties: a) a calorific value in the range of 5 to 43 MJ / kg, more preferably of 8 to 40 MJ / kg and most preferably of 12 to 38 MJ / kg, b) a carbon content in the range of 30 to 80 wt.-%, more preferably 35 to 75 wt.-% and most preferably 40 to 75 wt.-%,c) a hydrogen content in the range of 2 to 15 wt.-%, more preferably 3 to 13 wt.-% and most preferably 3.5 to12 wt.-%, d) an oxygen content in the range of 10 to 60 wt.-%, more preferably 12 to 55 wt.-% and most preferably 14 to50 wt.-%, e) a nitrogen content in the range of 0.0 to 5 wt.-%, more preferably 0.0 to 3 wt.-% and most preferably 0.0 to2 wt.-%, f) a sulfur content in the range of 0.0 to 15 wt.-%, more preferably 0.0 to 12 wt.-% and most preferably 0.0 to 10 wt.-%.The optional second waste stream W2 has at least one, preferably all the following properties: a) a calorific value in the range of 10 to 50 MJ / kg, more preferably of 13 to 46 MJ / kg and most preferably of 16 to 44 MJ / kg, b) a carbon content in the range of 30 to 90 wt.-%, more preferably 35 to 85 wt.-% and most preferably 40 to85 wt.-%, c) a hydrogen content in the range of 2 to 20 wt.-%, more preferably 3 to 18 wt.-% and most preferably 5 to16 wt.-%, d) an oxygen content in the range of 4 to 60 wt.-%, more preferably 6 to 55 wt.-% and most preferably 7 to50 wt.-%, e) a nitrogen content in the range of 0.0 to 5 wt.-%, more preferably 0.0 to 3 wt.-% and most preferably 0.0 to2 wt.-%, f) a sulfur content in the range of 0.0 to 4 wt.-%, more preferably 0.0 to 3 wt.-% and most preferably 0.0 to 2 wt.- %.The optional third waste stream W3 has at least one, preferably all the following properties: a) a calorific value in the range of 20 to 50 MJ / kg, more preferably of 25 to 45 MJ / kg and most preferably of 30 to 45 MJ / kg, b) a carbon content in the range of 50 to 85 wt.-%, more preferably 55 to 80 wt.-% and most preferably 60 to80 wt.-%, c) a hydrogen content in the range of 2 to 20 wt.-%, more preferably 5 to 18 wt.-% and most preferably 8 to15 wt.-%, d) an oxygen content in the range of 5 to 30 wt.-%, more preferably 8 to 25 wt.-% and most preferably 10 to25 wt.-%.Next, the first waste stream W1 is provided in step (i) after separation in the acrylate upgrading unit UU or the reaction unit RU. Optionally, a second waste stream W2 after separation in the educt recovery unit ERU and / or a third waste stream W3 after separation in the upgrading unit UU is provided in step (ii).Optionally, the first waste stream W1 and / or the optional second waste stream W2 and / or the optional third waste stream W3 is / are pretreated in step (iii). For example, the first waste stream which preferably has a higher viscosity than the optional second waste stream W2 and / or the optional third waste stream W3 is mixed with the optional second waste stream and / or the third waste stream W3. Thereby, the viscosity of the resulting mixture of waste streams (“W12” in case the first waste stream W1 and the second waste stream W2 are mixed, “W13” in case the first waste stream W1 and the third waste stream W3 are mixed, "W123” in case the first waste stream W1, the second waste stream W2 and the third waste stream W3 are mixed) is lowered. The first waste stream W1 can also be mixed with at least one waste stream from another (chemical) process whereby the viscosity of the first waste stream W1 is lowered. The lowered viscosity results in improved fluidic behavior, which is desired because such waste streams need to be transported in e.g., pipes and pumped. Other pretreatment methods can be selected and applied by the skilled person.Next, the first waste stream W1, optionally after pretreatment in step (iii), is subjected to a gasification process in step (iv) wherein said gasification process comprises at least one gasifier G, and thereby forming a gas stream GS1 wherein said gas stream GS1 comprises CO, CO2 and H2. In another aspect of the present invention, the optional second waste stream W2 and / or the optional third waste stream W3, optionally after pretreatment in step (iii) or at least a portion thereof is / are also subjected to said gasification process in step (iv), either fed separately into the gasifier G or mixed with each other in optional step (iii) as described above. Said aspect of the present invention is described in detail below.Preferably, a further feedstock F is also provided and subjected to said gasification process in step (iv). Said further feedstock F is preferably selected from the group comprising or consisting of biomass, refuse-derived fuel (RDF), pyrolysis oils made from plastic waste, pyrolysis oils made from end of life tires, pyrolysis oils made from biomass, heating oils, vacuum residues, preferably vacuum distillation residues, crude oil residues, heavy crude oils, extra heavy crude oils, tar sand bitumen, visbreaker bottom residues, deasphalter bottom residues, C5 asphalthene fraction, high viscous residues, fuel oils, pyrolysis gasolines, waste oils, used oils, municipal solid waste (MSW), automotive shredder residue (ASR), natural gas, coal, industrial waste streams, waste streams from an acrylic acid production plant and mixtures thereof.The further feedstock F is most preferably selected from the group consisting of biomass, refuse-derived fuel (RDF), pyrolysis oils made from plastic waste, pyrolysis oils made from end-of-life tires, pyrolysis oils made from biomass, municipal solid waste (MSW), waste streams from an acrylic acid production plant and mixtures thereof.The further feedstock F is optionally pretreated before subjected to the gasification process in step (iv), wherein said pretreatment preferably comprises a conversion of the further feedstock F in at least one fixed-bed gasifier Fl BG as gasifier GO into a pretreated further feedstock PF which comprises synthesis gas, synthetic natural gas (SNG) and a tar oil slurry which are then preferably fed into an entrained flow gasifier G in step (iv) as pretreated further feedstock PF. Said optional gasifier GO is upstream and fluidically connected to the at least one gasifier G. In another aspect ofthe present invention, the tar oil slurry is fed into the at least one gasifier G (step (iv)) and the synthesis gas and synthetic natural gas (SNG) are utilized in another process.The further feedstock F can also be pretreated in a fluidized-bed gasifier FLBG as gasifier GO which is upstream of and fluidically connected to the at least one gasifier G. The resulting pretreated further feedstock PF is then fed into the at least one gasifier G in step (iv) which is, for this pretreatment preferably an entrained flow gasifier G.The first waste stream W1 (or the first waste stream W1 pretreated in optional step (ill)) and the further feedstock F (or the pretreated further feedstock PF) and, optionally the second waste stream W2 and / or the third feedstock W3, optionally pretreated in step (ill), are then subjected to a gasification process wherein said gasification process comprises at least one gasifier G and whereby a gas stream GS1 is formed by said gasification process wherein said gas stream GS1 comprises CO, CO2 and H2.Subjecting a further feedstock F (or a pretreated further feedstock PF) to said gasification process in step (iv) enables balancing fluctuations in available amount and properties such as calorific value of waste stream W1 and / or optional waste streams W2 and W3 which may negatively influence the gasification process in step (iv). Hence, a more stable gasification process and thereby a more stable production of gas stream GS1 having the desired yield.The at least one gasifier G has at least one inlet through which a feedstock is fed into said at least one gasifier G and at least one outlet through which the gas stream GS1 is separated from said at least one gasifier G. Preferably, the at least one gasifier G has more than one inlet. Thereby, more than one feedstock can be fed into the at least one gasifier G through a separate inlet. The term "inlet” comprises openings in the at least one gasifier G such as flaps and locks but also annual gaps as part of a burner such as in twin fluid atomizers, pressure nozzles and pressure atomizers.The gasification process of step (iv) comprises at least one gasifier G. The at least one gasifier G is preferably an entrained flow gasifier or a plasma gasifier. A gas stream GS1 is formed in step (iv) from the first waste stream W1 (or the first waste stream W1 pretreated in optional step (ii)) and the further feedstock F (or the further feedstock PF formed by pretreatment of further feedstock F in optional step (iv)) and the optional second waste stream W2 and / or the optional third waste stream W3, optionally pretreated in step (ill).The further feedstock F (or pretreated further feedstock PF) is subjected to the gasification process in step (iv) wherein said gasification process comprises at least one gasifier G and whereby said further feedstock F (or pretreated further feedstock PF) is inserted into the at least one gasifier G with the first waste stream W1 provided in step (I) (or the first waste stream W1 pretreated in optional step (ii)) and the second waste stream W2 optionally provided in step (ii) (or the second waste stream W2 and / or the third waste stream W3, optionally pretreated in step (ill)). The meaning of the word "together” depends on the kind of optional further feedstock F (or pretreated further feedstock PF) and the type of gasifier G employed in step (iv) and is explained in detail below.The term "biomass” includes but is not limited to wood, wood pellets, wood chips, straw, lignocellulosic biomass, energy crops, algae, bio-based oils, and bio-based fats (preferably hydrated). Biomass is preferably torrefied or converted by pyrolysis into a pyrolysis oil before used in step (iv) as a further feedstock F. Municipal solid waste (MSW) is optionally pretreated by methods such as drying, shredding, sorting, inert removal and preferably used in step (iv) in form of refuse-derived fuel (RDF). Shredder residues such as automotive shredder residue (ASR) is preferably pretreated by methods such as sorting, metal removal and the like before used in step (iv) as further feedstock F. Furthermore, torrefied biomass is preferably pre-heated to a temperature such as 200 °C before fed into a gasifier G as a further feedstock F.Liquid further feedstocks F such as bio-based oils and pyrolysis oils are preferably pre-heated and / or pressurized before fed into the gasifier G. In case the gasifier G is a plasma gasifier, the liquid further feedstock F is preferably pressurized to > 1 bar(abs.), more preferably to > 2 bar(abs.) and most preferably to about 4 bar(abs.) before fed into the gasifier G. In case the gasifier G is an entrained flow gasifier, the liquid further feedstock F is preferably pressurized to > 10 bar(abs.), more preferably > 20 bar(abs.) and most preferably > 40 bar(abs.) before fed into the gasifier G. Suitable means for pre-heating and / or pressurizing liquid further feedstock F for feeding into a gasifier are known in the art, comprise for example flaps and locks but also annual gaps as part of a burner such as in twin fluid atomizers, pressure nozzles and pressure atomizers, and can be adapted to a given further feedstock F and / or gasifier G type by the skilled person.In case the gasifier G is an