Process for upcycling synthetic and organic wastes into valuable commodities

Abstract

The present invention relates to the process for upcycling synthetic and organic waste into valuable commodities. This invention offers method capable of transferring and managing mixed feedstock streams, including plastic waste, biological waste, municipal solid waste, municipal sewage sludge, and shredder residue, to produce gas, oil, light hydrocarbons, e.g., circular naphtha, specialty chemicals, and carbon solids that can be utilized directly or subjected to further refinement.

Description

[0001] PROCESS FOR UPCYCLING SYNTHETIC AND ORGANIC WASTES INTO VALUABLE COMMODITIES

[0002] DESCRIPTION

[0003] Technical Field

[0004] The present invention relates to the process for upcycling synthetic and organic waste into valuable commodities. This invention offers method capable of transferring and managing mixed feedstock streams, including plastic waste, biological waste, municipal solid waste, municipal sewage sludge, shredder residue, and / or other carbon and hydrogen rich substances to produce gas, oil, light hydrocarbons, e.g., circular naphtha, specialty chemicals, and carbon solids that can be utilized directly or subjected to further refinement or other processes.

[0005] State of the Art

[0006] Given the ongoing decline of fossil fuel resources, the escalating impact of CO2 and other greenhouse gas emissions, and the rising global demand for energy and petroleum-derived materials, the necessity for alternatives to conventional fossil resources has never been more pressing. Additionally, the substantial and increasing production of plastic and organic waste presents another significant challenge that must be addressed. Waste management has become increasingly complex due to technology advancements in materials and recycling initiatives often falling short in managing the expanding waste volume, the obsolescence of current waste management infrastructure, and limited space for constructing new facilities.

[0007] Various types of waste generated today include primary process solid (PPS), e.g., plastic and rubber waste, biological waste, municipal sewage sludge (MSS), municipal solid waste (MSW), shredder waste, and other carbon and hydrogen rich substances. PPS, derived from urban and industrial sources, often comprises substantial amounts of non-degradable materials that can cause significant environmental harm to terrestrial and marine ecosystems. Improper disposal of this waste can lead to groundwater and environmental pollution. Moreover, the longterm natural decomposition of waste plastics can result in detrimental impacts such as increased greenhouse gas emissions and disruption of underground water and natural ecosystems.

[0008] Proper management and disposal of polymeric and biological waste are essential, especially given increasing population density. Over the past few decades, the surging demand for plastics has driven extensive production of polyolefins. Presently, global production of thermoplastics stands at around 350 million tons annually, a figure projected to surpass 580 million tons by 2050, largely fueled by increased utilization of polyolefins and polystyrene. Polyolefins account for over half of plastic production, predominantly comprising disposable items that swiftly transform into waste. Unlike organic waste, plastic waste lacks natural recycling processes and endures in nature for centuries, posing significant environmental risks.

[0009] Plastic and rubber waste presents a significant environmental challenge due to its persistence and wide-ranging applications across industries. Plastics and rubbers are classified into distinct types based on chemical composition and properties, each with unique characteristics and recycling considerations. For example, polyethylene terephthalate (PET) is commonly used in beverage bottles and food packaging due to its transparency and moisture resistance, while high-density polyethylene (HDPE) is favored for its toughness and chemical resistance in products like milk jugs and pipes. Other types like rubber goods, tire, polyvinyl chloride (PVC), low-density polyethylene (LDPE), polypropylene (PP), and polystyrene (PS) each have specific applications and recycling challenges. Effective waste management strategies require a comprehensive understanding of plastic types to optimize recycling and promote responsible disposal practices, ultimately aiming to reduce plastic pollution and its environmental impact.

[0010] Plastic recycling involves various methods depending on the type of plastic and desired end products. Reusing waste plastics can create the least challenging in recycling plastics. Mechanical recycling is another common approach where plastics are sorted, cleaned, shredded, and melted to form new plastic items. However, challenges arise from the need for thorough sorting to avoid contamination and the limited recyclability of certain plastics due to degradation during processing. Chemical recycling processes, such as hydrolysis, steam cracking, pyrolysis and depolymerization, or other processes break down plastics and rubbers into raw materials for producing new plastics, other chemicals or rubbers. These methods offer potential for recycling mixed or contaminated plastics, but face challenges related to scalability, energy consumption, and cost-effectiveness. Additionally, challenges persist in creating efficient collection and sorting systems, raising awareness about recycling among consumers, and developing markets for recycled plastic products to close the loop in the circular economy of plastics. Addressing these challenges requires collaborative efforts across industries, governments, and communities to advance plastic recycling technologies and promote a sustainable approach to managing plastic waste.

[0011] Treatment of industrial waste, namely shredder residue, likewise presents another challenge. Shredder residue generally consists of the nonmetallic content of the automobile and other goods (and their constituents), such as air conditioners, refrigerators, dryers, and dishwashers, the latter products being commonly known as white goods. The shredder industry recovers about 10-12 million tons / year. of ferrous scrap, most of which is from shredded automobiles. However, for each ton of steel recovered, about 250 kg of shredder residue is produced. While many components of end-of-life automobiles, household and commercial appliances can be recycled, reused, or recovered, a significant portion is left over from the shredding process and finds its way into landfills. Disposal of shredder residue is made all the more difficult by the toxic materials found therein, e.g. , cadmium, lead, mercury, and other heavy metals. Due to the limited amount of space available for landfill use and the increasing costs of hazardous waste disposal, an alternative solution is needed. The automotive and recycling industries are currently under pressure to devise ways of using shredder residue in a cost-effective and energy-efficient manner.

[0012] While several waste management methods are in use, many of them are either impractical, contribute to additional pollution, or are economically and energetically costly. These methods encompass composting, incineration, landfill disposal, agricultural use, and ocean dumping. Each method is plagued by distinct drawbacks. Alternative waste management methods, including incineration, bioremediation, pyrolysis, and gasification, each pose unique challenges, particularly when applied to plastic waste. For instance, bioremediation via aerobic and anaerobic digestion necessitates extended and sometimes impractical residence times for plastics, precise monitoring and control of operating conditions like oxygen levels, pH, and temperature to promote specific microbial activity, it also requires specialized equipment, and often yields inconsistent treatment outcomes. The resulting products may contain pathogens. Additionally, genetically engineered bacteria targeting specific compounds can activate alternative enzyme systems upon exposure to the waste substrate, processing different compounds instead. Combustion requires specialized equipment and components to adhere to stringent emission regulations. Pyrolyzers have been utilized to break down organic materials and PPS (100) into gas, oil, tar, and carbonaceous substances. Typically, a pyrolyzer subjects organic materials to high temperatures, approximately 400-800 °C, with suboptimal energy efficiency and limited control over product composition. While this method may be effective for polyolefins, the presence of various plastic impurities like engineering plastics and PVC, along with rubber, and other organic wastes, can introduce contaminants into the final product, impacting the usability of the products as feedstocks in the chemical industry and, ultimately, increasing the costs of subsequent refining processes to convert it into a usable state. This renders the chemical recycling process economically unfeasible. An ideal process would incorporate measures to remove contaminants at minimal expense.

[0013] An auger reactor is employed as a cracking device in the chemical recycling of plastics through pyrolysis, facilitating the thermal degradation of plastic waste into valuable hydrocarbon products. The reactor features a rotating auger screw that continuously conveys the shredded plastic feedstock through a heated chamber, operating under an inert atmosphere to prevent combustion. By subjecting the plastics to elevated temperatures, the auger reactor effectively breaks down long- chain polymers into liquid hydrocarbons, gases, and solid char. This continuous and efficient process enables the scalable conversion of mixed plastic waste into reusable fuels and chemical feedstocks, addressing the growing need for sustainable waste management solutions.

[0014] Gasification involves the partial combustion of waste materials, but it is currently not well-suited for handling plastic waste and does not yield significant added value. The products of gasification, such as syngas and char, do not offer substantial value compared to other chemical recycling methods for plastics and rubbers. Syngas requires typically extensive clean up before it can be used in any subsequent synthesis step. Therefore, it is preferable to restrict the use of gasification to inexpensive and non-pure (contaminated) feedstocks.

[0015] Both pyrolysis and gasification methods can yield products with unacceptably high levels of impurities, including tar and asphalt, along with low calorific content. For example, waste containing nitrogen, oxygen, sulfur and chlorine can result in nitrogen-containing compounds, oxygen containing compounds, sulfur-containing compounds like mercaptans and organic or inorganic chlorides in the final products. Typically, hydrocarbons feedstocks in fuel or chemical applications can tolerate chlorinated hydrocarbons at levels of 1-2 ppm, but neither gasification nor pyrolysis methods reliably achieve such low levels directly. Inefficient heat transfer, uneven treatment, and energy-intensive water removal processes have limited the energy efficiency of pyrolysis and gasification approaches to around 30%.

[0016] In recent years, progress outlined in U.S. Patents 8,877,992, 5,269,947, 5,360,553, and 5,543,061 has targeted enhancements in the quality and functionality of oils derived from waste materials. However, these methods may encounter obstacles. For instance, they might struggle with handling nitrogen-, oxygen-, sulfur- and chlorine-containing compounds or efficiently processing plastics and rubbers due to challenges like melting issues, complexities in transferring, the necessity for specialized hydrolysis processes, and substantial energy demands, all of which hinder widespread adoption for commercial purposes. These examples highlight the ongoing necessity for sustainable recycling processes that are technically, economically, and environmentally viable.

