Process for repurposing synthetic and organic wastes into valuable products

Abstract

The present invention pertains to a process for upcycling synthetic and organic waste into valuable commodities. This invention provides a method for converting and managing mixed feedstock streams, such as plastic waste, biological waste, municipal solid waste, municipal sewage sludge, shredder residue, and other carbon- and hydrogen-rich materials. The process produces gas, oil, light hydrocarbons (e.g., circular naphtha), specialty chemicals, and carbon solids, which can be used directly or further refined or processed.

Description

[0001] PROCESS FOR REPURPOSING SYNTHETIC AND ORGANIC WASTES INTO VALUABLE PRODUCTS

[0002] DESCRIPTION

[0003] Technical Field

[0004] The present invention pertains to a process for upcycling synthetic and organic waste into valuable commodities. This invention provides a method for converting and managing mixed feedstock streams, such as plastic waste, biological waste, municipal solid waste, municipal sewage sludge, shredder residue, and other carbon- and hydrogen-rich materials. The process produces gas, oil, light hydrocarbons (e.g., circular naphtha), specialty chemicals, and carbon solids, which can be used directly or further refined or processed.

[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. Furthermore, the substantial and growing production of plastic and organic waste poses another significant challenge that needs to 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] Today's waste includes various types such as primary process solids (PPS), which encompass plastic and rubber waste, biological waste, municipal sewage sludge (MSS), municipal solid waste (MSW), shredder waste, and other carbon- and hydrogen-containing materials. PPS, originating from urban and industrial sources, frequently contains significant amounts of non-degradable materials that pose serious environmental risks to both terrestrial and marine ecosystems. Improper disposal of these wastes can result in groundwater contamination and broader environmental pollution. Additionally, the prolonged natural decomposition of plastic waste can lead to harmful effects, including higher greenhouse gas emissions and disturbances to groundwater and natural ecosystems.

[0008] Effective management and disposal of polymeric and biological waste are crucial, particularly with the growing population density. In recent decades, the rising demand for plastics has led to a significant increase in polyolefin production.

[0009] Currently, global production of thermoplastics is approximately 350 million tons per year and is projected to exceed 580 million tons by 2050, driven largely by the increased use of polyolefins and polystyrene. Polyolefins alone make up more than half of plastic production and are predominantly used in disposable items, which quickly become waste. Unlike organic waste, plastic waste does not decompose naturally and can persist in the environment for centuries, presenting substantial environmental challenges.

[0010] Plastic and rubber waste pose a major environmental challenge because of their durability and extensive use in various industries. These materials are categorized into different types according to their chemical composition and properties, each with specific characteristics and recycling requirements. For instance, polyethylene terephthalate (PET) is widely used in beverage bottles and food packaging due to its transparency and moisture resistance, while high-density polyethylene (HDPE) is chosen for its durability and chemical resistance in products like milk jugs and pipes. Other plastics, such as rubber goods, tires, polyvinyl chloride (PVC), low-density polyethylene (LDPE), polypropylene (PP), and polystyrene (PS), each serve specific purposes and present unique recycling challenges. Effective waste management strategies necessitate a thorough understanding of different plastic types to enhance recycling processes and encourage responsible disposal practices, with the goal of minimizing plastic pollution and its environmental impact.

[0011] Plastic recycling encompasses a range of methods tailored to the type of plastic and the intended end products. Reusing waste plastics is one of the least challenging recycling methods, as it involves minimal processing. Mechanical recycling is a widely used technique where plastics are sorted, cleaned, shredded, and melted to produce new plastic items. However, this method faces challenges, including the necessity for meticulous sorting to prevent contamination and the limited recyclability of certain plastics, which can degrade during processing. Chemical recycling methods, including hydrolysis, steam cracking, pyrolysis, and depolymerization, break down plastics and rubbers into raw materials that can be used to create new plastics, chemicals, or rubbers. These methods hold promise for recycling mixed or contaminated plastics but encounter challenges related to scalability, energy consumption, and cost-effectiveness. Moreover, creating efficient collection and sorting systems, raising consumer awareness about recycling, and developing markets for recycled plastic products are ongoing hurdles. Overcoming these challenges demands collaborative efforts from industries, governments, and communities to advance recycling technologies and foster a sustainable approach to managing plastic waste, ultimately supporting a circular economy for plastics.