entrained flow gasifier, solid further feedstocks F such as municipal solid waste (MSW), refuse-derived fuel (RDF), automotive shredder residue (ASR), wood chips, wood pellets and the like, said further feedstock F is preferably pressurized e.g., in a lock before fed into the gasifier G or, more preferably fed into a gasifier GO which is upstream of and fluidically connected to the entrained flow gasifier G. Thereby, said solid feedstock F is converted into a gas stream comprising CO, H2 and methane, which gas stream is then fed into the entrained flow gasifier G and further converted together with waste stream W1, which is also fed into gasifier G, and optionally waste stream W2 and / or W3 into the desired mixture mainly comprising CO and H2.The at least one gasifier G is selected from entrained flow gasifiers and plasma gasifiers. Preferably, the at least one gasifier G is a plasma gasifier. More preferably, the at least one gasifier G is a plasma fixed-bed gasifier.The temperature of the gas stream GS1 leaving the plasma gasifier G is preferably in the range of 1100 to 1400 °C or the temperature inside the entrained flow gasifier G ranges from 1000 to 1500 °C.An overview of gasifiers G, especially entrained flow gasifiers G and plasma gasifiers G is for example provided in James G. Speight, Handbook of Gasification Technology, Scrivener Publishing and Wiley, 2020, chapter 8.4.2, pages 259 to 262.The weight ratio (sum of first waste stream W1 and optional second waste stream W2 and optional third waste stream W3) : (further feedstock F) preferably ranges from 1 : 1 to 1 : 10, more preferably from 1 : 2 to 1 : 10 and most preferably from 1 : 5 to 1 : 10.Providing and subjecting a further feedstock F (or a pretreated further feedstock PF) to said gasification process in step (iv) in said ratios in respect to the waste stream W1 and optionally waste streams W2 and / or W3 enables balancing fluctuations in available amount and properties such as calorific value of waste stream W1 and / or optional waste streams W2 and W3 which may negatively influence the gasification process in step (iv). Hence, a more stable gasification process and thereby a more stable production of gas stream GS1 having the desired yield.The first waste stream W1 and the further feedstock F (or the pretreated further feedstock PF) and the optional second waste stream W2 and / or the optional third waste stream W3 can be fed into the gasifier G separately or be mixed before step (iv) to form a waste stream mixture W12, W13 or W123 and then the mixture W12, W13 or W123 is fed into the gasifier G. The mixture W12, W13 or W123 can have a lower viscosity than the individual first waste stream W1 and thereby feeding a waste stream mixture W12 requires simpler equipment than feeding the first waste stream W1 alone into the gasifier G. Feeding a mixture W12, W13 or W123 into the gasifier G can also result in an improved atomization of the feedstock(s) in the gasifier G compared to feeding the first waste stream W1, the optional waste stream W2 and / or the third waste stream W3 into the gasifier G. Thereby, the residence time and formation of coke inside the gasifier G can be reduced.The further feedstock F is preferably fed separately into the gasifier G, i.e., not mixed with the first waste stream W1 and / or the optional second waste stream W2 and / or optional third waste stream W3 before being fed into the gasifier G. Thereby, variations in mass flow, calorific value and other properties of the first waste stream W1 and / or the optional second waste stream W2 and / or the third waste stream W3 can be better balanced and as a result a steady operation of the gasifier G maintained. The further feedstock F is preferably fed into the gasifier G by means preferably selected from lock, screw conveyor, hopper, and flap. Most preferably, the further feedstock F is selected from the group consisting of torrefied biomass, pyrolysis oil and bio-based oils wherein the pyrolysis oil can be manufactured by pyrolysis from mixed plastic waste (MPW), end of life tires (ELT) and biomass. Such feedstocks F have more homogenized properties such as calorific value compared to, for example, municipal solid waste (MSW) and coal.The first waste stream W1 and / or the optional second waste stream W2 and / or the optional third waste stream W3 and / or the further feedstock F may be first fed into a fluidized bed gasifier GO or fixed bed gasifier GO in which said stream or streams are converted into a gas stream PGS1 which may be then fed into a gasifier G which is preferably an entrained flow gasifier in which the gas stream GS1 is formed from said gas stream PGS1 . Optionally, the first waste stream W1 is mixed with the optional second waste stream W2 and / or the optional third waste stream W3 and then a waste stream mixture W12, W13 or W123 may be fed into the fluidized bed gasifier GO or fixed bed gasifier GO, either with or without a further feedstock F. Preferably, the optional further feedstock F may be first fed into afluidized bed gasifier GO or fixed bed gasifier GO in which said further feedstock F is converted into a gas stream PGS1 and said gas stream PGS1 may be then fed together with the first waste stream W1 and / or the optional second waste stream W2 and / or the optional third waste stream W3 or a waste stream mixture W12, W13 or W123 into the gasifier G which is most preferably an entrained flow gasifier G in case a gasifier GO is utilized upstream of said gasifier G.In one aspect of the present invention, a CO2 waste stream from one or more chemical processes such as CO2 capture by absorption is also co-fed into the at least one gasifier G.Preferably, said further feedstock F is inserted into the at least one gasifier G in step (iv) with the first waste stream W1 provided in step (I) (optionally pretreated in step (ill)) and the optional second waste stream W2 and / or the optional third waste stream W3 (optionally pretreated in step (ill)) or a waste stream mixture W12, W13 or W123.Waste stream(s), waste stream mixtures and / or further feedstock F is / are injected into an entrained flow gasifier G in a high-velocity stream of gas and are heated to high temperatures (typically between 1000 and 1500 °C) in the presence of oxygen and / or steam. The solid particles are provided by the further feedstock F and the first waste stream W1 (optionally pretreated in step (ill)) and / or the optional second waste stream W2 and / or the optional third waste stream W3 (optionally pretreated in step (ill)) or the waste stream mixture W12, W13 or W123 are preferably transported in downdraft mode.In case the at least one gasifier G in step (iv) is an entrained flow gasifier, the first waste stream W1 (optionally pretreated in step (ill)) and the further feedstock F (or the pretreated further feedstock PF) and the optional second waste stream W2 and / or the optional third waste stream W3 (optionally pretreated in step (ill)) or the waste stream mixture W12, W13 or W123 are preferably compressed up to 40 bar(abs.) or higher before fed into the at least one gasifier G (step (iv).The temperature inside the entrained flow gasifier G (step (iv)) preferably ranges from 1000 to 1500 °C, more preferably from 1100 to 1450 °C and most preferably from 1200 to 1400 °C. The pressure inside the entrained flow gasifier preferably ranges from 1 to 55 bar(abs.), more preferably from 5 to 50 bar(abs.) and most preferably from 20 to 45 bar(abs.).Preferably, the first waste stream W1 and the further feedstock F (or the pretreated further feedstock PF) and the optional second waste stream W2 and / or the optional third waste stream W3 or the waste stream mixture W12, W13 or W123, and the further feedstock F (or the pretreated further feedstock PF) are fed into the entrained flow gasifier via at least one burner whereby said at least one burner comprises one annular gap for the first waste stream W1 and the optional waste stream W2 and / or the third waste stream W3, or the mixed waste stream W12, W13 or W123, and a separate annular gap through which the further feedstock F (or the pretreated further feedstock PF) is fed.Steam, preferably mixed with oxygen is co-fed into the entrained flow gasifier through a separate annular gap in said at least one burner.Plasma gasification is a high-temperature waste treatment process that uses plasma, a gas composed of highly charged particles, to break down organic matter into a gas. In this process, the first waste stream W1 (optionally pretreated in step (iii)), the further feedstock F (or the pretreated further feedstock PF) and the optional second waste stream W2 and / or the optional third waste stream W3 (optionally pretreated in step (iii)) or mixed waste stream W12, W13 or W123 are fed into a plasma reactor. Preferably, the first waste stream W1 (optionally pretreated in step (iii)) and the further feedstock F (or the pretreated further feedstock PF) and the optional second waste stream W2 and / or third waste stream W3 (optionally pretreated in step (iii)), or a waste stream mixture W12, W13 or W123 thereof are fed into the plasma reactor, where they / it are / is exposed to an electric arc or microwave radiation or at least one plasma torch, which ionizes the waste stream(s) and creates a plasma. Preferably, the plasma is generated by at least one plasma torch, more preferably, the plasma is generated by at least two plasma torches. Most preferably, the plasma gasifier comprises one to three plasma torches in the part of the gasifier where the first waste stream W1 (optionally pretreated in step (iii)) and / or the further feedstock F (or the pretreated further feedstock PF) and the optional second waste stream W2 and / or the third waste stream W3 (optionally pretreated in step (iii)) or the waste stream mixture W12, W13 or W123 are fed onto the plasma gasifier and one or two plasma torches in the part of the plasma gasifier where the gas stream GS1 leaves the plasma gasifier (most preferably in arrangement which forces the gas stream GS1 to pass said one or two plasma torches). The high temperatures inside the plasma gasifier, which can reach up to about 10000 K, cause the first waste stream W1 (optionally pretreated in step (iii)) and / or the further feedstock F (or the pretreated further feedstock PF) and, the optional second waste stream W2 and / or the third waste stream W3 (optionally pretreated in step (iii)) or the waste stream mixture W12, W13 or W123 to vaporize and break down into the constituent components, including hydrogen, carbon monoxide, and methane.In case the at least one gasifier G in step (iv) is a plasma gasifier, the first waste stream W1 (optionally pretreated in step (iii)), the further feedstock F (or the pretreated further feedstock PF) and the optional second waste stream W2 and / or the third waste stream W3 (optionally pretreated in step (iii)) or the mixed waste stream W12, W13 or W123 are preferably compressed up to 4 bar(abs.) before fed into the at least one gasifier G. The temperature of the gas stream GS1 leaving the plasma gasifier is preferably in the range of 1100 to 1400 °C, most preferably around 1300 °C. The pressure of the gas stream GS1 leaving the plasma gasifier is preferably at least 0.7 bar(abs.) and more preferably at least 1 bar(abs.). The residence