[0017] The present invention offers significant advancements over prior technologies in the field of waste upcycling. Unlike patents such as CN116096838A, which focus solely on carbonizing organic waste, or EP0702076A1, which is limited to producing fuel from rubber materials, this invention provides a comprehensive method capable of processing mixed feedstock streams. This includes synthetic and organic wastes such as plastics, rubber, municipal solid waste, and shredder residues. The unique integration of hydrolysis and thermal cracking stages allows for the efficient conversion of these diverse materials into valuable products such as naphtha, fuel gases, and carbon char, while addressing the challenges of contamination. In contrast to US5269947A, which focuses on thermal depolymerization but struggles with processing contaminants, the present invention excels in handling mixed and unsorted waste streams and produces high-purity outputs with lower energy consumption. Additionally, while ES2759939B2 and W02009108761A9 explore pyrolysis and cracking methods, they do not achieve the same level of versatility or efficiency in handling contaminated and polyolefin-rich waste as the current invention does. This invention's ability to upcycle a wide range of waste materials into high-value products with minimal preprocessing distinguishes it from existing technologies, offering a more sustainable and economically viable solution.

[0018] CN106635115 relates to a method for efficiently and cleanly producing oil from mixed waste plastics using a hydrothermal reaction system. The method comprises the steps of subjecting mixed waste plastic to pyrohydrolysis under conditions of 160 °C to 300 °C and 20 bar to 220 bar, in the presence of an alkaline aqueous solution. This alkaline solution ensures that The waste plastic feedstock contains one or more of PE, PP, PS, and PET, and may optionally include PVC. After hydrothermal treatment, the resulting material is separated into a water phase and a solid phase, with the solid phase subsequently processed to produce oil. This process relies on a liquid phase alkaline hydrolysis at high temperatures and pressures, making it a challenging process.

[0019] US7771699 relates to a process for converting low-value mixed feedstocks, such as shredder residue, offal, manures, sewage sludge, tires, and plastics, into useful products including oils, gases, carbon solids, and specialty chemicals. The process employs heat and pressure, combined with thermal or catalytic cracking, in one or more stages to separate and upgrade components. The invention also relates to an apparatus for carrying out the multi-stage conversion and to oil products obtainable from the process, as well as other useful products derived from materials diverted at different stages. The process includes the use of a aqueous alkalic solution which offers problems related to high temperature and pressure and heat transfer.

[0020] Summary of the Invention

[0021] The purpose of the invention is to provide method for generating sustainable energy, hydrocarbons in the naphtha and gasoil boiling point range, fuel, raw materials, specialty chemicals, carbon char and other beneficial products from plastic and organic waste containing streams. In certain embodiments, a method involves creating a slurry of a starting material mixed with various mineral powders. This slurry is then pumped into a reactor under pressure and heated. Subsequently, the mineral containing phase is separated, and the plastic- containing phase is transferred to the next reactor, where it undergoes conversion into diverse products such as fuel, hydrocarbons in the naphtha and gasoil boiling point range, sustainable energy, hydrocarbon fuel and gases, and more, under high temperature and elevated pressure conditions.

[0022] In further embodiments, this approach might involve the hydrolysis of certain contaminants like engineering plastics, PVC, and other organic compounds found in polyolefin containing waste. This invention also offers waste treatment techniques and apparatus. In certain configurations, the input primarily consists of polyolefin plastic waste. In other configurations the input consists for polyolefin plastic waste mixed with other plastic and non-plastic waste. In alternate configurations, the input material mostly consists of municipal solid waste. In additional configurations, the feedstock consists of shredder residues. In other configurations, the feedstock consists of a mixture of any of the above feedstock in varying quantities and at various initial moisture (incl. water) content.

[0023] Various embodiments of this invention offer innovative solutions for energy and petroleum feedstock that are both environmentally and economically sustainable. The described processes generate a variety of products with a higher net energy value (NEV) compared to conventional methods like traditional incineration / combustion, pyrolysis, and gasification, while also addressing waste management challenges. These embodiments possess the capability to handle contaminated and unclean materials as Primary Process Solids (PPS) such as plastic containing (waste) streams, agricultural waste, municipal solid waste (MSW), and shredder residues, which can be costly and energy-intensive to dispose of. They transform these materials into valuable products. Examples of products resulting from these inventive processes include hydrocarbon liquids, in the naphtha and gasoil boiling point range, solid carbon, fuel oil, fuel gas, and other useful intermediates. These intermediates can be optionally extracted at different stages and further converted directly into usable energy forms, such as fuel, or feedstocks for fuel and chemical applications, along with various specialized chemicals.

[0024] Another notable advantage of this invention is its capacity to effectively convert mixed and / or unsorted streams of diverse waste streams into valuable products. The described processes can handle a range of plastic containing streams, as well as agricultural and food processing residues, including forest residues. These feedstocks vary significantly in their handling properties, resistance to conversion, and energy content, all of which are critical considerations when integrating them into a refinery and / or chemical processing setting with waste feed. The broad applicability of this invention in addressing these challenges underscores its remarkable and superior performance compared to conventional technologies.

[0025] Unlike conventional methods, the embodiments of this invention can manage waste substrates containing sulfur, nitrogen, oxygen, halogen, and other elements while still producing products with very low levels of impurities. This enables the direct use of the products without requiring additional processing. The assessment of a process's environmental benefit depends not only on the type of feedstock used but also on the energy efficiency of the process, which ultimately affects the NEV and the net CO2 footprint of the resulting products. Therefore, the exceptional efficiency demonstrated by the methods and apparatus described here in handling wet feedstock, leveraging moisture content to drive the process, and effectively sterilizing the feedstock is noteworthy.

[0026] Figures

[0027] Figure 1: a flowchart illustrating an exemplary process according to the invention.

[0028] Figure 2: a schematic diagram depicting exemplary apparatuses used to perform an exemplary process of the invention.

[0029] Figure 3: a flowchart illustrating a feed preparation stage through hydrolysis stage of an embodiment of the invention.

[0030] Figure 4: a flowchart illustrating a separation stage of an embodiment of the invention.

[0031] Figure 5: a flowchart illustrating a thermal cracking stage of an embodiment of the invention.

[0032] Figure 6: a block diagram illustrating an exemplary process of the present invention adapted for full scale processing of plastic wastes.

[0033] Figure 7: depicts an exemplary bench-scale test apparatus useful for the invention.

[0034] References

[0035] 100. Primary Process Solids, PPS 110. Preparation

[0036] 112. Slurry

[0037] 114. Heat exchanger

[0038] 120. Hydrolysis Stage

[0039] 122. Reacted feed

[0040] 126. Vent gases

[0041] 130. Separation

[0042] 132. Steam and gas

[0043] 134. Secondary Process Solids, SPS

[0044] 135. Intermediate conveyor

[0045] 139. Condensation

[0046] 140. Cracking

[0047] 142. Carbon solids

[0048] 144. Naphtha

[0049] 146. Fuel-gas

[0050] 148. Hydrocarbon vapor and gas

[0051] 149. Oil

[0052] 150. Separation

[0053] 151. Organic liquid

[0054] 152. Heavy Oil

[0055] 210. PPS preparation

[0056] 220. Mixed storage tank

[0057] 230. Hydrolysis Complex

[0058] 240. Second stage

[0059] 252. The first cracker phase

[0060] 260. Cracking reactor

[0061] 280. Product oil storage

[0062] 320. Feed storage

[0063] 336. Vent

[0064] 322. Conditioned feed

[0065] 338. Steam and gaseous impurities

[0066] 340. Heat recovery

[0067] 400. Intermediate feed

[0068] 410. First Separation

[0069] 414. PPS / remaining SPS

[0070] 440. Second Separation

[0071] 500. Separated PPS

[0072] 540. Carbon storage 630. Carbon solids cooker

[0073] 850. Cooler

[0074] 1002. Metal detector

[0075] 1004. Grinding

[0076] 1008. Grinder

[0077] 1028. SPS mixing tank

[0078] 1032. Hydrolysis reactor

[0079] 1036. High pressure flash vessel

[0080] 1038. Low pressure flash vessel

[0081] 1040. Gravity Separation

[0082] 1042. Centrifuge

[0083] 1043. Vibratory Screen

[0084] 1051. Distillation Tower

[0085] 1052. Flash Drum

[0086] 1054. Compressor

[0087] Detailed Description of the Invention

[0088] The present invention relates to the process for upcycling synthetic and organic wastes into valuable commodities. This invention offers method capable of transferring and managing mixed feedstock streams, including plastic waste, biological waste, municipal solid waste, municipal sewage sludge, and shredder residue, to produce gas, oil (149), naphtha (144) specialty chemicals, and carbon solids that can be utilized directly or subjected to further refinement. Valuable products can be extracted or integrated at different stages of the process to optimize system efficiency.

[0089] The term "sustainable energy," as used in this context, encompasses energy sources that are not derived from fossil fuels. Examples of sustainable energy sources include solar energy, hydropower, wind power, geothermal energy, wave energy, nuclear energy, and energy derived from various sources such as waste and renewable resources.

[0090] The term "plastic waste," in the context of this discussion, refers to waste primarily composed of polyolefins along with a portion of other plastics like engineering plastics and PVC. These waste streams may contain synthetic, organic, such as rubber, soil and organic substances, and inorganic materials, such as minerals, glass, metals, ceramics and other inorganic substances, and typically retain a certain amount of moisture. The term "biomass" as used here, refers to organic material obtained from plants, fungi and animals.