[0012] The treatment of industrial waste, particularly shredder residue, also poses a significant challenge. Shredder residue typically includes the nonmetallic components of automobiles and other products, such as air conditioners, refrigerators, dryers, and dishwashers, which are often referred to as white goods, and from other industrial goods. The shredder industry recovers approximately 10- 12 million tons of ferrous scrap annually, mostly from shredded automobiles. However, for each ton of steel recovered, around 250 kg of shredder residue is generated. Although many components from end-of-life vehicles and appliances can be recycled, reused, or recovered, a significant portion of residue from the shredding process ends up in landfills. The disposal of shredder residue is further complicated by the presence of toxic materials, such as cadmium, lead, mercury, and other heavy metals. With limited landfill space and rising hazardous waste disposal costs, there is a pressing need for alternative solutions. The automotive and recycling industries are under increasing pressure to find cost-effective and energy-efficient methods for managing shredder residue.

[0013] Although various waste management methods are employed, many are impractical, contribute to further pollution, or are costly in terms of both economics and energy. These methods include composting, incineration, landfill disposal, agricultural use, and ocean dumping, each of which has its own specific disadvantages.

[0014] Alternative waste management methods, such as incineration, bioremediation, pyrolysis, and gasification, each present distinct challenges, especially when dealing with plastic waste. For example, bioremediation through aerobic and anaerobic digestion requires extended and often impractical residence times for plastics, precise monitoring and control of conditions like oxygen levels, pH, and temperature to encourage specific microbial activity, and specialized equipment. Additionally, this method can lead to inconsistent treatment results and may produce products that contain pathogens. Furthermore, genetically engineered bacteria that target specific compounds can switch to alternative enzyme systems when exposed to a waste substrate, enabling them to process different compounds. On the other hand, combustion necessitates specialized equipment and components to comply with strict emission regulations.

[0015] Pyrolyzers have been used to decompose organic materials and primary process solids (PPS) into gas, oil, tar, and carbonaceous residues. Typically, a pyrolyzer operates at high temperatures, around 400-800 °C, but this method often suffers from suboptimal energy efficiency and limited control over the composition of the end products. While pyrolysis can be effective for polyolefins, the presence of various plastic impurities, such as engineering plastics, PVC, rubber, and other organic wastes, can introduce contaminants into the final product. This contamination affects the usability of the products as feedstocks in the chemical industry and increases the costs of subsequent refining processes needed to make the products usable. Consequently, this makes the chemical recycling process economically unfeasible. An ideal process would include measures to remove contaminants cost-effectively. An auger reactor functions as a cracking device in the chemical recycling of plastics via pyrolysis, promoting the thermal degradation of plastic waste into valuable hydrocarbon products. This reactor is equipped with a rotating auger screw that steadily transports shredded plastic feedstock through a heated chamber, all while operating in an inert atmosphere to prevent combustion. By exposing the plastics to high temperatures, the auger reactor effectively decomposes long-chain polymers into liquid hydrocarbons, gases, and solid char. This continuous and efficient process allows for the scalable transformation of mixed plastic waste into reusable fuels and chemical feedstocks, effectively addressing the increasing demand for sustainable waste management solutions.

[0016] Gasification, which involves the partial combustion of waste materials, is not currently well-suited for processing plastic waste and does not provide significant added value. The outputs of gasification, such as syngas and char, offer less value compared to other chemical recycling methods for plastics and rubbers. Additionally, syngas usually requires extensive cleaning before it can be used in any subsequent synthesis processes. As a result, it is preferable to limit gasification to low-cost, non- pure (contaminated) feedstocks.

[0017] Both pyrolysis and gasification methods can produce products with unacceptably high levels of impurities, such as tar and asphalt, and often have low calorific value. For instance, waste that contains nitrogen, oxygen, sulfur, and chlorine can lead to the formation of nitrogen-containing compounds, oxygen-containing compounds, sulfur-containing compounds like mercaptans, and organic or inorganic chlorides in the final products. Typically, hydrocarbon feedstocks used in fuel or chemical applications can tolerate chlorinated hydrocarbons at concentrations of 1-2 ppm. However, neither gasification nor pyrolysis methods consistently achieve such low levels of contamination directly. The energy efficiency of these approaches is often limited to around 30% due to inefficient heat transfer, uneven treatment, and energy-intensive water removal processes.