time of the reactants inside the plasma gasifier is at least 2 to 3 s. The plasma is preferably generated from a gas selected from the group comprising CO2, steam, O2, air and mixtures thereof. More preferably, the plasma is generated from CO2, steam or a mixture of CO2 and steam.The first waste stream W1 (optionally pretreated in step (iii)) and the optional second waste stream W2 and / or the third waste stream W3 (optionally pretreated in step (iii)) or the mixed waste stream W12, W13 or W123 is / are preferably fed into the plasma gasifier through an opening separate of the opening through which the furtherfeedstock F (or the pretreated further feedstock PF) is fed. Steam is preferably fed to the plasma gasifier through still another opening.Preferably, the weight ratio "(first waste stream W1 and optionally co-fed second waste stream W2 and / or third waste stream W3, and optionally co-fed further feedstock F) : steam” ranges from 1 : 1 to 10 : 1 , more preferably from 2 : 1 to 10 : 1 and most preferably from 5 : 1 to 10 : 1 or higher. These rations enable the conversion of the feedstock(s) in step (iv) into a gas stream GS1 yield of CO and H2.Optionally the process according to the present invention comprises a further step (v) wherein said further step (v) is selected from the group comprising or consisting of cleaning gas stream GS1 and thereby forming gas stream GS11 , separating H2 and CO from gas stream GS1 and / or GS11 , compressing at least one of the gas streams GS1 , GS11 , H2 separated from GS1 , H2 separated from GS11 , CO separated from GS1 , CO separated from GS11, and combinations thereof. Preferably, said step (v) comprises, in this order, cleaning gas stream GS1 and thereby forming gas stream GS11, separating H2 and CO from gas stream GS11 and compressing at least one of H2 and CO separated from gas stream GS11 .Typical impurities in the gas stream GS1 comprise chlorides, sulfur-containing organic compounds such as sulfur dioxide, trace heavy metals (e.g., as respective salts), tars / condensable hydrocarbons and particulate residues. Various chemical and / or physical methods for removal of such impurities from said gas stream GS1 such as filtration, scrubbing, condensation and ab- / adsorption are known and can be chosen and adapted according to the type and respective concentration of the impurities in said gas stream GS1 and the tolerance to such impurities in a further process FP1 . Some selected methods for removal of impurities from said gas stream GS1 will be discussed in more detail. One or more of said methods can also be implemented into the optional gas treatment unit GTU. However, this selection of methods is not limiting the scope of the present invention.Other gaseous substances such as HOI and H2S are formed and / or separated from the gas stream GS1 in the optional gas treatment unit GTU. The impurities are removed from the gas stream GS1 and a gas stream GS11 having a first molar ratio H2 : CO is obtained.Particulate impurities can be removed from the gas stream GS1 by a cyclone and / or filters, chlorides by wet scrubbing, trace heavy metals, catalytic hydrolysis for converting sulfur-containing organic compounds to H2S and acid gas removal for extracting sulfur-containing gases such as H2S. Bulky and (fine) particles such as dust in the gas stream GS1 may also be removed with a quench in a soot water washing unit.Particulate impurities can be optionally removed from the gas stream GS1 directly by a cyclone and / or filters after the gas stream GS1 leaves the gasifier. Hence, the removal of particles from the gas stream GS1 can be part of a gasifier and / or part of the optional gas treatment unit GTU which is fluidically connected to the at least one gasifier G.Fine particles can be optionally removed from the raw synthesis gas directly with filters after the gas stream GS1 leaves the at least one gasifier G. Hence, the removal of fine particles from the gas stream GS1 can be part of the at least one gasifier G and / or part of the optional gas treatment unit GTU which is fluidically connected to the at least one gasifier G.The optional gas treatment unit GTU preferably comprises a washing unit for removing CO2 from the gas stream GS1. Most preferably, said washing unit is an "amine wash” or a "methanol” wash which uses one or more amine compounds such as alkanolamines or methanol to absorb CO2. Such washing units are known in the art and can be adapted for removal of CO2 from a gaseous stream GS1 by the skilled person.CO and / or H2 are optionally separated from the gas stream GS1 or GS11 . CO can be separated from the gas stream GS1 or GS11 in a synthesis gas separation unit which is, optionally, downstream of and fluidically connected to the at least one gasifier G or the gas treatment unit GTU. CO can be separated from gas stream GS1 or GS11 by cryogenic separation methods, commonly referred to as a "cold box” which makes use of the different boiling points of CO and H2. H2 can be separated using ^-selective membranes thorough which H2 permeates and is thereby separated from the GS1 or GS11 stream.The gas stream GS1 has a first molar ratio H2 : CO. Optionally, the gas stream GS1 is then preferably subjected to a water-gas shift reaction in a water-gas shift unit. Thereby, the H2 content in the gas stream GS1 is increased by reacting a portion of the CO of the gas stream GS1 with water to form additional H2 and CO2 and thereby gas stream GS11 having a second molar ratio H2 : CO is formed and leaves the water-gas shift unit. Optionally, the gas stream GS11 can be subjected to a water-gas shift reaction in a water-gas shift unit instead of gas stream GS1 . The H2 content in said gas stream GS11 leaving the water-gas shift unit and having a second molar ratio H2 : CO is higher than in said gas stream GS1 leaving the at least one gasifier having a first molar ratio H2 : CO. The hydrogen content in gas stream GS1 can for example also be increased by adding hydrogen provided by another source such as hydrogen formed by electrolysis of water, preferably using electrical energy from a renewable source such as solar and / or wind energy.The water-gas shift reaction will operate with a variety of catalysts (such as copper-zinc-aluminum catalysts and chromium or copper promoted iron-based catalysts) in the temperature range between about 200 °C and about 480 °C.The gas stream GS11 is optionally compressed, preferably, in case the first waste stream W1 and the further feedstock F (or the pretreated further feedstock PF) and the optional second waste stream W2 and / or the optional third waste stream W3 (or waste stream mixture W12, W13, W123) were converted to gas stream GS1 in a plasma gasifier. In this case, gas stream GS11 is preferably compressed to a pressure in the range 1.5 to 4 bar(abs.).Optionally, the gas stream GS1 and / or the gas stream GS11 are / is then subjected to a further process FP1 selected from the group comprising methanization, alcohol synthesis (preferably methanol synthesis) and Fischer-Tropsch synthesis whereby at least one first product stream PS1 is formed. The gas stream GS1 and / or the gas stream GS11 can also be used as a fuel gas. Said optional further processes FP1 are briefly described below:Optionally, the gas stream gas stream GS11 can be converted into methane by a methanation reaction. The methanation reaction and suitable methanation units are for example described in S. Rdnsch, J. Schneider, S. Matthischke, M. Schluter, M. Gdtz, J. Lefebvre, P. Prabhakaran, S. Bajohr: Review on methanation - From fundamentals to current projects; Fuel 166 (2016) 276-296 and can be selected and adapted by the skilled person. The methanation reaction is for example a catalytic reaction using nickel on alumina catalysts, preferably a honeycomb shape catalyst, at 1 to 70 bar and 200 to 700 °C, preferably 5 to 60 bar, more preferably 10 to 45 bar and preferably 200 to 550 °C, more preferably 10 to 45 bar.Alcohols, preferably methanol, are another chemical product which can be manufactured from the gas stream GS11 by an optional further process FP1. The most preferred, methanol, is produced from synthesis gas by a catalytic gas phase reaction at about 5 to 10 MPa and a temperature of about 200 to about 300 °C using a catalyst in a low- pressure methanol process in e.g., adiabatic reactors or quasi-isothermal reactors. The catalyst is for example a mixture of copper and zinc oxides, supported on alumina. The methanol synthesis and various options thereof suitable to be combined with the production system according to the present invention are disclosed in Ullmann's Encyclopedia of Industrial Chemistry (2012), Chapter "Methanol”, p. 3 to 12.The gas stream GS11 can also optionally be converted into hydrocarbons such as light synthetic crude oil in an optional Fischer-Tropsch (FT) reaction unit by the FT process. Such hydrocarbons are also denoted "Fischer- Tropsch hydrocarbons”. The light synthetic oil can be further converted by hydrocracking and / or isomerization to naphtha, light olefins, or diesel fuel. For production of gasoline and light olefins, the FT process is operated in a temperature range of about 330 to about 350 °C and a pressure of about 2.5 MPa (high-temperature FT-process), for production of waxes and / or diesel fuel, in a temperature range of about 220 to about 250 °C and a pressure of about 2.5 to about 4.4 MPa (low-temperature FT-process). Suitable reactors for low-temperature FT-processes comprise tubular fixed-bed reactors and slurry bed reactors. Suitable reactors for high-temperature FT-processes comprise circulating fluidized-bed reactors and SAS (Sasol advanced synthol) reactors. Iron- and / or cobalt-based catalysts are used for the FT-process. The Fischer-Tropsch synthesis and various options thereof suitable to be combined with the production system according to the present invention are disclosed in Ullmann's Encyclopedia of Industrial Chemistry (2012), Chapter "Coal Liquefaction”, p. 20 to 33.In another aspect of the present invention, the gas stream GS1 obtainable by or formed in step (iv) and / or the gas stream GS11 obtainable by or formed in step (v) and / or H2 separated from gas stream GS1 or GS11 and / or CO separated from gas stream GS1 or GS11 or another chemical material obtainable by or obtained by the process according to the present invention is converted to obtain a product.The publication Prior Art Disclosure; Issue 684; paragraphs
[1000] to
[8005] ; ISSN: 2198-4786; published: February 12, 2024 will be regarded as Reference RF1, which is incorporated herein by reference in its entirety. Preferably, the product is a product as described in Reference RF1; paragraphs
[1000] to
[8005] , Preferably, the process described herein is further a process for the production of a product.The converting step to obtain the product preferably comprises one or more step(s) as described below and can be performed by conventional methods well known to a person skilled in the art. The converting step preferably comprises one or more step(s) selected from: recycling, preferably depolymerizing, gasifying, pyrolyzing, and / or steam cracking; and / or purifying, preferably crystallizing, (solvent) extracting, distilling, evaporating, hydrotreating, absorbing, adsorbing and / or subjecting to ion exchanger; and / or assembling, preferably foaming, synthesizing, chemical conversion, chemically transforming, polymerizing and / or compounding; and / or forming, preferably foaming, extruding and / or molding; and / or finishing, preferably coating and / or smoothing. In addition, the one or more step(s) are described in detail in Reference RF1; paragraphs