[0091] As used herein, the term "organic feedstock" broadly refers to carbon compounds and any feedstock in which carbon compounds are found.

[0092] "Agricultural waste" as used herein, includes waste, refuse, reject streams and recycle streams from the agricultural industries and food processing industries.

[0093] As used herein, "biological waste" broadly includes medical and infectious wastes as well as any refuse, garbage, waste, etc., perceived to be capable of transmitting disease, or posing a biological hazard to humans or to selected living things. Biological waste may be encompassed within other types of wastes defined herein. The term "municipal solid waste" (MSW), as used in this context, refers to solid waste typically gathered through municipal garbage collection systems. This waste generally includes household waste, food waste, yard waste, office-generated waste, and may also contain some industrial waste and scrap materials. Municipal solid waste encompasses mixed waste, such as unseparated household waste, as well as source-separated waste like organics from sewage treatment plants and food waste from restaurants and certain food processing facilities. Depending on its source, MSW may contain components similar to agricultural waste. Higher-value materials such as metals are typically removed during the garbage collection process.

[0094] "Shredder residue," abbreviated as "SR" and also known as shredder fluff, refers to the material left after large portions of metals and glass have been recovered from shredded or dismantled vehicles, appliances, and consumer goods. Without the benefit of the present invention, such materials often end up in landfills.

[0095] Shredder residue may include various materials such as fragments of plastics (including thermoplastics, thermosets, and polyurethane foam (PUF)), rubber, wood, paper, elastomers, fabrics, glass, fines, residual ferrous and nonferrous metal pieces, paints, and tar in different sizes. Shredder residue from old television sets, refrigerators and other consumer goods referred to as white goods, for example, often contains heavy metals or polychlorinated biphenyls (PCBs), which are hazardous chlorinated compounds. Other potentially toxic components found in shredder residue include polybrominated diphenyl ethers (PBDEs), commonly used as flame retardants and chemically similar to PCBs, as well as phthalates found in polyvinyl chloride (PVC), a key component in automobile manufacturing.

[0096] When used in relation to embodiments of the present invention, terms like "react," "reacting," and "reaction" can encompass a wide range of chemical or physical changes. Specifically, "reaction" can refer to a chemical change resulting from the combination or association of two or more species to produce one or more products. It can also include other types of decompositions or conversions involving the breakdown or transformation of a single species under conditions of temperature, pressure, or exposure to electromagnetic radiation, and can further involve transformations occurring in a solvent environment.

[0097] The term "PPS" (100) as "Primary Process Solid" in the context of this discussion, refers to the plastic and rubber wastes from industrial and post-consumer sources, including MSW, shredder residue and other mixed waste types, potentially containing polyolefins, PVC, engineering plastics, tire, etc. The primary process solid (100) comprises one or more substances selected from polyethylene, polypropylene, polystyrene, PET, polyester, textile, mineral, biomass, fat, rubber, tire, polyurethane, polyamide, and other types of synthetic and natural plastics and polymeric materials.

[0098] The term "SPS" (134) as "Secondary Process Solid" in the context of this discussion, refers to the original mineral containing substance used as the conveying aid or conveying medium, such as various soils (devoid of or containing organic material) or commercial minerals like bentonite or calcium carbonate in dry or in slurried form. The upcycling process involves transforming synthetic and organic wastes into sustainable energy, liquid hydrocarbons (144), intermediate feedstock, and other valuable products with consistent purity levels, utilizing water, heat, and pressure. Embodiments of this invention utilize water, heat, and pressure across multiple stages to convert organic waste and PPS (100) into valuable products such as liquid hydrocarbons in the naphtha and gasoil boiling point range (144), fuel, feed, gas, and others. Typically, PPS (100) are initially prepared as a slurry (112) with SPS (134) and water, then pumped and heated in the hydrolysis reactor (1032) under steam pressure to initiate the hydrolysis process. During this process, heterogeneous bonds like carbon-oxygen, carbon-nitrogen, carbon-sulfur, and others are broken, leading to the separation (130) of impurities from the plastic in the feed. Furthermore, organic liquids (151) and solid particles may undergo further reactions due to the higher temperatures and pressures, causing complex organic molecules to break down into simpler molecules through, e.g., hydrolysis. In this stage, a mixture of hydrolyzed PPS (500) with lower molecular weight compared to the original feedstock is produced. This process also yields separated water and smaller mineral particles. Subsequently, during the complex separation (130) stage, the hydrolyzed PPS (500) stream is separated from the SPS (134) and water, while steam, gases, and organic liquids (151) are condensed. A high-level block diagram illustrating exemplary embodiments of this invention is presented in Figure 1, with more detailed depictions of processes and devices provided in subsequent Figures and elaborated upon below. Embodiments of the current invention are capable of managing and processing a mixed stream of PPS (100) without requiring initial sorting into pure streams. In certain embodiments depicted in the Figures, the PPS (100) (also referred to herein as "raw material") undergoes an optional feed preparation (110) prior to entering the initial stage. During this step, the PPS (100) is treated with a mixture of water combined with a SPS (134) to facilitate smooth conveying (refer to Figure 1 and Figure 3). Alternatively, the purpose of the feed preparation (110) stage may be to enhance the flowability of the raw materials, thereby improving movement, heat transfer, and mixing in subsequent process stages. For certain feedstocks, this could involve reducing the viscosity of the semi-solids to enable continuous pumping (or metering) in the initial stage. In other cases, the ingredients may already be sufficiently sized and may only require the addition of an appropriate liquid component.

[0099] Feedstock preparation (110) is accomplished through a process that involves mixing and optionally grinding (1004), either independently or in conjunction with preheating. This preparatory phase may encompass waste pretreatments, such as washing the Primary Process Solid (100) (PPS) after grinding (1004), which helps reduce a substantial portion of contaminants like engineering plastics, PVC, and various water-soluble organic compounds. Typically, PPS preparation (210) occurs at ambient pressure and temperature conditions. This process aims to optimize the feedstock for subsequent stages by enhancing its consistency and cleanliness, thereby improving overall efficiency and product quality within the system.

[0100] The mixing or slurrying in feed preparation (110) is flexible and not limited to specific grinding (1004) requirements or feed rates, thanks to the system's utilization of optional buffer storage. This approach helps mitigate disruptions caused by fluctuations in feedstock quantity, quality, composition and / or initial particle size. The resulting slurry (112) can be conveyed through a piping system into on-site feed storage (320) tanks for subsequent processing or can be directly introduced into the processing system. This capability to prepare and store incoming waste before processing offers flexibility to handle significant variations in delivery times and waste composition effectively.

[0101] As evident from the subsequent disclosure, embodiments of the current invention may employ wet grinding (1004) to facilitate the movement of materials through pipes, tanks, and various equipment within the system. Larger particles are transported through the process as previously indicated. The process of slurrying with SPS (134), such as in feed preparation (110), serves also to decrease friction and energy consumption. Typically, maintaining a minimal slurry (112) moisture content of at least 20%, preferably above 30%, most preferably around or above 40% is advantageous for optimal processing in the described embodiments, primarily to address the viscosity limitations of the pumps involved.

[0102] Individuals with ordinary expertise will understand that the minimum moisture content threshold mentioned can be adjusted by employing alternative pumping or conveying technologies, contingent upon specific feedstock characteristics. The processes described herein exhibit relatively high energy efficiency, as the majority of water entering the system exits in liquid form rather than as vapor or gas. The addition of solvents other than water at this stage may or may not be necessary, depending on the specific properties of the feedstock and process conditions.

[0103] In accordance with embodiments of the current invention, these incoming streams can undergo processing as they are, unlike conventional methods that struggle with wet feedstock and usually prioritize removing water and other contaminants first. However, embodiments of this invention leverage the water already present in the feedstock to enhance efficiency further and aid in the removal of contaminants and toxic chemicals from organic streams.

[0104] Feedstock preparation (110) and slurring can be carried out in a feedstock preparation (110) apparatus, as diagrammed in FIG. 2.

[0105] As depicted in Figure 2, the preparation (110) and optional grinding (1004) of PPS (100) can be carried out using the raw material preparation (110) machine. Once the PPS (100) is incorporated into the feed stream, they are conveyed into the mixed storage tank (220) along with pre-prepared SPS (134) slurry (112). The initial handling of PPS (100) can be accomplished using underflow buckets, conventional conveyors, and / or bucket elevators or other suitable equipment under ambient conditions. If necessary, the mixed storage tank (220) comprises vibratory screens (1043) can be utilized for fine sizing to eliminate dirt, loose debris and / or other contamination. In the following, for injecting the generated slurry (112) into the hydrolysis complex (230), it is recommended to utilize specialized high-pressure equipment, e.g., pumps. The required reduction in material size depends on the composition of the PPS (100); for instance, optimal particle sizes typically range from 0.1 mm to 100 mm, preferably from 1 mm to 50 mm, more preferably from 5 mm to 30 mm.

[0106] However, for practical purposes, the PPS (100) particles are typically sized between 6 to 26 mm to facilitate pumping along with the SPS (134). The initial size of the material generally depends on the capacity and capabilities of the equipment being used. Upon exiting the raw material preparation (110) step, the particle size should be optimized for the subsequent treatments outlined in this process. In alternative embodiments of the invention, the feed preparation (110) step may involve adding or removing materials from the raw materials, essentially conducting specific pretreatments to refine the plastic content. Those with ordinary skill in the field will also recognize that certain feedstocks with high fluid content can be directly fed into the hydrolysis stage (120) without compromising the objectives and advantages of the present invention.