[0018] Recent advancements detailed in U.S. Patents 8,877,992, 5,269,947, 5,360,553, and 5,543,061 have focused on improving the quality and functionality of oils derived from waste materials. However, these methods may face challenges, such as difficulties in handling compounds containing nitrogen, oxygen, sulfur, and chlorine, as well as inefficiencies in processing plastics and rubbers. Issues like melting problems, complex transfer processes, the need for specialized hydrolysis techniques, and high energy requirements all contribute to the obstacles hindering their widespread commercial adoption. These examples underscore the ongoing need for sustainable recycling processes that are technically feasible, economically viable, and environmentally sound.

[0019] Unlike prior art such as JP2024525488A, which focuses on processing mixed plastic waste through dechlorination in a reactive extrusion vessel followed by distillation, the present invention offers a broader scope by upcycling not only plastics but also organic wastes (e.g., sewage sludge, agricultural waste, shredder residue). This process integrates hydrolysis and thermal cracking, allowing for the efficient conversion of diverse feedstocks into valuable products like hydrocarbons, carbon solids, and specialty chemicals. Compared to US4051212A, which describes continuous hydrolytic degradation of plastics using water in a screw extruder, the current invention's multi-stage separation and hydrolysis technique efficiently removes impurities such as PVC and engineering plastics, enhancing the quality of the final product. Additionally, US4605762A focuses on the depolymerization of condensation polymers like PET and polyamides, while the present invention handles a wider range of polymers, including polyolefins and rubbers, providing superior flexibility in treating mixed waste streams. Further distinguishing itself from US7691344B2, which centers on oil reconversion through thermal cracking of plastics, this invention utilizes a more advanced thermal-chemical platform that optimizes the cracking stage to yield hydrocarbons within the naphtha and gasoil range, along with carbon solids, while managing sulfur, chlorine, and nitrogencontaining waste effectively. Compared to GB2565831A, which also targets depolymerization via extrusion under supercritical conditions, the present invention's hydrolysis stage operates under a broader range of temperatures and pressures, maximizing energy recovery and minimizing environmental pollutants. Lastly, patents like US11802245B1 that focus on converting plastic waste to hydrocarbon oils through visbreaking are limited in terms of feedstock variability and product purification. In contrast, this invention's method effectively handles mixed, contaminated, and unsorted waste streams, producing cleaner and more versatile end products. The process also addresses the limitations of other methods such as W02006039872A1, which rely heavily on chemical recycling techniques like multi-stage hydrolysis but lack efficient impurity management, especially for challenging contaminants like halogens and heavy metals.

[0020] 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.

[0021] 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.

[0022] Summary of the Invention

[0023] The invention aims to develop a method for producing sustainable energy, hydrocarbons within the naphtha and gasoil boiling point range, fuel, raw materials, specialty chemicals, carbon char, and other valuable products from streams containing plastic and organic waste.

[0024] 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.

[0025] In additional embodiments, this method could include the hydrolysis of specific contaminants, such as engineering plastics, PVC, and other organic compounds present in polyolefin-containing waste. This invention also provides waste treatment techniques and apparatus. In some configurations, the input primarily comprises polyolefin plastic waste. In other configurations, the input includes polyolefin plastic waste mixed with other types of plastic and non-plastic waste. Alternatively, the input material may predominantly consist of municipal solid waste. Additional configurations use shredder residues as the feedstock. Furthermore, there are configurations where the feedstock is a mixture of any of the above types, in varying quantities and with different initial moisture (including water) content. Various embodiments of this invention provide innovative solutions for energy and petroleum feedstocks that are both environmentally and economically sustainable. The processes described produce a range of products with a higher net energy value (NEV) compared to conventional methods such as traditional incineration, pyrolysis, and gasification, while also addressing waste management challenges. These embodiments are capable of handling contaminated and unclean materials, such as plastic-containing waste streams, agricultural waste, municipal solid waste (MSW), medical waste and shredder residues, which are often costly and energy-intensive to dispose of. These processes convert the materials into valuable products. Examples of products generated through these innovative methods include hydrocarbon liquids within the naphtha and gasoil boiling point range, solid carbon, fuel oil, fuel gas, and other useful intermediates. These intermediates can be selectively extracted at various stages and further transformed into usable energy forms, such as fuel, or used as is or transformed into feedstocks for fuel and chemical applications, as well as a variety of specialized chemicals.