[1000] to
[8005] ,The term "building block”, as used herein, comprises compounds, which are in a gaseous or liquid state under standard conditions of 0 °C and 0.1 MPa. Building blocks are typically used in chemical industry to form secondary products, which provide a higher structural complexity and / or higher molecular weight than the building block on which the secondary product is based. The building block is preferably selected from the group consisting of hydrogen, carbon monoxide, carbon dioxide, ethylene oxide, ethylene glycols, synthesis gas comprising a mixture of hydrogen and carbon monoxide, alkanes, alkenes, alkynes and aromatic compounds. The alkanes, alkenes, alkynes and aromatic compounds comprise in particular 1 to 12 carbon atoms, respectively.The term "monomer”, as used herein, comprises molecules, which can react with each other to form polymer chains by polymerization. The monomer is preferably selected from the group consisting of (meth-)acrylic acid, salts of (meth-)acrylic acid; in particular sodium, potassium and zinc salts; (meth-)acrolein and (meth-)acrylates. (Methacrylates comprising 1 to 22 carbon atoms are preferred, in particular comprising 1 to 8 carbon atoms. The terms (meth-)acrylic acid, (meth-)acrolein or (meth-)acrylate relate to acrylic acid, acrolein or acrylate and also to methacrylic acid, methacrolein or methacrylate, where applicable. Further, the monomer can be selected from hexamethylenediamine (HMD) and adipic acid.The building block can further be an intermediate compound. The term "intermediate compound”, as used herein, comprises organic reagents, which are applied for formation of compounds with higher molecular complexity. The intermediate compound can be selected for example from the group consisting of phosgene, polyisocyanates and propylene oxide. The polyisocyanates are in particular aromatic di- and polyisocyanates, preferably toluene diisocyanate (TDI) and / or diphenylmethane diisocyanate (MDI). The building block and the monomer and typical converting step(s) to obtain the building block or monomer are described in more detail in paragraphs
[1000] to
[1012] of Reference RF1.The term "polymer A”, as used herein, comprises thermoplastic, e.g., polyamide or thermoplastic polyurethane, thermoset, e.g., polyurethane, elastomer, e.g., polybutadiene, or a copolymer or a mixture thereof and is defined in more detail in paragraphs
[2001] to
[2007] of Reference RF1. The term "polymer composition A”, as used herein, comprises all compositions comprising a polymer as described above and one or more additive(s), e.g., reinforcement, colorant, modifier and / or flame retardant, and is defined in more detail in paragraph
[2008] of Reference RF1 . The term "polymer product A”, as used herein, comprises any product comprising the polymer A and / or polymer composition A as described above and is defined in more detail in paragraphs
[2009] and
[2010] of Reference RF1 . The step(s) to obtain the polymer, preferably polymer A, polymer composition, preferably polymer composition A or polymer product, preferably polymer product A is / are described in more detail in paragraph
[2011] of Reference RF1.The term "industrial use polymer”, as used herein, comprises rheology, polycarboxylate, alkoxylated polyalkylenamine, alkoxylated polyalkylenimine, polyether-based, dye inhibition and soil release cleaning polymers defined in more detail in paragraphs
[3035] to
[3044] of Reference RF1. The term "industrial use surfactant”, as used herein, comprises non-ionic, anionic and amphoteric industrial use surfactants defined in more detail in paragraphs
[3008] to
[3034] of Reference RF1. The term "industrial use descaling compound”, as used herein, comprises nonphosphate based builders (NPB) and phosphonates (CoP) described in more detail in paragraphs
[3001] to
[3005] of Reference RF1. The term "industrial use biocide”, as used herein, refers to a chemical compound that kills microorganisms or inhibits their growth or reproduction defined in more detail in paragraphs
[3006] to
[3007] of Reference RF1. The term "industrial use solvent”, as used herein, comprises alkyl amides, alkyl lactamides, alkyl esters, lactate esters, alkyl diester, cyclic alkyl diester, cyclic carbonates, aromatic aldehydes and aromatic esters defined in more detail in paragraphs
[3045] to
[3055] of Reference RF1. The term "industrial use dispersant”, as used herein, comprises anionic and non-ionic industrial use dispersants defined in more detail in paragraphs
[3056] to
[3058] of Reference RF1 . The term "composition and / or formulation thereof' with reference to the industrial use polymers, industrial use surfactants, descaling compounds and / or industrial use biocides refers to industrial use compositions and / or institutional use products and / or fabric and home care products and / or personal care products defined in more detail in paragraph
[3059] of Reference RF1. The converting step(s) to obtain the industrial use polymer, industrial use surfactant, descaling compound and / or industrial use biocide are defined in more detail in paragraph
[3060] of Reference RF1 . The converting steps to obtain the industrial use composition or formulation of the industrial use polymer, industrial use surfactant, descaling compound and / or industrial use biocide are defined in more detail in paragraph
[3061] of Reference RF1.The term "agrochemical composition”, as used herein, typically relates to a composition comprising an agrochemically active ingredient and at least one agrochemical formulation auxiliary. Examples of agrochemical compositions, active ingredients and auxiliaries are described in more detail in Reference RF1, paragraph
[4001] , The agrochemical composition may take the form of any customary formulation. The agrochemical compositions are prepared in a known manner, e.g., described by Mollet and Grubemann, Formulation technology, Wiley VCH,Weinheim, 2001; or Knowles, New developments in crop protection product formulation, Agrow Reports DS243, T&F Informa, London, 2005. The converting step(s) to obtain the agrochemically active ingredients and auxiliaries may be conducted in analogy to the production step(s) of their analogues that are based on petrochemicals or other precursors that are not gained by recycling processes. In addition, conversion to compounds mentioned in sections "Polymer” and "Cosmetic surfactant, emollient, wax, cosmetic polymer, UV filter, further cosmetic ingredient or compositions or formulations thereof' may be performed as described in these sections as well as the respective paragraphs in Reference RF1.The term active pharmaceutical ingredients and / or intermediates thereof, as used herein, comprises substances that provide pharmacological activity or other direct effect in the diagnosis, cure, mitigation, treatment, or prevention of disease, or to affect the structure or any function of the body. Intermediates thereof are isolated products that are generated during a multi-step route of synthesis of an active pharmaceutical ingredient. The term pharmaceutical excipients, as used herein, comprises compounds or compound mixtures used in compositions for various pharmaceutical applications, which are not substantially pharmaceutically active on itself. Active pharmaceutical ingredients and / or intermediates thereof and pharmaceutical excipients are defined in more detail in paragraph
[5001] of Reference RF1. The converting step(s) to obtain the active pharmaceutical ingredients and / or intermediates thereof and pharmaceutical excipients may comprise one or more synthesis steps and can be performed by conventional synthesis and techniques well known to a person skilled in the art.The terms animal feed additives, human food additives, dietary supplements, as used herein, comprises Vitamins, Pro-Vitamins and active metabolites thereof including intermediates and precursors, especially Vitamin A, B, E, D, K and esters thereof, like acetate, propionate, palmitate esters or alcohols thereof like retinol or salts thereof and any combinations thereof; Tetraterpenes, especially isoprenoids like carotenoids and xanthophylls including their intermediates and precursors as well as mixtures and derivates thereof, especially beta carotene, Canthaxanthin, Citranaxanthin, Astaxanthin, Zeaxanthin, Lutein, Lycopene, Apo-carotenoids, and any combinations thereof; organic acids, especially formic acid, propionic acid and salts thereof, such as sodium, calcium or ammonium salts, and any combinations thereof, such as but not limited to mixtures of formic acid and sodium formiate, propionic acid and ammonium propionate, formic acid and propionic acid, formic acid and sodium formiate and propionic acid, propionic acid and sodium propionate and formic acid and sodium formiate; glycerides of carboxylic acids and short and medium chain fatty acids, conjugated linoleic acids, such as omega-6 fatty acid (C18:2) methyl ester and 1,2- propandiol and beverage stabilizers, such as polyvinylpyrrolidone-polymer or polyvinylimidazole / polyvinylpyrrolidone- copolymer. Animal feed additives, human food additives and dietary supplements are defined in more detail in paragraph
[5002] of Reference RF1. The converting step(s) to obtain the animal feed additives, human food additives, dietary supplements may comprise one or more synthesis steps and can be performed by conventional synthesis and techniques well known to a person skilled in the art.The terms aroma chemical and aroma composition as used herein, comprise a volatile organic substance with a molecular weight between 70-250 g / mol comprising a functional group with a carbon skeleton of C5-C16 carbonatoms comprising linear, branched, cyclic, for example with a ring size of C5-C18, bicyclic or tricyclic aliphatic chains and but not necessarily one or more unsaturated structural elements like double bonds, triple bonds, aromatics or heteroaromatics and preferably the one or more additional functional groups are selected from alcohol, ether, ester, ketone, aldehyde, acetal, carboxylic acid, nitrile, thiol, amine. In one aspect, the aroma chemical is a terpene-based aroma chemical, for example selected from monoterpenes and monoterpenoids, sesquiterpenes and sesquiterpenoids, diterpenes, triterpenes or tetraterpenes. Aroma chemicals can be combined with further aroma chemicals to give an aroma composition. Aroma chemicals and aroma compositions are defined in more detail in paragraph
[5003] of Reference RF1. The converting step(s) to obtain the aroma chemical and aroma composition may comprise one or more synthesis steps and can be performed by conventional synthesis and techniques well known to a person skilled in the art.The term "aqueous polymer dispersion”, as used herein, comprises aqueous composition(s) comprising dispersed polymer(s) and is defined in more detail in the section