[0107] The first stage of separating organic and mineral waste is in the hydrolysis stage (120). Referring to Figure 1, a slurry (112) consisting of a mixture of PPS (100) and SPS (134) is transported from the feed preparation (110) to the hydrolysis stage (120), where it undergoes heating while being subject to elevated pressure. The combined effects of temperature, pressure, and residence time lead to the molecular semi-degradation of the raw materials. In the hydrolysis stage (120), the process effectively targets the weaker bonds within the PPS (100) stream, including various heterogeneous bonds such as nitrogen, oxygen, sulfur, and chlorine commonly found in organic materials, rubber, polymers, engineering plastics, and PVC. These bonds are broken down primarily forming gas or water-soluble gases or liquids, facilitating their separation (130) from the PPS (100) flow. The hydrolysis process has less impact on polyolefins but may reduce their molecular weight to some extent. Following the hydrolysis stage (120), the reactor contents proceed to a complex and multi-component separation (130) step. In the second stage (240) as separation (130) step, various solid components such as SPS (134), light ash solids, heavy ash solids, minerals (containing inorganic elements, like silicon, aluminum, iron, calcium and phosphorus), fixed carbon, and other carbonaceous materials with low hydrogen content are separated from the slurry as SPS (134). Organic and acidic gases produced during hydrolysis are also separated along with steam at this stage. The purified PPS (500) stream, enriched in polyolefins and other polymers with reduced heteroatom content, is directed to unit for further processing.

[0108] In certain embodiments of the invention, bulk / mineral separation (130) at this stage of the process involves a combination of hydrocyclonic separation (130) and gravity discharge. The minerals or other solids thus separated can optionally be directed to storage for further handling. Generally, the hydrolysis stage (120) occurs within a temperature range of 50 °C to 550 °C, preferably 80 °C to 500 °C, more preferably 100 °C to 450 °C and most preferably 125°C to 400 °C, depending on the starting material. However, the temperature is carefully controlled for specific feedstock compositions to minimize or eliminate the formation of char, ash, resin, or undesired reactions, ideally preventing any coal or ash formation. In exemplary embodiments, the pressure typically ranges from about 1 bar to 200 bar, preferably from 1.2 bar to 150 bar, more preferably from 1.5 bar to 100 bar, most preferably from 2 bar to 80 bar, depending on the raw material. The duration of this step typically varies from about 1 minute to 1440 minutes, preferably from 2 minutes to 600 minutes, more preferably from 5 minutes to 240 minutes, most preferably from about 15 minutes to 180 minutes. Additionally, in certain embodiments, the average pH of the material at this stage is in the range of 4 to 8.5, preferably 5 to 8, more preferably from 5.5 to 7.5, most preferably it is approximately 6.5. The duration of the run time can vary depending on the conditions applied, for example ranging from less than 15 minutes at higher temperatures to over an hour at lower temperatures, as appreciated by individuals skilled in the field.

[0109] Elevating the temperature to these levels reduces the overall viscosity of the slurry (112) and facilitates the breakdown of various components for subsequent processing. For instance, organics undergo breakdown into smaller molecular weights, e.g., shorter chains. In PPS (100), plastic can be softened or melted, and rubber can be devulcanized, long-chain molecules can be fragmented, and solid materials like fixed carbon and metals can be liberated. This viscosity reduction also enables the separation (130) of bound insoluble solids (134), such as minerals, including fillers, composite materials, fibrous materials, etc., for example.

[0110] In an exemplary implementation of the hydrolysis stage (120), as shown in FIG. 2, Feed Storage (320) supplies a constant feed stream to a high-pressure slurry pump that pressurizes the slurry (112) of SPS (134) and PPS (100) and transports it to hydrolysis complex (230). Hydrolysis reactor (1032) designs can be implemented using simple existing technologies, e.g., batch, auger, stirred, extruder or flow through jacketed reactors, as higher than atmospheric pressures are being utilized in the current process.

[0111] In hydrolysis as generally illustrated in FIG. 1, the slurry (112) is delivered to the hydrolysis stage (120) and subjected to elevated temperature and pressure to initiate the removal of heteroatoms and the breaking down of longer chain molecules into shorter chains. The result is a reacted feed (122), i.e., a mixture of renewable fuel / oil (149), separated water, PPS (100) with higher melt flow index (MFI) and SPS (134), the composition of which will be discussed in detail below in connection with the second separation (440) or separation (130) stage. Generally, the hydrolysis stage (120) is carried out at temperatures in the range from about 50 °C to 550 °C, preferably 80 °C to 500 °C, more preferably 100 °C to 450 °C and most preferably 125 °C to about 400 °C so that at least one of a number of transformations or reactions may occur. For example, depending on PPS (100) composition, such transformations may include deoxygenation, denitrogenation, desulphurization, dechlorination, decarbonylation, and decarboxylation of PPS (100), organic decontaminations and partial depolymerization and / or isomerization and / or cyclization of the polymer chain or its constituents. The hydrolysis stage (120) creates conditions suitable for eliminating gaseous impurities like ammonia, nitrogen oxides, HCI, carbon monoxide, carbon dioxide, and sulfur-containing gases, and for venting sulfur-containing gases resulting from the breakdown of sulfur-containing components in the feedstock. Sources of sulfur may include various rubbers and organic contaminants. The combined impact of heat, pressure, and duration applied during this phase also ensures the destruction of any pathogens present in the waste. Consequently, embodiments of this innovation can be utilized for the sterilization and processing of biological waste.

[0112] Given that heterogenous bonds involving elements like oxygen, sulfur, nitrogen, chlorine with carbon have similar or lower bond energy than carbon-carbon bonds and they typically have a higher inherent reactivity due to covalent bond polarization, they are more susceptible to breaking under the elevated temperature and pressure conditions of the hydrolysis reactor (1032). The hydrolysis reactor (1032) is typically a batch reactor, a continuous stirred-tank reactor, an auger reactor, an extruder, or other reactor types suitable for maintaining the reaction conditions.

[0113] Consequently, the hydrolysis process becomes highly effective in minimizing contamination in the final products. Moreover, under these reactor conditions, engineering plastics are likely to undergo molecular breakdown, converting into primary monomers that can be readily separated from polyolefins due to their higher water solubility or more polyolefinic type substances due to the removal of the heteroatoms. Conversely, polyolefin chains also undergo cracking (140) under these conditions, leading to a reduction in their molecular weight. The lower average molecular weight makes them more susceptible to further cracking (140) in the subsequent reactor or reactors.

[0114] The pressure in the hydrolysis reactor (1032) is preferably selected to be close to the saturation pressure of the entrained water in the liquid mixture at the operating temperature in question. The saturation pressure is the pressure that needs to be applied at a given temperature to keep the water from boiling, and also depends on the presence and quantity of other gases in the purified feed slurry (112). The total pressure in the reactor is greater than the vapor pressure of the water in the slurry (112) mixture, so that the water does not boil off preferentially. Typically, the pressure is adjusted within a range of 0 to 15 bar, preferably within the range of approximately 0 to 7 bar above saturation to allow for the release of unwanted gases. Generally, the total pressure can vary between 1 and 200 bar, preferably between 2 and 150 bar, more preferably between 3 and 100 bar, most preferably between 6 and 80 bar.

[0115] As illustrated in FIG. 1, the reacted feed (122) resulting from this stage typically consists of a mixture of reacted PPS (100), SPS (134) and a mixture of reacted liquid and gas products. These various products may be characterized as an oil phase, a water phase, a mixed oil-water phase, and a wet solid (mineral) phase. The water phase, the oil phase, and the mixed oil-water phase are typically enriched with various dissolved organic materials.

[0116] In one embodiment of the present invention, the initial stage hydrolysis (referred to as stage 1 hydrolysis) can be conducted within a hydrolysis reactor (1032) as illustrated in FIG. 2. This reactor may feature a multi-chamber design to ensure a narrow distribution of residence times for the constituent materials within the slurry (112). Alternatively, the hydrolysis reactor (1032) could also be configured as an augured reactor or an extruder in different embodiments. In certain variations, the slurry (112) is heated and / or pressurized in multiple stages prior to entering the reactor vessel, such as within a separate storage, pressurizing, and heating unit. The reactor vessel might include baffles and a motorized stirrer with multiple blades to effectively stir the slurry (112) within each chamber simultaneously. For instance, in one specific embodiment, the vessel could be equipped with four chambers. It is imperative that the reactor vessel possesses sufficient strength to withstand the pressure exerted by the gas phase when the feed stream is subjected to operational conditions.

[0117] Referring to FIG. 1, reacted feed (122), which typically comprises PPS (100), SPS (134), and reacted product is fed to a separation (130) stage to separate the components therein into gases and steams (132), separated water (138), SPS (134), organic liquid (151) and PPS (500) stream. The various components of reacted feed (122) can be separated, for example, by techniques described herein. Steam and gases (132) can be driven off and redirected to, e.g., preheat the incoming slurry (112).