[0026] Another significant advantage of this invention is its ability to efficiently transform mixed and / or unsorted waste streams into valuable products. The described processes can manage a variety of plastic-containing streams, as well as agricultural and food processing residues, including forest by-products. These feedstocks differ greatly in their handling properties, resistance to conversion, and energy and carbon content, all of which are crucial factors when incorporating them into a refinery or chemical processing environment with waste feed. The versatility of this invention in tackling these challenges highlights its exceptional and superior performance compared to conventional technologies.

[0027] 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. Evaluating the environmental benefit of a process involves considering not just the type of feedstock used but also the energy efficiency of the process, which impacts the Net Energy Value (NEV) and the net CO2 footprint of the final products. Therefore, the impressive efficiency of the methods and apparatus described here in managing wet feedstock, utilizing moisture content to drive the process, and effectively sterilizing the feedstock is particularly notable.

[0028] Figures

[0029] Figure 1 : a flowchart illustrating an exemplary process according to the invention.

[0030] Figure 2: a schematic diagram depicting exemplary apparatuses used to perform an exemplary process of the invention.

[0031] Figure 3a: a flowchart illustrating a feed preparation stage through hydrolysis stage of an embodiment of the invention.

[0032] Figure 3b: a flowchart illustrating a feed preparation stage through hydrolysis stage of an embodiment of the invention.

[0033] Figure 4a: a flowchart illustrating a separation stage of an embodiment of the invention.

[0034] Figure 4b: a flowchart illustrating a separation stage of an embodiment of the invention.

[0035] Figure 5: a flowchart illustrating a thermal cracking stage of an embodiment of the invention.

[0036] Figure 6a : a block diagram illustrating an exemplary process of the present invention adapted for full scale processing of plastic wastes.

[0037] Figure 6b : a block diagram illustrating an exemplary process of the present invention adapted for full scale processing of plastic wastes.

[0038] Figure 7: depicts an exemplary bench-scale test apparatus useful for the invention.

[0039] References

[0040] 100. Primary Process Solids, PPS

[0041] 110. Preparation

[0042] 112. Slurry

[0043] 114. Heat exchanger

[0044] 120. Hydrolysis Stage

[0045] 122. Reacted feed

[0046] 126. Vent gases

[0047] 130. Separation

[0048] 132. Steam and gas

[0049] 134. Secondary Process Solids, SPS

[0050] 135. Intermediate conveyor

[0051] 139. Condensation

[0052] 140. Cracking

[0053] 142. Carbon solids

[0054] 144. Naphtha

[0055] 146. Fuel-gas

[0056] 148. Hydrocarbon vapor and gas

[0057] 149. Oil

[0058] 150. Separation

[0059] 151. Organic liquid 152. Heavy Oil

[0060] 210. PPS preparation

[0061] 220. Mixed storage tank

[0062] 230. Hydrolysis Complex

[0063] 240. Second stage

[0064] 252. Extruder

[0065] 260. Cracking reactor

[0066] 280. Product oil storage

[0067] 320. Feed storage

[0068] 336. Vent

[0069] 322. Conditioned feed

[0070] 338. Steam and gaseous impurities

[0071] 340. Heat recovery

[0072] 400. Intermediate feed

[0073] 410. First Separation

[0074] 414. SPS / remaining PPS

[0075] 440. Second Separation

[0076] 500. Separated PPS

[0077] 540. Carbon storage

[0078] 630. Carbon solids cooker 850. Cooler

[0079] 1002. Metal detector

[0080] 1004. Grinding

[0081] 1006. High-pressure slurry pump

[0082] 1008. Grinder

[0083] 1028. SPS mixing tank

[0084] 1032. Hydrolysis reactor

[0085] 1036. High pressure flash vessel

[0086] 1038. Low pressure flash vessel

[0087] 1040'. Gravity separation

[0088] 1040. Separation

[0089] 1042. Centrifuge

[0090] 1043. Vibratory Screen

[0091] 1051'. Distillation Tower

[0092] 1051. Quench column

[0093] 1052'. Flash Drum

[0094] 1052. Overhead chiller

[0095] 1053. Overhead accumulator

[0096] 1054'. Compressor 1054. Heavy oil stripper

[0097] Detailed Description of the Invention

[0098] The present invention pertains to a process for upcycling synthetic and organic wastes into valuable commodities. It provides a method for handling and processing 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. These outputs can be used directly or further refined. Valuable products can be extracted or integrated at various stages of the process to enhance system efficiency.