[6001] entitled "aqueous polymer dispersion” of Reference RF1. The dispersed polymer(s) may be selected from acrylic emulsion polymer(s), styrene acrylic emulsion polymer(s), styrene butadiene dispersion(s), aqueous dispersion(s) comprising composite particles, acrylate alkyd hybrid dispersion(s), polyurethane(s) (including UV-curable polyurethanes) and polyurethane - poly(meth-)acrylate hybrid polymer(s). The term "emulsion polymer”, as used herein, comprises polymer(s) made by free-radical emulsion polymerization. Aqueous polyurethane dispersion(s) are defined in more detail in the section
[6002] entitled "Polyurethane dispersions” of Reference RF1. UV-curable polyurethane(s) is / are defined in more detail in the section
[6017] of Reference RF1. Polyurethane - poly(meth-)acrylate hybrid polymer(s) is / are defined in more detail in the section
[6016] of Reference RF1.The term "polymeric dispersant”, as used herein, comprises preferably polymer(s) comprising polyether side chain, in particular polycarboxylate ether polymer(s) and polycondensation product(s) defined in more detail in paragraph
[6020] entitled "Polymeric dispersant” of Reference RF1. The converting (polymerization) step(s) to obtain the aqueous polymer dispersion(s) comprising emulsion polymer(s) is / are defined in more detail in the section
[6003] entitled "Emulsion polymerization” of Reference RF1. The converting (polymerization) step(s) to obtain the aqueous polyurethane dispersion(s) is / are defined in more detail in the section
[6014] entitled "Process for the preparation of aqueous polyurethane dispersions” and section [6017)] entitled "Aqueous UV-curable polyurethane dispersions, their preparation and use and compositions containing them” of Reference RF1. Composition(s) and uses of aqueous polymer dispersion(s) and of polymeric dispersant(s) are defined in more detail in the following sections of Reference RF1 : section
[6004] entitled "Uses of aqueous polymer dispersions”, section
[6005] entitled "Binders for architectural and construction coatings”, section
[6006] entitled "Binders for paper coating” section
[6007] entitled "Binders for fiber bonding”, section
[6008] entitled "Adhesive polymers and adhesive compositions”, section
[6015] entitled "Aqueous polyurethane dispersions suitable for use in coating compositions”, section
[6016] entitled "Aqueous polyurethane - poly(meth-)acrylate hybride polymer dispersions suitable for use in coating compositions”, section
[6017] entitled "Aqueous UV-curable polyurethane dispersions, their preparation and use and compositions containing them”,section
[6018] entitled "Inorganic binder compositions comprising polymeric dispersants and their use”
[6019] 100% curable coating compositions.UV-crosslinkable poly(meth-)acrylate(s) and its / their uses are defined in more detail in section
[6009] entitled "UV- crosslinkable poly(meth-)acrylates for use in UV-curable solvent-free hotmelt adhesives and their use for making pressure-sensitive self-adhesive articles” of Reference RF1.Polyisocyanate(s), composition(s) comprising them and their uses are defined in more detail in section
[6010] entitled "Polyisocyanates” of Reference RF1.Hyperbranched polyester polyol(s) and its / their uses are defined in more detail in section
[6011] entitled "Organic solvent based hyperbranched polyester polyols suitable for use in coating compositions” of Reference RF1. The converting step(s) to obtain the hyperbranched polyester polyols is / are defined in more detail in the section
[6012] entitled "Preparation of organic solvent based hyperbranched polyester polyols” of Reference RF1. Coating composition(s) comprising hyperbranched polyester polyol(s), polyisocyanate(s) and additive(s) and substrate(s) coated therewith are defined in more detail in section
[6013] entitled "Organic solvent based two component coating compositions comprising hyperbranched polyester polyols and polyisocyanates” of Reference RF1.Unsaturated polyester polyol(s), solvent-based coating composition(s) comprising said unsaturated polyester polyol(s) and substrate(s) for coating with said coating composition (s) are defined in more detail in section
[6018] entitled "Organic solvent-based coating composition comprising unsaturated polyester polyols” of Reference RF1. 100% curable coating composition (s) is / are defined in more detail in section
[6019] of Reference RF1.Polymeric dispersant(s) for inorganic binder compositions is / are defined in more detail in section
[6020] of Reference RF1. The inorganic binder composition(s) comprising the polymeric dispersants and their use are defined in more detail in section
[6021] of Reference RF1. The converting step(s) to obtain the polymeric dispersant(s) are defined in more detail in section
[6020] of Reference RF1. The term "inorganic binder composition” comprising the polymeric dispersant(s), as used herein, comprises preferably in particular hydraulically setting compositions and compositions comprising calcium sulfate and is defined in more detail in section
[6021] of Reference RF1 entitled "Inorganic binder compositions comprising the polymeric dispersant and their use”. Specific building material formulation(s) comprising polymeric dispersant(s) or building product(s) produced by a building material formulation comprising a polymeric dispersant are disclosed in more detail in section
[6021] of Reference RF1.The term "cosmetic surfactant”, as used herein, comprises non-ionic, anionic, cationic and amphoteric surfactants and is defined in more detail in paragraph
[7002] of Reference RF1. The term "emollient”, as used herein, refers to a chemical compound used for protecting, moisturizing, and / or lubricating the skin and is defined in more detail in paragraph
[7003] of Reference RF1. The term "wax”, as used herein, comprises pearlizers and opacifiers and is defined in more detail in paragraph
[7004] of Reference RF1. The term "cosmetic polymer”, as used herein,comprises any polymer that can be used as an ingredient in a cosmetic formulation and is defined in more detail in paragraph
[7005] of Reference RF1. The term "UV filter”, as used herein, refers to a chemical compound that blocks or absorbs ultraviolet light and is defined in more detail in paragraph
[7006] of Reference RF1. The term "further cosmetic ingredient”, as used herein, comprises any ingredient suitable for making a cosmetic formulation. Several sources disclose cosmetically acceptable ingredients. E. g. the database Cosing on the internet pages of the European Commission discloses cosmetic ingredients and the International Cosmetic Ingredient Dictionary and Handbook, edited by the Personal Care Products Council (PCPC), discloses cosmetic ingredients. The term "composition and / or formulation thereof' with reference to the cosmetic surfactant, emollient, wax, cosmetic polymer, UV filter and / or further cosmetic ingredient refers to personal care and / or cosmetic compositions or formulations defined in more detail in paragraph
[7007] of Reference RF1. The converting step(s) to obtain the cosmetic surfactant, emollient, wax, cosmetic polymer, UV filter or further cosmetic ingredient is / are defined in more detail in paragraph
[7008] of Reference RF1.The terms "polymer B”, "polymer composition B”, "coating composition”, "other functional composition”, "foil”, "molded body”, "coating” and "coated substrate” are well known to the person skilled in the art and are defined in more detail from paragraph
[8000] to
[8005] of Reference RF1.The present invention also concerns an alkyl (meth-)acrylate plant comprising an integrated production waste stream treatment facility wherein said alkyl (meth-)acrylate plant comprises wherein said alkyl (meth-)acrylate production plant comprises a) an acrylate reaction unit RU, b) an educt recovery unit ERU downstream and fluidically connected to said acrylate reaction unit RU, c) an upgrading unit UU downstream and fluidically connected to said acrylate reaction unit RU, d) at least one gasifier G downstream and directly or indirectly fluidically connected to said upgrading unit UU, wherein said educt recovery unit ERU is upstream of and optionally directly or indirectly fluidically connected to said at least one gasifier G. This alkyl (meth-)acrylate plant is shown schematically in Figures 1 and 2.The outlet for the first waste stream W1 in the upgrading unit UU and the outlet of the optional second waste stream W2 in the educt recovery unit ERU is directly or indirectly fluidically connected to the respective inlet of the at least one gasifier G. Optionally, also an outlet for the third waste stream W3 in the upgrading unit UU is directly or indirectly fluidically connected to the respective inlet of the at least one gasifier G.In another aspect of the present invention, said alkyl (meth-)acrylate plant comprises a) an acrylate reaction unit RU, b) an educt recovery unit ERU downstream and fluidically connected to said acrylate reaction unit RU, c) an upgrading unit UU downstream and fluidically connected to said acrylate reaction unit RU, d) at least one gasifier G downstream and directly or indirectly fluidically connected to said reaction unit RU, wherein said educt recovery unit ERU is upstream of and optionally directly or indirectly fluidically connected to said at least one gasifier G. This alkyl (meth-)acrylate plant is shown schematically in Figure 3."Directly” is defined as fluidically connected by a suitable means such as a pipe. Accordingly, respective outlet for the first waste stream W1 and / or the optional second waste stream W2 and / or the optional third waste stream W3 is fluidically connected by a suitable means such as a pipe with the respective inlet of the at least one gasifier G."Indirectly” is defined as interrupted by e.g., an additional unit for pretreating the respective feedstock, storage tank(s), transporting the first waste stream W1 and / or the optional waste stream W2 and / or the optional third waste stream W3 or the waste stream mixture W12, W13 or W123 from the alkyl (meth-)acrylate production plant to the at least one gasifier G for example by truck, train or a pipeline. Accordingly, "indirectly” means for example that the respective outlet for the first waste stream W1 in the upgrading unit UU or the reaction unit RU and / or the optional second waste stream W2 in the educt recovery unit ERU and / or the optional third waste stream W3, is fluidically connected to the inlet of a feedstock pretreatment unit for the first waste stream W1 , which is downstream of the upgrading unit UU and / or the second waste stream W2, which is downstream of the educt recovery unit ERU and / or the third waste stream W3, which is downstream of the upgrading unit UU, and the outlet of the feedstock pretreatment unit is fluidically connected to the respective inlet of the at least one gasifier G which is downstream of the pretreatment unit.The present invention is further illustrated by the following set of embodiments and combinations of embodiments resulting from the dependencies and back-references as indicated. In particular, it is noted that in each instance where a range of embodiments is mentioned, for example in the context of a term such as "The method of any of embodiments 1 to 3", every embodiment in this range is meant to be explicitly disclosed for the skilled person, i.e. the wording of this term is to be understood by the skilled