[0118] The separation (130) step as the second stage (240) in the process may involve a sequence of one or more steps that can be performed either sequentially or simultaneously. In exemplary implementations, the reacted feed (122) initially undergoes a solid / liquid separation (130) followed by a liquid / liquid separation (130). While the order of these separations (130) can be adjusted, it is understood by those skilled in the field that altering the sequence may impact the overall efficiency of the separation (130) process. Mineral and other solid particles that were not removed during the first hydrolysis stage (120) can be separated from the liquids by, e.g., decanting, and the renewable oil (149) and separated water can be separated using, e.g., a centrifuge (1042) or by gravity separation (1040). Once substantially isolated, the hydrocarbon liquid or unfinished oil (149) can be transferred into storage tanks for holding or further refined and processed into higher-value products. In certain embodiments of the separation (130) stage, as depicted in FIG. 3, the reacted feed (122) undergoes a process known as flashing to lower pressure allowing the reuse of excess heat in the earlier heating stages. Typically, flashing involves multiple stages of pressure reduction, often conducted in two, three or more stages. The purpose of flashing is to vent (336) off remaining steam and gases (132) associated with the reacted feed (122). Dehydration through depressurization is an efficient method as water is removed without the need for additional heat. The effective utilization of this excess heat is referred to as heat recovery (340), representing a further advancement in the current process.

[0119] After the reacted feed (122) has been flashed, and heat has been recovered, the intermediate feed (400) still typically comprises at least one reacted liquid product, at least one reacted organic solid product, at least one reacted inorganic solid product and water. At least one reacted liquid product is typically a constituent of hydrocarbon liquid; the at least one reacted organic solid product typically comprises plastics, the at least one reacted inorganic solid product typically comprises minerals and / or rejected solids. The intermediate feed (400) preferably is substantially free of gaseous products.

[0120] FIG. 4 illustrates a series of separation (130) steps that can be implemented on the intermediate feed (400). An additional benefit of embodiments of the present invention is the ability to subject the intermediate feed (400) resulting from the first hydrolysis stage (120) to one or more separation (130) stages to remove SPS (134), minerals and water before proceeding to the third stage or cracking (140).

[0121] In this embodiment, the intermediate feed (400), typically comprising the hydrolyzed PPS (500) stream, water, SPS (134), such as some minerals or other contaminated solids is preferably subjected to a first separation (410) that removes most SPS (134), rejected solids (134) and produces a mixture of plastic and water- PSS / remaining SPS (414). Such a separation (130) may be characterized as a solid / liquid separation (130) and may be achieved with a first centrifuge (1042) or via other known solid / liquid separation (130) devices. The SPS (134) is separated from the rejected (inorganic) solids, and it is sent back to the SPS mixing tank.

[0122] In this embodiment, the mixture of the hydrolyzed PPS (500) and SPS (134) undergoes a second separation (440) step to remove the SPS (134) and isolate the hydrolyzed PPS (500). This second separation (440) can be achieved using a second solid / liquid centrifuge (1042), gravity separation (1040) column, or another suitable separation device. Separation (130) is based on differences in specific gravity, enabling the centrifugal separation (130) of the separated water and plastic.

[0123] The separated SPS (134) typically contains a certain amount of dissolved small organic molecules resulting from the breakdown of engineering plastics, PVC, and / or organic contaminants. Additionally, the separated SPS (134) often includes ash, chloride, and other impurities. By separating out these impurities priorto the thermal cracking (140) reactions, especially in thermal-chemical processes described below, the present invention offers the added benefit of ensuring that later products are not contaminated. This enhancement improves the combustibility of the fuels produced and it reduces the impurities for both fuel and chemical applications. Afterward, the SPS (134) proceeds into the SPS mixing tank (1028), where the water undergoes continuous treatment in water waste treatment process (WWTP) and is then returned to the tank.

[0124] It should be noted that the present invention is not restricted to a separation (130) stage consisting of two steps, nor is it constrained by the sequence in which separation (130) steps are performed. Therefore, the present invention accommodates scenarios where the separation (130) of the intermediate feed (400) into products such as hydrolyzed PPS (500), SPS (134), inorganic rejected solids, and water may occur in a single step or in more than two steps.

[0125] Referring to the exemplary apparatus depicted in FIG. 2, the flashing of the reacted feed (122) in the second stage (240) can be accomplished using one or more flash vessels equipped with vents. Ideally, the pressure within the flash vessel is significantly lower than that within the hydrolysis complex (230). In one configuration, the pressure inside the flash vessel is approximately 20 bar, whereas the pressure within the hydrolysis reactor (1032) is around 30 bar. Various pieces of equipment can be employed to facilitate the separation (130) of materials emerging from the first stage hydrolysis reactor (1032). These separations (130) yield a mixture consisting of steam and gases (132), hydrolyzed PPS (500), SPS (including minerals and soil) (134), and separated water with solubles. The steam and gases (132) are preferably redirected back to the hydrolysis stage (120) to aid in feed heating following preheating.

[0126] Solids or particulates such as SPS (134) can be separated from hydrolyzed PPS (500) using suitable equipment, e.g., centrifuges (1042), hydrocyclones, or static tanks. The separated SPS (134) is reintroduced into the SPS mixing tank (1028) to serve as a medium for transferring PPS (100) to the hydrolysis reactor (1032) once more. The hydrolyzed PPS (500) that has been separated from the SPS (134), inorganic rejected materials and the water may be contained in the first cracker phase (252) prior to transfer to the cracking reactor (260). The first cracker phase involves a lock-hopper and a melting system that operates using hot oil or electricity.

[0127] Drawing from the principles described herein, someone skilled in the field may choose to incorporate centrifuges (1042), hydrocyclones, distillation towers (1051), filtration devices, screens or other suitable equipment into the second separation (440) process. Additionally, distillation can be utilized to eliminate very fine carbon solids from an intermediate feed (400). Generally, additional pressure reduction enhances steam recovery and facilitates solid / liquid separation (130) to recover SPS (134), and other rejected (inorganic) solids.

[0128] The hydrolyzed PPS (500) stream intended for conversion into end products, like hydrocarbons in the naphtha -and / or gasoil boiling point range (144) and hydrocarbon gases, is directed to a high-temperature reactor operating under moderate pressure, as advised by experts familiar with the techniques outlined in this disclosure. This approach leverages established industry knowledge and best practices for processing plastics into desired chemical products and / or fuel components. In certain embodiments, residual fractions or fractionated liquor, sometimes referred to as "heavy oil" (152) containing fractions that are not suitable for specialty and / or generic chemical applications, can be routed to the first cracker phase (252) or to the cracking reactor (260) as shown in Figure 2. These residual fractions may include waxes collected at the bottom of the distillation tower (1051) or towers and can be transferred to the first cracker phase (252) or to the cracking reactor (260).

[0129] Depending on the composition of the PPS (100) used, e.g., if it contains PVC, engineering plastics, or organic contaminants, the separated water may contain nitrogen, oxygen, sulfur, and / or chlorine-containing materials.

[0130] Alternatively, in certain embodiments, see Figure 5, the cracking (140) stage may undergo further processing within a thermal-chemical platform. For instance, the hydrolyzed PPS (500) stream could be cracked using established methods to yield fuel gas (146), carbon solids (142), and hydrocarbons in the naphtha and gasoil boiling point range (144). Additional thermal-chemical treatments include visbreaking, hydrotreating, gasifying, and pyrolyzing and other thermal treatments suitable for the alteration of the boiling point curve of the resulting hydrocarbon mixture. While techniques like gasifying and pyrolyzing PPS (500) streams have historically faced challenges, the homogeneity of the output from the second stage (240) separation (130) in the present invention's embodiments enables more successful implementation of such treatments.

[0131] In Figure 5 in the exemplary cracking (140) within a thermal chemical platform, the hydrolyzed PPS (500) is exposed to conditions that induce a reaction involving one or more established processes like thermal cracking (140), catalytic cracking (140), and other reactions known in the field. Additionally, it is possible that the plastic may contain a certain amount of reacted solid product that is also introduced into the cracking reactor (260). A lock hopper is used as the entrance to the auger reactor in the first cracker phase (252), serving to facilitate the controlled and safe introduction of feedstock while maintaining an inert atmosphere. The lock hopper comprises two chambers separated by a valve, allowing one chamber to be loaded with shredded plastic waste while the other feeds directly into the auger reactor. This design prevents the ingress of oxygen and the escape of volatile gases during the feeding process, which is critical for ensuring safe pyrolysis conditions. By regulating the valve between the chambers, the lock hopper enables precise control of the feed rate, optimizing the reactor's operational efficiency and enhancing product yield. Additionally, the lock hopper minimizes the risk of contamination by providing a sealed environment, contributing to the overall stability and effectiveness of the pyrolysis process in converting plastic waste into valuable hydrocarbons.

[0132] In the cracking reactor (260), when subjected to high temperature and moderate pressure, the hydrolyzed PPS (500) undergoes conversion into a mixture of valuable materials, typically comprising carbon solids (142) and a blend of hydrocarbons that is typically emitted as hydrocarbon vapor and gases (148).

[0133] In the cracking (140) stage, optimal conditions typically involve higher temperatures and lower pressures compared to the hydrolysis stage (120). The cracking (140) process may also incorporate the use of additional water, nitrogen and / or hydrogen. Various apparatuses can be utilized to facilitate the cracking (140) stage.

[0134] The temperature range for these cracking (140) reactions is typically between about 250 °C and 800 °C, preferably between about 300 °C and 750 °C, more preferably between about 350 °C and 700 °C and most preferably between about 400 °C and 600 °C, with a reaction duration ranging from about 1 minute to about 360 minutes, preferably about 2 minutes to about 240 minutes, more preferably about 3 minutes to about 180 minutes and most preferably about 5 minutes to about 120 minutes. Different components within the resulting products spend varying durations in the cracking reactor (260); for instance, vapors pass through quickly whereas liquids have a longer exposure.

[0135] The output from the cracking (140) stage consists of two distinct components: a mixture of hydrocarbon vapor and gases (148) including CO2, CO, nitrogencontaining compounds, sulfur-containing compounds, and carbon solids (142) resembling high-quality coke. Hydrocarbon vapor and gases (148) typically include oil (149) vapor. The conditions of the cracking (140) stage are carefully selected to optimize the purity of the carbon solids (142) and the hydrocarbon vapor and gas (148) mixture. Rapid quenching of hot vapors, such as the hydrocarbon vapor and gas (148) mixture, is crucial to prevent secondary reactions and to minimize carbon char formation after exiting the cracking reactor (260). In an exemplary setup, rapid quenching of vapors can be achieved by directing them into a water-filled drum or through multiple quenching steps using thermal fluids and cooling media. Employing multiple quenching steps can leverage the recovery of hydrocarbons in the naphtha and / or gasoil boiling point range (144) from the PPS (500). Alternatively, vapors with a lower boiling point range can be quenched in the presence of incoming hydrocarbon liquid, facilitating energy recovery.

[0136] In thermal-chemical platforms utilized for the cracking (140) stage, temperatures typically range between about 250 °C and 800 °C, preferably between about 300 °C and 750 °C, more preferably between about 350 °C and 700 °C and most preferably between about 400°C and 600°C to enable the breakdown of PPS (500) into hydrocarbons or the cracking (140) of hydrocarbon molecules into lower molecular weight distributions (occurring at temperatures above 400-650 °C). According to the open art, hydrocarbon cracking (140) generally occurs at temperatures above 480 °C. The cracking (140) stage may operate at higher temperatures compared to the hydrolysis stage (120), with the second stage (240) reactor pressurized between about 0.1 bar and 30 bar, more preferably between 0.5 bar and 25 bar, most preferably between about 1 bar and 20 bar in one embodiment.

[0137] In certain configurations, the pressure within the cracking (140) stage reactor may be lower than that in the first stage, aligning with the specific operational requirements of the process.

[0138] An example of cracking (140) stage is illustrated in FIG.5. Carbon solids (142) generated from a cracking reactor (260) as described above are typically first passed to a carbon solids cooler (630) wherein the carbon is permitted to lose its residual heat. After cooling, the carbon solids (142) are typically subject to a form of passivation by, e.g., a controlled dosing of air to reduce and / or eliminate the chance of self-heating when exposed to air, before passed to carbon storage (540) and subsequent use. The mixture of hydrocarbon vapor and gases (148) produced by the cracking reactor (260) can be directed to a cooler (850) (condenser) which separates the mixture into fuel-gas (146) and hydrocarbon oil (149). After separating hydrocarbon oil (149) into its components such as liquid hydrocarbons (144) and heavy oil (152) compounds (including wax), any heavy compound is sent back to the cracking reactor (260) while the liquid hydrocarbons (144) are isolated. Although the invention's process can be executed within a specified range of parameters as described earlier, specific adjustments to operating conditions like temperature and pressure can be implemented to improve process yield and efficiency, as demonstrated below for various feedstock types. It should be noted that the operating parameters in this invention may be modified as needed to accommodate different raw feed materials or other process requirements without deviating from the essence of the invention.

[0139] This process has the capability to address various types of plastic waste streams, as PPS (100), including (micro)plastics retrieved from waterways, flowing and stationary water bodies, residues remaining after mechanical separation (130) of plastics, post-consumer and post-industrial waste plastic, plastic containing packaging materials and more.

[0140] For instance, within the realm of PPS (100) raw feedstock, the primary constituents consist predominantly of polyolefins, with presence of polyesters, polyamides, polyurethanes, engineering plastics, PVC, rubbers, paper, organic (food) contaminations and minerals.

[0141] Consequently, the composition balance of these main components may influence certain operational parameters of the processing step(s) of the current invention. Furthermore, the temperature range applied during initial-stage reactions and subsequent processing steps can be managed to promote the production of specific products like light hydrocarbons e.g., circular naphtha (144) over alternative pathways, thereby optimizing the economic value derived from the resultant products.

[0142] Various embodiments of the present invention have been evaluated using a range of waste types, mostly the varied streams of plastics, and have been compiled to predetermine the composition and product breakdown for different plastic waste streams.

[0143] For PPS (100) feedstocks containing significant amounts of polyolefins like polyethylene and polypropylene, it can be beneficial to remove contaminants such as polyesters, polyamides, polyurethanes, engineering plastics, PVC, rubber, paper, minerals, etc., during feed preparation (110) or before.

[0144] Methods for removing contamination are well-known to those skilled in the art and may include, but are not limited to, separating contaminants before slurring or using water washing.

[0145] Shredder residue typically consists of approximately 50% combustible material and 50% noncombustible (inert) material. It may also contain substances like brake fluid, gasoline, engine oil (149), windshield washing fluids, antifreeze (ethylene glycol), FREON™ refrigerants, and occasionally polychlorinated biphenyls (PCBs), which can be introduced during the shredding of electronics and old white goods with intact capacitors. Furthermore, heavy metals such as lead, mercury, and cadmium can be present in shredder residue. The moisture content of shredder residue varies based on the shredding method (wet or dry) and exposure to rain while in storage. Although shredder residue is generally considered "dry," it can still contain up to 15% moisture by weight.

[0146] Similarly, MSW, tires, and mixed plastics used as feedstock may share common attributes with shredder residue. However, MSW presents additional considerations based on specific batch content, which may include animal by-products that can undergo premature reactions like hydrolysis of fats and proteins if the temperature exceeds the decomposition limits of these materials, particularly when moisture content is high. Premature hydrolysis can lead to the formation of stable emulsions that are challenging to break down in subsequent process stages. In some cases, a two-step decomposition reaction may be employed to address specific feedstock content effectively.

[0147] Shredder residue, municipal solid waste (MSW), and tires / mixed plastics have demonstrated on the bench-scale and pilot-scale levels to follow the following conversion patterns on average:

[0148] Solvents and Modifications

[0149] Depending on the composition of the raw feed, specific modifications to the feedstock may be beneficial to improve processing efficiency. One example of a feedstockspecific modification involves adding an organic solvent to dense hydrocarbon feedstocks such as plastics, rubber, tires, and foam to increase the organic content and improve the yield of usable liquid mixtures. Other modifications may include adding acids and / or alkaline materials to control pH levels.

[0150] When the raw feedstock includes plastics, whether alone or as part of shredder residue (SR) or municipal solid waste (MSW), it has been observed that a hydrocarbon oil (149) produced by the process itself serves as a highly effective solvent compared to other known solvents in the field. Consequently, some of the hydrocarbons generated by the process can be reintroduced into the input raw feed or earlier stage reactions. In exemplary embodiments, these hydrocarbons have a boiling range typically between 100 °C and 350 °C. The hydrocarbon solvent may be preheated before application to the shredder residue, MSW, and tires / mixed plastics feedstock. Alternatively, in other embodiments, the hydrocarbons are applied directly to the feedstock, and the mixture is heated to a temperature ranging from 200 °C to 350 °C. Utilizing the final stage oil (149) product eliminates the need for recurring expenses associated with other solvents and the replenishment of these solvents. In certain embodiments of the present invention, either the entire range of constituents in the oil (149) or a selected portion thereof is used to dissolve tires, shredder residue, MSW, and / or mixed plastics. For instance, all of the hydrocarbon oil (149) produced in the initial batch can be directed back to the input tire feedstock. Alternatively, in different embodiments, only the final-stage heavy oil (152) product is redirected in this manner. If only a portion of the constituents is utilized, the solvent can be separated into its components during either the hydrocarbon oil (149) finishing or the first stage of the process. Using the hydrocarbon oil (149) produced as a solvent can enhance the economic viability of the present process compared to conventional methods. Since this oil (149) may not be immediately available for processing the first batch of feedstock, an additional solvent may be used initially to aid in breaking down of the feedstock.

[0151] Examples of effective solvents for this purpose include toluene; additional suitable solvents would be recognized by those skilled in the field. During the initial stage of hydrolysis for tire and / or mixed plastics processing, additional water may be added to aid in the removal of chlorine or other halogen-containing materials.

[0152] Shredder residue typically consists of approximately 50% combustible material and 50% noncombustible (inert) material. It may also contain substances like brake fluid, gasoline, engine oil (149), windshield washing fluids, antifreeze (ethylene glycol), FREON™ refrigerants, and occasionally polychlorinated biphenyls (PCBs), which can be introduced during the shredding of electronics and old white goods with intact capacitors. Furthermore, heavy metals such as lead, mercury, and cadmium can be present in shredder residue. The moisture content of shredder residue varies based on the shredding method (wet or dry) and exposure to rain while in storage. Although shredder residue is generally considered "dry," it can still contain up to 15% moisture by weight.