person as being synonymous to "The method of any of embodiments 1, 2 and 3". Further, it is explicitly noted that the following set of embodiments represents a suitably structured part of the general description directed to preferred aspects of the present invention, and thus, suitably supports the claims of the present invention.1. Process for utilizing at least one waste stream from an alkyl (meth-)acrylate production plant, wherein the alkyl (meth-)acrylate production plant comprises a) a reaction unit RU, b) an educt recovery unit ERU, and c) an upgrading unit UU, the process comprising the steps(oi) feeding (meth-)acrylic acid (M)AA, an alkanol and an acid catalyst into said reaction unit RU which comprises at least one reactor and preferably consists of a cascade of two or more reactors,(i) providing a first waste stream W1, wherein the first waste stream W1 is separated from the reaction unit RU or the upgrading unit UU,(ii) optionally providing a second waste stream W2, wherein the optional second waste stream W2 is separated from the educt recovery unit ERU and / or a third waste stream W3, wherein the optional third waste stream W3 is separated from the upgrading unit UU,(iii) optionally pretreating the first waste stream W1 and / or the optional second waste stream W2 and / or the optional third waste stream W3,(iv) subjecting the first waste stream W1, optionally after pretreatment in step (iii), and optionally the optional second waste stream W2 and / or the optional third waste stream W3, optionally after pretreatment in step (iii), to a gasification process wherein said gasification process comprises at least one gasifier G, wherein said at least one gasifier G is an entrained flow gasifiers or a plasma gasifier, and thereby forming a gas stream GS1 wherein said gas stream GS1 comprises CO, CO2 and H2.2. Process according to embodiment 1 wherein the first waste stream W1 has at least one, preferably all the following properties: a) a calorific value in the range of 5 to 43 MJ / kg, more preferably of 8 to 40 MJ / kg and most preferably of 12 to 38 MJ / kg, b) a carbon content in the range of 30 to 80 wt.-%, more preferably 35 to 75 wt.-% and most preferably 40 to 75 wt.-%, c) a hydrogen content in the range of 2 to 15 wt.-%, more preferably 3 to 13 wt.-% and most preferably 3.5 to 12 wt.-%, d) an oxygen content in the range of 10 to 60 wt.-%, more preferably 12 to 55 wt.-% and most preferably 14 to 50 wt.-%, e) a nitrogen content in the range of 0.0 to 5 wt.-%, more preferably 0.0 to 3 wt.-% and most preferably 0.0 to 2 wt.-%, f) a sulfur content in the range of 0.0 to 15 wt.-%, more preferably 0.0 to 12 wt.-% and most preferably 0.0 to 10 wt.-%.3. Process according to embodiment 1 or 2 wherein the optional second waste stream W2 has at least one, preferably all the following properties: a) a calorific value in the range of 10 to 50 MJ / kg, more preferably of 13 to 46 MJ / kg and most preferably of 16 to 44 MJ / kg, b) a carbon content in the range of 30 to 90 wt.-%, more preferably 35 to 85 wt.-% and most preferably 40 to 85 wt.-%, c) a hydrogen content in the range of 2 to 20 wt.-%, more preferably 3 to 18 wt.-% and most preferably 5 to 16 wt.-%, d) an oxygen content in the range of 4 to 60 wt.-%, more preferably 6 to 55 wt.-% and most preferably 7 to 50 wt.-%, e) a nitrogen content in the range of 0.0 to 5 wt.-%, more preferably 0.0 to 3 wt.-% and most preferably 0.0 to 2 wt.-%, f) a sulfur content in the range of 0.0 to 4 wt.-%, more preferably 0.0 to 3 wt.-% and most preferably 0.0 to 2 wt.-%.4. Process according to any one of embodiments 1 to 3 wherein the optional third waste stream W3 has at least one, preferably all the following properties: a) a calorific value in the range of 20 to 50 MJ / kg, more preferably of 25 to 45 MJ / kg and most preferably of 30 to 45 MJ / kg, b) a carbon content in the range of 50 to 85 wt.-%, more preferably 55 to 80 wt.-% and most preferably 60 to 80 wt.-%, c) a hydrogen content in the range of 2 to 20 wt.-%, more preferably 5 to 18 wt.-% and most preferably 8 to 15 wt.-%, d) an oxygen content in the range of 5 to 30 wt.-%, more preferably 8 to 25 wt.-% and most preferably 10 to 25 wt.-%,5. Process according to any one of embodiments 1 to 4 wherein the first waste stream W1 and / or the optional second waste stream W2 and / or the optional third waste stream W3 are optionally mixed to form a mixed waste stream W12, W13 or W123.6. Process according to any one of embodiments 1 to 5 wherein said at least one gasifier G is selected from the group consisting of plasma gasifier G, entrained flow gasifier G and a combination of a fixed bed gasifier GO and an entrained flow gasifier G.7. Process according to any one of embodiments 1 to 6 wherein the temperature of the gas stream GS1 leaving the plasma gasifier G is preferably in the range of 1100 to 1400 °C or the temperature inside the entrained flow gasifier G ranges from 1000 to 1500 °C.8. Process according to any one of embodiments 1 to 7 wherein the at least one gasifier G is a fixed-bed plasma gasifier.9. Process according to any one of embodiments 1 to 8 wherein a further feedstock F is subjected to said gasification process in step (iv), whereby said further feedstock F is inserted into the at least one gasifier G together with the first waste stream W1 provided in step (I) and with the second waste stream W2 and / or the third waste stream W3 optionally provided in step (ii), and / or with the first waste stream W1 and / or second waste stream W2 and / or the third waste stream W3 pretreated in step (ill).10. Process according to embodiment 9 wherein the further feedstock F is selected from the group comprising or preferably consisting of biomass, refuse-derived fuel (RDF), pyrolysis oils made from plastic waste, pyrolysis oils made from end of life tires, pyrolysis oils made from biomass, heating oils, vacuum residues, preferably vacuum distillation residues, crude oil residues, heavy crude oils, extra heavy crude oils, tar sand bitumen, visbreaker bottom residues, deasphalter bottom residues, C5 asphalthene fraction, high viscous residues, fueloils, pyrolysis gasolines, tire pyrolysis oils (TPO), waste oils, used oils, municipal solid waste (MSW), automotive shredder residue (ASR), coal, natural gas, industrial waste streams, waste streams from a (methacrylic acid production plant and mixtures thereof.11 . Process according to embodiment 9 or 10 wherein the weight ratio (sum of first waste stream W1 and optional second waste stream W2 and optional third waste stream W3) : (further feedstock F) preferably ranges from 1: 1 to 1 : 10, more preferably from 1 : 2 to 1 : 10 and most preferably from 1 : 5 to 1 : 10.12. Process according to any one of embodiments 1 to 11 wherein the molar ratio CO : H2 in the gas stream GS1 formed in step (iv) preferably ranges from 0.7 : 1 to 1 : 0.7, more preferably from 0.8 : 1 to 1 : 0.8 and most preferably is about 1 : 1.13. Process according to any one of embodiments 1 to 12 wherein the gas stream GS1 formed in step (iv) preferably comprises < 15 Vol.-% CO2, more preferably < 10 Vol.-% CO2 and most preferably < 8 Vol.-% CO2.14. Process according to any one of embodiments 1 to 13 wherein the process comprises a further step (v) said further step (v) selected from the group comprising or consisting of cleaning gas stream GS1 formed in step (iv) and thereby forming gas stream GS11, separating H2 and CO comprised in said gas stream GS1 and / or GS11 from each other, compressing at least one of the aforementioned gas streams, and combinations thereof.15. Process according to embodiment 14 wherein step (v) comprises, in this order, cleaning gas stream GS1 formed in step (iv), thereby forming gas stream GS11 , separating H2 and / or CO from gas stream GS11 and compressing at least one of H2 and CO separated from said gas stream GS11 .16. Process according to any one of embodiments 1 to 15 wherein steam is co-fed into the at least one gasifier G in step (iv).17. Process according to embodiment 16 wherein the weight ratio "(first waste stream W1 and optionally co-fed second waste stream W2 and / or third waste stream W3, and optionally co-fed further feedstock F) : steam” preferably ranges from 1 : 1 to 10 : 1 , more preferably from 2 : 1 to 10 : 1 and most preferably from 5 : 1 to 10 : 1 or higher.18. Process according to any one of embodiments 1 to 17 wherein the at least one gasifier G is an entrained flow gasifier and wherein oxygen and steam are co-fed in step (iv).19. Process according to any one of embodiments 1 to 18 wherein the at least one gasifier G is a plasma gasifier utilizing a plasma and wherein said plasma is formed from one or more sources selected from the group comprising or consisting of H2O, CO2, O2 and air.20. Process according to embodiment 19 wherein the plasma is formed by a method selected from the group comprising or consisting of microwave radiation, electrical arc and plasma torch.21 . Process according to embodiment 19 or 20 wherein the plasma is formed by at least one plasma torch.22. Process according to any one of embodiments 14 to 21 wherein the gas stream GS11 formed in step (v) or H2 and / or CO formed therefrom is subjected to a further process FP1 selected from the group comprising methanization, alcohol synthesis (preferably methanol synthesis), and Fischer-Tropsch synthesis whereby at least one first product stream PS1 is formed.23. Process according to any one of embodiments 1 to 22, comprising the step: converting the gas stream GS1 obtainable by or formed in step (iv) and / or gas stream GS11 obtainable by or formed in optional step (v) to obtain a product.24. Process according to embodiment 23, wherein the product is selected from: I) building block or monomer; or ii) polymer, preferably polymer A, polymer composition, preferably polymer composition A, or polymer product, preferably polymer product A; or ill) cleaning polymer, cleaning surfactant, descaling compound, cleaning biocide or composition or formulation thereof; or iv) agrochemical composition, agrochemical formulation auxiliary or agrochemically active ingredient; or v) active pharmaceutical ingredient or intermediate thereof, pharmaceutical excipient, animal feed additive, human food additive, dietary supplements, aroma chemical or aroma composition; or vi) aqueous polymer dispersion, preferably polyurethane or polyurethane - poly (meth-)acrylate hybrid polymer dispersion, emulsion, binder for paper and fiber coatings, UV-curable acrylic polymer for hot melts and coatings polyisocyanates, hyperbranched polyester polyol, polymeric dispersant for inorganic binder compositions, unsaturated polyester polyol or 100% curable composition; or vii) cosmetic surfactant, emollient, wax, cosmetic polymer, UV filter, further cosmetic ingredient or composition or formulation thereof; or viii) polymer B, polymer composition B, coating composition, other functional composition, foil, molded body, coating or coated substrate.25. Process according to embodiment 23 or 24, wherein the content of the gas stream GS1 obtainable by or formed in step (iv) and / or the gas stream GS11 obtainable by or formed in step (v) in the product is 1 weight- % or more, preferably 2 weight-% or more, more preferably 5 weight-% or more, more preferably 15 weight- % or more, more