[0153] In certain embodiments, the hydrocarbon vapor and gases (148) produced from the cracking (140) stage consist primarily of hydrocarbon gases, potentially with minor impurities of non-hydrocarbon gases. These hydrocarbon gases include fuel gas (146), while the hydrocarbon vapors can be easily condensed into liquids or oils (149). The fuel gas (146) possesses a high calorific value and can be internally redistributed within the process to provide heating energy at various stages, or it can be used to generate electrical or other forms of energy for internal or external use. Oil (149) typically contains hydrocarbons with carbon chains of 30 or fewer carbon atoms, resembling the lighter components found in fuel oils (149) like naphtha and / or gasoil (144). This product is also commercially viable for sale. The heavy oil (152), including wax or waxy components, can be sent to cracking (140) reactor for re-cracking.

[0154] It should be noted that the specific composition of oil (149) is influenced by both the feedstock used and the reaction conditions applied during the conversion step(s) and the oil (149) finishing step. Consequently, the oil (149) may contain paraffins, a- olefins, naphthenes, and aromatics, among other constituents. For instance, the composition of the oil (149) differs depending on whether the feedstock is tires or waste plastic. It has been observed that oil (149) derived from feedstocks high in plastic content tends to be rich in olefins and di-olefins, whereas oil (149) from tires contains aromatics, naphthenes and sulphur compounds. If desired, these olefins can be removed from the oil (149) through saturation or using various posttreatments techniques known to those skilled in the field.

[0155] Equipment

[0156] Various apparatuses for implementing the processes described in embodiments of the present invention are discussed herein. Given the guidance provided in this document, assembling the various components for the described apparatus would be within the capabilities of individuals skilled in process engineering or chemical engineering. Therefore, technical details familiar to those with ordinary expertise are not detailed in this description. Generally, suitable equipment can be fabricated using any heat- and water-resistant materials known in the field. In exemplary embodiments, the apparatus of the invention is primarily constructed from carbon steel, with limited use of 316L stainless steel or other corrosion resistant alloys suitable for lower or higher than neutral pH environments. Although more specialized metals could be utilized, they are not essential for achieving the objectives and benefits of the invention. Examples of exotic metals that may be employed include Hastelloy, titanium, tantalum, and various hardened steels suitable for acidic service, control valve trim, and grinding (1004) equipment.

[0157] Individuals skilled in the field will acknowledge that a wide range of reactors, tanks, separators, conveyors, and other devices can be employed for the purposes of this invention. For instance, various types of filters with openings smaller than the suspended solid particles can be used for solid material that does not deform significantly under strain. Additionally, clarifiers, settling chambers, and simple cyclones can be effective when there is a notable density difference between the solid particles and the fluid. As the size or density difference decreases, active devices employing centrifugal forces can be advantageous.

[0158] Handling of Problematic Waste

[0159] The processes described in this invention can effectively manage challenging waste materials. One benefit of this invention is that during feed preparation (110), downstream feed storage, and hydrolysis (e.g., feed storage (320) as shown in FIG. 3), the system allows for the removal of gaseous impurities like ammonia, nitrous 1 oxides, carbon monoxide, carbon dioxide, and sulfur-containing gases. Depending on the composition of the feedstock used, hydrolysis may generate sulfur-containing gases due to the breakdown of sulfur-containing components in the PPS (100). A significant source of sulfur comes from (vulcanized) rubber pieces, many of which contain sulfur bridges between rubber chains. The sulfur-containing gases typically include hydrogen sulfide (H2S) and mercaptans (alkyl-sulfur compounds) like methyl mercaptan. Additionally, certain sulfur rich salts such as calcium sulfide (CaS) may be produced, which are typically separated in subsequent stages.

[0160] The hydrolysis of chlorinated and / or brominated organics within the mixture disrupts the carbon-halide and / or oxygen-halide bonds, transferring metals and halides into the water phase. Consequently, the present invention is well-suited for PVC recycling and the treatment of waste containing PCBs and PBDEs. As experts in waste management will recognize, PVC contains approximately 58% chlorine by weight, making it prone to generating toxic substances like dioxins when subjected to incineration and traditional technologies. One advantage of employing water in the process of this invention is that the hydrogen ions in water react with chloride and halogen ions from PVC, producing solubilized products such as hydrochloric acid. This chemical is relatively benign and commercially valuable, finding applications in cleaners and solvents while being substantially free of contaminants and debris.

[0161] Efficiency

[0162] High energy efficiency in embodiments of this invention is achieved through countercurrent heat exchange and the utilization of moisture in the feedstock to aid in optional sizing and conveying materials throughout the system. A significant portion of the energy utilized in these systems is dedicated to heating liquid water within the initial process step or steps. Following hydrolysis, flashing produces steam, which is then separated and redirected to pre-heat incoming feed, effectively recycling the system energy efficiently. Due to the diverse composition of raw feed used, energy efficiency will fluctuate from one operation to another. Nonetheless, based on multiple test runs, the process's energy efficiency was determined to be approximately 91%.

[0163] The utilization of water in hydrolysis, which can be vented as steam alongside other gases, contributes to efficient energy recovery. Water and steam are effective mediums for heat exchange and can be redirected to the heating stages preceding hydrolysis using one or more condensers. Condensers are compact devices that enhance efficiency. Consequently, steam and gases (132) released from the reacted feed (122) are preferably utilized to aid in heating the influent feed and maintaining the hydrolysis reactor's (1032) temperature, thereby minimizing energy loss within this process. In some scenarios, steam may also be directly injected back into the incoming feed or into one of the reactors or multiple reactors.

[0164] The following examples are presented to offer comprehensive disclosure and guidance on implementing and utilizing the present invention for those skilled in the field. They are not meant to restrict the scope of the inventors' conception of their invention, nor do they imply that the listed experiments represent the entirety or exclusive experiments conducted. While efforts were made to ensure accuracy in the quantities used (e.g. , amounts, temperature, etc.), some experimental errors and variations should be considered.

[0165] Example l-Operatino Plant Plastic Waste

[0166] A full-sized, commercial-scale installation has been constructed with a system as illustrated in Figure. 6 for the processing of waste plastics. At peak capacity, the plant is designed to yield over 10 metric cubic tons of oil (149) per day, based on an average PPS (100) input of approximately 15 tons. The oil (149) produced is a high- quality oil of a similar environment-friendly grade as naphtha and / or gasoil (144). The plant also produces about 2 tons of char and about 3 tons of gaseous hydrocarbon gas per day. This design can also be used for a plant with a capacity of more than a thousand tons of feedstock.

[0167] FIG. 6 presents a commercial-scale implementation of the described invention, suitable for treating PPS (100), specifically plastic waste feedstocks rich in polyolefinic components. Initially, PPS (100) is received and potentially stored temporarily. In the PPS preparation (210), the solid raw feed passes through one or more metal detectors (1002) to identify and remove metal particles that could adversely affect downstream processing equipment. Subsequently, the raw material undergoes particle sizing by means of grinding (1004) using a counter-rotating drum crusher, which reduces particle sizes to approximately 25 mm.

[0168] After initial particle sizing, the feedstock is delivered to fine grinder (1008). In the fine grinder (1008), particle size is reduced to an average of approximately <25 mm and a substantially homogenous feed slurry (112) is created with SPS (134). Apparatus suitable for use in fine grinding (1004) include commercially available plastic processing grinders (1008).

[0169] Following particle sizing and mixing with SPS (134), the feedstock achieves sufficient flowability for pumping into the pressurized hydrolysis reactor (1032); conveyors may be necessary for transport prior to this stage. Throughout the process, various pumps are employed to transport and pressurize the feedstock according to specified process parameters. Suitable pumps can be selected from commercially available processing equipment based on the teachings provided herein. The hydrolysis reactor (1032) operates typically at about 10 bara to about 100 bara, which is dependent on the desired operating temperature in the reactor. It may be between about 150 °C and about 300 °C but it is typically at least about 250 °C. The hydrolysis reactor (1032) may be a stirred tank reactor with or without hydraulic stages or baffles.

[0170] Vapors including non-condensable gas such as light hydrocarbons, CO2, some water vapor and other gases are exhausted from the top section of the hydrolysis reactor (1032) and can be partially condensed and subsequently the condensed liquids and non-condensable gases can be processed or discarded. These vapors also can be combined with similar vapors as described above.

[0171] The reacted feed (122) stream typically flows from the top to the bottom of the hydrolysis reactor (1032) in a plug flow or semi plug flow fashion. The hydrolysis reactor (1032) may be jacketed with high pressure steam, high temperature thermal fluid or other thermal input to maintain hydrolysis temperature.

[0172] Reacted feed (122) from the hydrolysis reactor (1032) is directed to separation section as the second stage (240) separation (130). High-pressure flash vessel (1036) receives the reacted feed (122) from hydrolysis reactor (1032) via a control valve. As mentioned earlier, usable waste steam is usually used from the high- pressure flash tank as recycled thermal energy throughout the plant.

[0173] In one embodiment, pressure in the high-pressure flash tank is flashed down through the control valve from above 10 bara in the hydrolysis reactor (1032) to about 8-10 bara. Mixing may be employed in the high-pressure flash tank. Other pressure set points may be selected in the high-pressure flash vessel to create thermal energy at desired pressure and temperature if the waste heat is to be used elsewhere in the plant.

[0174] Additional flash vessels (e.g., one or more medium pressure flash vessels) can be added to the pressure reduction train in order to produce waste steam at more than one pressure and temperature.

[0175] From high-pressure flash vessel (1036), the reacted feed (122) stream is directed to low-pressure flash vessel (1038) (or alternatively to a medium pressure flash tank and then to a low-pressure flash tank in series). Pressure is further reduced to between 0 bara to about 1.5 bara. Again, waste steam and non-condensable gases are removed from the top of the vessel and are condensed and treated as appropriate. From low pressure flash vessel (1038), the reacted feed (122) stream is directed to a decanting and dewatering apparatus. In this step, SPS (134) and inorganic solid particles are removed using standard commercial equipment such as a centrifugal decanter, a centrifugal basket centrifuge (1042), a hydro cyclone, a settling tank, etc. The separated SPS (134) and solid particles are sent to the SPS

[0176] (134) tanker.

[0177] The separated PPS (500) is transferred to a centrifuge (1042) along with some water collected from dewatering process. The remaining water and any solid particles are then separated out from the plastic stream in the centrifuge (1042) and directed back to the SPS mixing tank (1028).

[0178] The separated PPS (500) stream is directed to the first cracker phase (252), from where it is pumped to the cracker reactor (260) once melted using specialized pumps. The temperature of the first cracker phase (252) may vary depending on process conditions, typically ranging between 150 °C and 250 °C.

[0179] In the subsequent stage, the molten PPS (500), in the first cracker phase (252), is directed to the cracker reactor (260), typically operating at a temperature between 400 and 600 °C, depending on the composition, percentage, and molecular weight of the incoming PPS (100). The cracker reactor (260) is an extruder, an auger reactor, a continuous stirred-tank reactor, a fluidized bed reactor, or another suitable reactor type that facilitates the heating and the movement of the solid material. The reactor pressure can be adjusted between 1 and 15 bar; higher pressure generally results in reduced molecular weight of the liquid hydrocarbon (144) product and increased gas and coke production. The carbon solids (142), which is separated at the reactor's end after undergoing several stages of cooling and optionally passivation with air and / or other oxygen containing gas stream, is packaged as a product.

[0180] The gaseous products, hydrocarbon vapor and gas (148), discharged from the reactor proceeds to the condensation (139) phase. Through several stages of distillation, flash drum (1052) processes, membrane or molecular sieves, and compression, the fuel gas (146) is thoroughly separated. Typically, this gas is utilized for energy production within the plant. Meanwhile, the condensed oil (149) undergoes further separation (130) in a distillation tower (1051) or towers. The heavy oil (152) including any wax or waxy products, is extracted from the bottom and redirected to the first cracker phase (252). Lighter liquid compounds with specific properties are separated and packaged as naphtha and / or gasoil (144), serving as feedstock for chemical plants, such as steam cracking (140) plants or other chemical or refining conversion plants requiring such liquid hydrocarbon feedstocks.

[0181] To further illustrate how exemplary components of the feedstock are transformed by the processes described above, yield evaluation studies were performed to trace components through the process. For example, such studies have shown that chlorine in PVC in the raw feed ends up primarily as chlorine in the oil product (149). Approximately >99% of the chlorine is removed by HCI emission. Similar to chlorine, approximately more than 99% of other heterogeneous atoms, e.g. , oxygen, nitrogen and sulfur are transferred directly to the water stream and the content of heterogeneous atoms in liquid hydrocarbons (144) as final products fall within the acceptable range for typical industrial applications.

[0182] Example 2-The produced oil (1491

[0183] Due to the hydrolysis occurring midway through the process, the resulting liquid hydrocarbons (144) derived from various plastic sources exhibit relatively uniform quality. This hydrolysis step effectively eliminates most of the heterogeneities originating from polyesters, polyamides, polyurethanes, other engineering plastics, PVC, and biomass within the PPS (100). While chemical recycling processes, including hydrolysis, are highly efficient in removing contaminants, the quality and quantity of liquid hydrocarbon (144) produced are notably influenced by the proportion of polyolefins in the primary feed. Higher proportions of polyolefins yield higher-quality liquid hydrocarbons (144) and increased liquid hydrocarbon (144) production. Certain compounds, such as primary sugars and fats on the plastic surfaces, contribute to impurities in the final product but can be easily remedied through, e.g., basic washing procedures, leading to improved product quality.

[0184] Table-1 : The characteristics of light hydrocarbons (144) produced using different combinations of plastic percentages in the PPS (100), with the associated testing methods identified by ASTM codes Example 3-Benchtop Conversion of PPS (100)

[0185] Using a benchtop setup similar to the one depicted in FIG. 2 featuring an approximately 20-liter reactor chamber, waste plastic underwent processing based on the present invention outlined in this document, resulting in the production of cracked oil (149) with the specified characteristics.

[0186] Example 4-Benchtop Conversion of waste plastics In a pilot run, about 5 kg of PPS (100) feedstock was size-reduced to 25 mm pieces for input into a Parr reactor fitted with a mechanical stirrer to implement the process described herein. Components of the PPS (100) feedstock included polyethylene, polypropylene, polystyrene, polyethylene terephthalate, PVC and minerals. Approximately 15% SPS (134) and 30% water are mixed into the plastic, thoroughly stirred, and subsequently transferred to the reactor. The reactor is sealed, and heating is initiated. The raw feed first underwent first stage hydrolysis at 250 °C, 50 bar for a duration of lh. To maintain constant reactor pressure, a portion of the water, representing roughly half of the total water in the reactor, is evaporated along with approximately 1 to 5% of the plastic in the form of polar and non-polar organic compounds resulting from PPS (100) hydrolysis. The reactor output undergoes partial condensation (139), yielding various components including CO, CO2, HCI, sulfur compounds, light hydrocarbon gases, and other gases. Some hydrolysis byproducts dissolve in water, while others accumulate on the water's surface. Noncondensable gases are directed to a flare for disposal.

[0187] Once the reactor has been cooled, the PPS (500) is removed and subsequently reintroduced into the reactor following washing and separation (130) from soil and water. It is reintroduced along with 5 to 15% water to maintain a constant pressure of 15 bar. The reactor temperature is carefully regulated at 450 °C. The products resulting from PPS (500) cracking (140) are cooled in a condenser post-reactor. Liquid products are collected, while non-condensable compounds are directed to the flare for disposal. Table 1 outlines the characteristics of circular naphtha (144) produced using different combinations of plastic percentages in the PPS (100), with the associated testing methods identified by ASTM codes.

Claims

34CLAIMS1. A method of upcycling synthetic and organic waste characterized in comprising steps of• Preparation (110) of primary process solid (100) as a slurry (112) with secondary process solid (134) and water, o wherein the primary process solid (100) comprises synthetic and organic waste, and o wherein the secondary process solid comprises a mineral based solid• Conveying primary process solid (100) into mixed storage tank (220) along with secondary process solid slurry (112),• Subjecting the slurry (112) to hydrolysis (120) in a hydrolysis reactor (1032),• Conducting separation (130) post-hydrolysis to eliminate secondary process solid (134), minerals, and gases from the hydrolyzed primary process solid,• Directing the hydrolyzed primary process solid (500) to a thermal cracker reactor (260) using a lock-hooper and an auger reactor respectively.

2. A method of upcycling according to claim 1, characterized in that said primary process solid (100) is plastic or rubber waste of polyolefin, or tire.

3. A method of upcycling according to claim 1, characterized in that said primary process solid (100) is selected from group comprising polyethylene, polypropylene, polystyrene, PET, polyester, PVC, textile, mineral, biomass, fat, rubber, tire, polyurethane, polyamide, synthetic plastics, natural plastics or mixtures thereof.

4. A method of upcycling according to claim 1, characterized in that said secondary process solid (134) is mineral-containing substance preferably different types of soil, bentonite, calcium carbonate, silicates, aluminosilicates, alkali metal compounds, alkali earth metal compounds, transition, and metal compounds.

5. A method of upcycling according to claim 1, characterized in that temperature of the hydrolysis (120) of the slurry (112) is between from 50 °C to 550 °C, preferably 80 °C to 500 °C, more preferably 100 °C to 450 °C and most preferably 125 °C to about 400 °C.

6. A method of upcycling according to claim 1, characterized in that pressure of hydrolysis (120) of the slurry (112) is from 1 bar to 200 bar, preferably from351.2 bar to 150 bar, more preferably from 1.5 bar to 100 bar, most preferably from 2 bar to 80 bar.

7. A method of upcycling according to claim 1, characterized in that period of hydrolysis (120) of the slurry (112) is from 1 minute to 1440 minutes, preferably from 2 minutes to 600 minutes, more preferably from 5 minutes to 240 minutes, most preferably from about 15 minutes to 180 minutes.

8. A method of upcycling according to claim 1, characterized in that said slurry's (112) moisture content is at least 20%, preferably above 30%, most preferably above 40%.

9. A method of upcycling according to claim 1, characterized in that said mixed storage tank (220) comprises a vibratory screen (1043) for fine sizing to eliminate contamination.

10. A method of upcycling according to claim 1, characterized in that said hydrolysis reactor (1032) comprises a multi-chamber design.

11. A method of upcycling according to claim 1, characterized in that said hydrolysis reactor (1032) is a batch reactor, a continuous stirred-tank reactor, an auger reactor, an extruder, or another suitable reactor type that facilitates the heating and the mixing of the solid material.

12. A method of upcycling according to claim 1, characterized in that said thermal conversion reactor (260) is an auger reactor, a batch reactor, an extruder, a continuous stirred-tank reactor, a fluidized bed reactor, or another suitable reactor type that facilitates the heating and the movement of the solid material.

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