preferably 30 weight-% or more, more preferably 40 weight-% or more, more preferably 60 weight-% or more, more preferably 80 weight-% or more, more preferably 90 weight-% or more, more preferably 95 weight-% or more; and / or wherein the content of the gas stream GS1 obtainable by or formed in step (iv) and / or at least one of the gas stream GS11 obtainable by or formed in step (v) in the product is 100 weight-% or less, preferably 95 weight-% or less, more preferably 90 weight-% or less, more preferably 50 weight-% or less, more preferably 25 weight-% or less, more preferably 10 weight-% or less; and preferably wherein the content is determined based on identity preservation and / or segregation and / or mass balance and / or book and claim chain of custody models, preferably based on mass balance, preferably the International Sustainability and Carbon Certification (ISCC) standard.26. Alkyl (meth-)acrylate production plant comprising an integrated waste stream treatment facility wherein said alkyl (meth-)acrylate production plant comprises a) a reaction unit RU, b) an educt recovery unit ERU downstream and fluidically connected to said reaction unit RU, c) an upgrading unit UU downstream and fluidically connected to said reaction unit RU, d) at least one gasifier G downstream of and directly or indirectly fluidically connected to said upgrading unit UU or said reaction unit RU, wherein said educt recovery unit ERU is upstream of and optionally directly or indirectly fluidically connected to said at least one gasifier G.27. Alkyl (meth-)acrylate production plant according to embodiment 26 wherein the first waste stream W1 of the upgrading unit UU is directly or indirectly fluidically connected to the at least one gasifier G.28. Alkyl (meth-)acrylate production plant according to embodiments 26 or 27 wherein the second waste stream W2 of the alkanol stripping unit ASU is directly or indirectly fluidically connected to the at least one gasifier G.29. Use of an alkyl (meth-)acrylate production plant according to any one of embodiments 26 to 28 for the process according to any one of embodiments 1 to 22.The process according to the present invention can be worked in one site, e.g., the gasifier G is at the same site as the reaction unit RU, the educt recovery unit ERU, and the upgrading unit UU. The exit points from which the waste stream W1 and the optional waste stream W2 and / or the optional third waste stream W3 are purged are directly fluidically connected with the at least one gasifier G or an optional pretreatment unit for pretreating said waste stream W1 and the optional waste stream W2 and / or the third waste stream W3 before feeding into the gasifier G by e.g., one or more pipes.Or the process can be worked in at least two different sites, e.g., reaction unit RU, the educt recovery unit ERU, and the upgrading unit UU are located at a first site and the gasifier G is located at a second site which is different from the first site. The exit points from which the waste stream W1 and the optional waste stream W2 and / or the optional third waste stream W3 is / are purged are indirectly fluidically connected with the at least one gasifier G or an optional pretreatment unit for pretreating said waste stream W1 and the optional waste stream W2 and / or the third waste stream W3 before feeding into the gasifier G e.g., by means such as a truck, a train or a pipeline transporting the waste stream W1 and the optional waste stream W2 and / or the third waste stream W3 from the reaction unit RU, the educt recovery unit ERU, and the upgrading unit UU to the gasifier G and / or an optional unit in which waste stream W1 and optional waste stream W2 and / or the optional third waste stream W3 is / are pretreated before fed into said gasifier G. Optionally, the reaction unit RU, the educt recovery unit ERU and the upgrading unit UU on the one hand and the gasifier G on the other hand are operated by different legal entities.An optional pretreatment unit for the waste stream W1 and the optional waste stream W2 and / or the optional third waste stream W3 can located at the same site as the reaction unit RU, the educt recovery unit ERU the upgrading unit UU and the gasifier G or at the same site where the gasifier G is located in case the gasifier is located at a different site than the reaction unit RU, the educt recovery unit ERU, and the upgrading unit UU or at a third site which is different from the site where the reaction unit RU, the educt recovery unit ERU, and the upgrading unit UU are located and where the gasifier G is located. The exit points from which the waste stream W1 and the optional waste stream W2 and / or the third waste stream W3 are purged are indirectly fluidically connected with the optional pretreatment unit, e.g., by means such as a truck, a train or a pipeline transporting the waste stream W1 and the optional waste stream W2 and / or the third waste stream W3 from the reaction unit RU, the educt recovery unit ERU, and the upgrading unit UU to the optional unit in which waste stream W1 and optional waste stream W2 and / or the third waste stream W3 is / are pretreated before fed into said gasifier G. Optionally, the reaction unit RU, the educt recovery unit ERU the upgrading unit UU on the one hand and the gasifier G (and / or the pretreatment unit) on the other hand are operated by different legal entities.The invention will be further explained by the following non-limiting examples.A gasification agent (steam) was injected into the gasifier G, enabling a plasma gasification reaction at a temperature of 1350 °C (Examples 1 to 5), an entrained flow gasification at 1350 °C (Examples 6 to 10) or a fluidized bed reactor (gasifier G1) at 830 °C with subsequent entrained flow gasification (gasifier G2) at 1350 °C (Examples 11 to 14). A plasma was formed in case of plasma gasification from the inserted steam at the plasma torch outlets of the gasifier G. The plasma generation was performed by electric energy with a power given for the individual examples. The resulting raw synthesis gas (stream GS1), comprising CO, H2O, CO2, H2 and optionally ash or dust, which left the gasifier G via the gas outlet of the gasifier G was washed and dried to reduce the amount of water and ash comprised therein. Slag was removed from the gasifier G directly. After washing and drying, the gas stream GS1 hada temperature of 25 °C and was subjected to acid gas removal, by amine scrubbing, to separate acids such as CO2. The composition and normalized mass flow of the respective gas stream GS2 is given in the tables below. All simulations were performed with the Aspen Plus simulation package, version 14. Table 1 : results from examples 1 to 5 (gasifier G = plasma gasifier). feed mass flow steam: gasifier G GS2 composition stream: pressure mass flow plasma temperature pressure composition temperatureExample 1 W1 0.59 kg feed / kg GS2 kg / h 0.41 kg 7563 60.8 mol.-% H21 bar(abs.), 100 °C steam / kg kW / kg GS2 39.0 mol.-% CO64.9 wt.-% C GS2 rest steam9.3 wt.-% H 5.4 bar (abs.)25.4 wt.-% 0 180 °C0.4 wt.-% SExample 2 W1 0.65 kg feed / kg GS2 kg / h 0.35 kg 7195 58.5 mol.-% H21 bar(abs.), 100 °C steam / kg kW / kg GS2 41.2 mol.-% CO59.5 wt.-% C GS2 rest steam8.2 wt.-% H 5.4 bar(abs.)31.7 wt.-% 0 180 °C0.1 wt.-% N0.5 wt.-% SExample 3 W1 + 0.68 kg feed / kg GS2 kg / h 0.38 kg 7439 59.7 mol.-% H2F 1 bar(abs.), 100 °C steam / kg kW / kg GS2 40.2 mol.-% C0(= RDF1) 56.7 wt.-% C GS2 rest steam8.0 wt.-% H 5.4 bar(abs.)26.8 wt.-% 0 180 °C8.5 wt.-% ashExample 4 W1 0.82 kg feed / kg GS2 kg / h 0.31 kg 56.6 mol.-% H2+ F 1 bar(abs.), 100 °C steam / kg 7001 42.7 mol.-% C0(= RDF1) 47.1 wt.-% C GS2 kW / kg GS2 rest steam6.4 wt.-% H 5.4 bar(abs.)31.1 wt.-% O 180 °C15.4 wt.-% ashExample 5 W1 + W2 0.58 kg feed / kg GS2 kg / h 0.43 kg 7784 62.1 mol.-% H2+ W3 1 bar(abs.), 100 °C steam / kg kW / kg GS2 37.5 mol.-% C066.1 wt.-% C GS2 rest steam10.2 wt.-% H 5.4 bar(abs.)23.4 wt.-% 0 180 °C0.02 wt.-% N0.3 wt.-% S1: 45 wt.-% C, 6 wt.-% H, 32 wt.-% 0, 17 wt.-% ash.Table 2: results from examples 6 to 10 (gasifier G = entrained flow gasifier). feed stream: mass flow steam: gasifier G GS2 pressure mass flow composition temperature pressure and mass composition temperature flowExample 6 W1 0.69 kg feed / kg steam: entrained 45.4 mol.-% H2GS2 kg / h 0.10 kg flow 54.4 mol.-% C047 bar(abs.) steam / kg GS2 gasification rest steam100 °C 70 bar(abs.)64.9 wt-% C 400 °C9.3 wt.-% H oxygen:25.4 wt.-% 0 0.54 kg 02 / kg0.4 wt.-% S GS247 bar(abs.) 25 °CExample 7 W1 0.77 kg feed / kg steam: entrained 43.1 mol. -% H2GS2 kg / h 0.09 kg flow 56.5 mol.-% C047 bar(abs.) steam / kg GS2 gasification rest steam100 °C 70 bar(abs.)59.5 wt-% C 400 °C8.2 wt.-% H oxygen:31.7 wt-% 0 0.53 kg O2 / kg0.1 wt-% N GS20.5 wt-% S 47 bar(abs.)25 °CExample 8 W1 + F (= 0.68 kg feed / kg steam: entrained 37.0 Vol. -% H2 torrefied wood1) GS2 kg / h 0.12 kg flow 62.7.4 Vol. -% CO47 bar(abs.) steam / kg GS2 gasification rest steam100 °C 70 bar(abs.)65 wt-% C 400 °C5.4 wt-% H oxygen:18.7 wt-% 0 0.46 kg O2 / kg0.2 wt-% S GS210.9 wt-% ash 47 bar(abs.)25 °CExample 9 W1 + W2 0.78 kg feed / kg steam: entrained 43.9 Vol. -% H2GS2 kg / h 0.17 kg flow 55.8 Vol.-% C047 bar(abs.) steam / kg GS2 gasification rest steam100 °C 70 bar(abs.)59.4 wt-% C 400 °C8.3 wt-% H oxygen:31.7 wt-% 0 0.54 kg O2 / kg0.5 wt-% S GS247 bar(abs.) 25 °CExample 10 W1 + W2 + W3 0.68 kg feed / kg steam: entrained 46.2 Vol. -% H2GS2 kg / h 0.12 kg flow 53.4 Vol.-% C047 bar(abs.) steam / kg GS2 gasification rest steam100 °C 70 bar(abs.)65.8 wt-% C 400 °C9.6 wt-% H oxygen:24.6 wt-% 0 0.55 kg 02 / kgGS2 47 bar(abs.)25 °C1: 65 wt.-% C, 5 wt.-% H, 18 wt.-% 0, 12 wt.-% ash.Table 3: results from examples 11 to 14 (gasifier G = combination of fluidized bed gasifier G1 and entrained flow gasifier G2). feed stream: mass flow steam: gasifier G GS2 pressure mass flow composition temperature pressure and mass flow composition temperatureExample 11 W1 + F 1.1 kg feed / kg steam: Fluidized bed 46.8 mol. -% H2(= torrefied GS2 kg / h 0.44 kg steam / kg gasification 52.8 mol.-% CO wood1) 47 bar(abs.) GS2 and entrained rest steam100 °C 5 bar(abs.) flow65.0 wt.-% C 180 °C gasification5.9 wt.-% H oxygen:19.4 wt.-% 0 0.66 kg O2 / kg GS20.2 wt.-% S 47 bar(abs.)9.6 wt.-% ash 25 °CExample 12 W1 + F 1 .02 kg feed / kg steam: Fluidized bed 47.1 mol. -% H2(=RDF2) GS2 kg / h 0.38 kg steam / kg gasification 52.6 mol. -% CO47 bar(abs.) GS2 and entrained rest steam100 °C 70 bar(abs.) flow50.7 wt.-% C 400 °C gasification7.1 wt.-% H oxygen:29.4 wt.-% 0 0.65 kg O2 / kg GS212.8 wt.-% ash 47 bar(abs.)25 °CExample 13 W1 + W2 + 1.1 kg feed / kg steam: Fluidized bed 47.0 mol. -% H2W3 + F (= GS2 kg / h 0.46 kg steam / kg gasification 52.3 mol.-% CORDF2) 47 bar(abs.) GS2 and entrained rest steam100 °C 70 bar(abs.) flow48.9 wt.-% C 400 °C gasification6.7 wt.-% H oxygen:30.2 wt.-% 0 0.67 kg O2 / kg GS214.2 wt.-% ash 47 bar(abs.)25 °CExample 14 W1 + W2 0.88 kg feed / kg steam: Fluidized bed 46.5 Vol.-% H2+W3 + F GS2 kg / h 0.24 kg steam / kg gasification 53.1 Vol. -% CO(=RDF2) 47 bar(abs.) GS2 and entrained rest steam100 °C 70 bar(abs.) flow55.3 wt.-% C 400 °C gasification7.9 wt.-% H oxygen:27.3 wt.-% 0 0.60 kg O2 / kg GS29.5 wt.-% ash 47 bar(abs.)25 °C1: 65 wt.-% C, 5 wt.-% H, 18 wt.-% 0, 12 wt.-% ash.2: 45 wt.-% C, 6 wt.-% H, 32 wt.-% 0, 17 wt.-% ash.
Claims
Claims1. Process for utilizing at least one waste stream from an alkyl (meth-)acrylate production plant, wherein the alkyl (meth-)acrylate production plant comprises a) a reaction unit RU, b) an educt recovery unit ERU, and c) an upgrading unit UU, the process comprising the steps(oi) feeding (meth-)acrylic acid (M)AA, an alkanol and an acid catalyst into said reaction unit RU which comprises at least one reactor and preferably consists of a cascade of two or more reactors,(I) providing a first waste stream W1, wherein the first waste stream W1 is separated from the reaction unit RU or the upgrading unit UU,(ii) optionally providing a second waste stream W2, wherein the optional second waste stream W2 is separated from the educt recovery unit ERU and / or a third waste stream W3, wherein the optional third waste stream W3 is separated from the upgrading unit UU,(ill) optionally pretreating the first waste stream W1 and / or the optional second waste stream W2 and / or the optional third waste stream W3,(iv) subjecting the first waste stream W1, optionally after pretreatment in step (ill), and optionally the optional second waste stream W2 and / or the optional third waste stream W3, optionally after pretreatment in step (ill), to a gasification process wherein said gasification process comprises at least one gasifier G, wherein said at least one gasifier G is an entrained flow gasifiers or a plasma gasifier, and thereby forming a gas stream GS1 wherein said gas stream GS1 comprises CO, CO2 and H2.
2. Process according to claim 1 wherein the first waste stream W1 has at least one, preferably all the following properties: a) a calorific value in the range of 5 to 43 MJ / kg, more preferably of 8 to 40 MJ / kg and most preferably of 12 to 38 MJ / kg, b) a carbon content in the range of 30 to 80 wt.-%, more preferably 35 to 75 wt.-% and most preferably 40 to 75 wt.-%, c) a hydrogen content in the range of 2 to 15 wt.-%, more preferably 3 to 13 wt.-% and most preferably 3.5 to 12 wt.-%, d) an oxygen content in the range of 10 to 60 wt.-%, more preferably 12 to 55 wt.-% and most preferably 14 to 50 wt.-%, e) a nitrogen content in the range of 0.0 to 5 wt.-%, more preferably 0.0 to 3 wt.-% and most preferably 0.0 to 2 wt.-%, f) a sulfur content in the range of 0.0 to 15 wt.-%, more preferably 0.0 to 12 wt.-% and most preferably 0.0 to 10 wt.-%.
3. Process according to claim 1 or 2 wherein the optional second waste stream W2 has at least one, preferably all the following properties: a) a calorific value in the range of 10 to 50 MJ / kg, more preferably of 13 to 46 MJ / kg and most preferably of 16 to 44 MJ / kg, b) a carbon content in the range of 30 to 90 wt.-%, more preferably 35 to 85 wt.-% and most preferably 40 to 85 wt.-%, c) a hydrogen content in the range of 2 to 20 wt.-%, more preferably 3 to 18 wt.-% and most preferably 5 to 16 wt.-%, d) an oxygen content in the range of 4 to 60 wt.-%, more preferably 6 to 55 wt.-% and most preferably 7 to 50 wt.-%, e) a nitrogen content in the range of 0.0 to 5 wt.-%, more preferably 0.0 to 3 wt.-% and most preferably 0.0 to 2 wt.-%, f) a sulfur content in the range of 0.0 to 4 wt.-%, more preferably 0.0 to 3 wt.-% and most preferably 0.0 to 2 wt.-%.
4. Process according to any one of claims 1 to 3 wherein the optional third waste stream W3 has at least one, preferably all the following properties: a) a calorific value in the range of 20 to 50 MJ / kg, more preferably of 25 to 45 MJ / kg and most preferably of 30 to 45 MJ / kg, b) a carbon content in the range of 50 to 85 wt.-%, more preferably 55 to 80 wt.-% and most preferably 60 to 80 wt.-%, c) a hydrogen content in the range of 2 to 20 wt.-%, more preferably 5 to 18 wt.-% and most preferably 8 to 15 wt.-%, d) an oxygen content in the range of 5 to 30 wt.-%, more preferably 8 to 25 wt.-% and most preferably 10 to 25 wt.-%.
5. Process according to any one of claims 1 to 4 wherein the first waste stream W1 and / or the optional second waste stream W2 and / or the optional third waste stream W3 are optionally mixed to form a mixed waste stream W12, W13 or W123.
6. Process according to any one of claims 1 to 5 wherein the temperature of the gas stream GS1 leaving the plasma gasifier G is preferably in the range of 1100 to 1400 °C or the temperature inside the entrained flow gasifier G ranges from 1000 to 1500 °C.
7. Process according to any one of claims 1 to 6 wherein a further feedstock F is subjected to said gasification process in step (iv), whereby said further feedstock F is inserted into the at least one gasifier G together with the first waste stream W1 provided in step (I) and with the second waste stream W2 and / or the third wastestream W3 optionally provided in step (II), and / or with the first waste stream W1 and / or second waste stream W2 and / or the third waste stream W3 pretreated in step (iii).
8. Process according to claim 7 wherein the further feedstock F is selected from the group comprising or preferably consisting of biomass, refuse-derived fuel (RDF), pyrolysis oils made from plastic waste, pyrolysis oils made from end of life tires, pyrolysis oils made from biomass, heating oils, vacuum residues, preferably vacuum distillation residues, crude oil residues, heavy crude oils, extra heavy crude oils, tar sand bitumen, visbreaker bottom residues, deasphalter bottom residues, C5 asphalthene fraction, high viscous residues, fuel oils, pyrolysis gasolines, tire pyrolysis oils (TPO), waste oils, used oils, municipal solid waste (MSW), automotive shredder residue (ASR), coal, natural gas, industrial waste streams, waste streams from a (methacrylic acid production plant and mixtures thereof.
9. Process according to claim 7 or 8 wherein the weight ratio (sum of first waste stream W1 and optional second waste stream W2 and optional third waste stream W3) : (further feedstock F) preferably ranges from 1 : 1 to 1 : 10, more preferably from 1 : 2 to 1 : 10 and most preferably from 1 : 5 to 1 : 10.
10. Process according to any one of claims 1 to 9 wherein the process comprises a further step (v) said further step (v) selected from the group comprising or consisting of cleaning gas stream GS1 formed in step (iv) and thereby forming gas stream GS11, separating H2 and CO comprised in said gas stream GS1 and / or GS11 from each other, compressing at least one of the aforementioned gas streams, and combinations thereof.11 . Process according to any one of claims 1 to 10 wherein steam is co-fed into the at least one gasifier G in step (iv).
12. Process according to claim 11 wherein the weight ratio "(first waste stream W1 and optionally co-fed second waste stream W2 and / or third waste stream W3, and optionally co-fed further feedstock F) : steam” preferably ranges from 1 : 1 to 10 : 1, more preferably from 2 : 1 to 10 : 1 and most preferably from 5 : 1 to 10 : 1 or higher.
13. Process according to any one of claims 1 to 12, comprising the step: converting the gas stream GS1 obtainable by or formed in step (iv) and / or gas stream GS11 obtainable by or formed in optional step (v) to obtain a product.
14. Process according to claim 13, wherein the product is selected from: i) building block or monomer; or ii) polymer, preferably polymer A, polymer composition, preferably polymer composition A, or polymer product, preferably polymer product A; oriii) cleaning polymer, cleaning surfactant, descaling compound, cleaning biocide or composition or formulation thereof; or iv) agrochemical composition, agrochemical formulation auxiliary or agrochemically active ingredient; or v) active pharmaceutical ingredient or intermediate thereof, pharmaceutical excipient, animal feed additive, human food additive, dietary supplements, aroma chemical or aroma composition; or vi) aqueous polymer dispersion, preferably polyurethane or polyurethane - poly(meth-)acrylate hybrid polymer dispersion, emulsion, binder for paper and fiber coatings, UV-curable acrylic polymer for hot melts and coatings polyisocyanates, hyperbranched polyester polyol, polymeric dispersant for inorganic binder compositions, unsaturated polyester polyol or 100% curable composition; or vii) cosmetic surfactant, emollient, wax, cosmetic polymer, UV filter, further cosmetic ingredient or composition or formulation thereof; or viii) polymer B, polymer composition B, coating composition, other functional composition, foil, molded body, coating or coated substrate.
15. Alkyl (meth-)acrylate production plant comprising an integrated waste stream treatment facility wherein said alkyl (meth-)acrylate production plant comprises a) a reaction unit RU, b) an educt recovery unit ERU downstream of and fluidically connected to said reaction unit RU, c) an upgrading unit UU downstream of and fluidically connected to said reaction unit RU, d) at least one gasifier G downstream of and directly or indirectly fluidically connected to said upgrading unit UU or said reaction unit RU, wherein said educt recovery unit ERU is upstream of and optionally directly or indirectly fluidically connected to said at least one gasifier G.
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