[0099] 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.

[0100] In this context, "plastic waste" refers to waste made up of polyolefins, as well as other plastics such as engineering plastics and PVC. These waste streams may also include synthetic and organic materials, such as rubber, soil, and other organic substances, along with inorganic materials like minerals, glass, metals, ceramics, and other inorganic substances. Additionally, this waste typically contains some moisture.

[0101] The term "biomass" as used here, refers to organic material obtained from plants, fungi and animals.

[0102] As used herein, the term "organic feedstock" broadly refers to carbon compounds and any feedstock in which carbon compounds are found.

[0103] "Agricultural waste" as used herein, includes waste, refuse, reject streams and recycle streams from the agricultural industries and food processing industries.

[0104] As used herein, "biological waste" broadly refers to medical and infectious wastes, as well as any refuse, garbage, or waste that is perceived to pose a risk of disease transmission or a biological hazard to humans or specific living organisms. Biological waste may fall under other waste categories defined herein. In this context, "municipal solid waste" (MSW) refers to solid waste collected through municipal garbage collection systems. This waste typically includes household waste, food waste, yard waste, office-generated waste, and may also incorporate some industrial waste and scrap materials. MSW encompasses both mixed waste, such as unsorted household refuse, and source-separated waste, like organics from sewage treatment plants and food waste from restaurants and certain food processing facilities. Depending on its source, MSW can contain components similar to agricultural waste. During the garbage collection process, higher-value materials, such as metals, are usually removed.

[0105] "Shredder residue," abbreviated as "SR" and also known as shredder fluff, refers to the material remaining after most metals and glass have been extracted from shredded or dismantled vehicles, appliances, consumer goods and industrial goods. In the absence of the present invention, such materials frequently end up in landfills. Shredder residue can include a variety of materials, such as fragments of plastics (including thermoplastics, thermosets, and polyurethane foam (PUF)), rubber, wood, paper, elastomers, fabrics, glass, fines, and residual ferrous and nonferrous metal pieces. It may also contain paints and tar in various sizes. Shredder residue from old television sets, refrigerators, and other consumer goods, often referred to as white goods, can include hazardous substances like heavy metals and polychlorinated biphenyls (PCBs), which are harmful chlorinated compounds. Additionally, shredder residue may contain other toxic components, such as polybrominated diphenyl ethers (PBDEs), which are used as flame retardants and are chemically similar to PCBs, as well as phthalates found in polyvinyl chloride (PVC), a common material in automobile manufacturing.

[0106] Typically, shredder residue is a mixture of solids and liquids. The liquids typically originate from the shredded entities. The liquids can be of water- or oil-based substances or the mixture of these.

[0107] In the context of embodiments of the present invention, terms such as "react," "reacting," and "reaction" can encompass a broad spectrum of chemical or physical changes. Specifically, "reaction" can refer to a chemical change resulting from the combination or interaction of two or more substances to produce one or more products. It also includes other forms of decomposition or conversion involving the breakdown or transformation of a single substance under conditions of temperature, pressure, or exposure to electromagnetic radiation. Additionally, these terms can involve transformations occurring in a solvent environment.

[0108] In this discussion, the term "PPS" (100), or "Primary Process Solid," refers to plastic and rubber wastes from both pre-industrial, post-industrial, pre-consumer and postconsumer sources. This includes municipal solid waste (MSW), shredder residue, and other mixed waste types that may contain polyolefins, PVC, engineering plastics, tires, and similar materials. The primary process solid (100) encompasses a range of substances, including polyethylene, polypropylene, polystyrene, PET, polyester, polycarbonate, textiles, minerals, biomass, fats, rubber, tires, polyurethane, polyamide, and other synthetic and natural plastics and polymeric materials.

[0109] In this context, the term "SPS" (134), or "Secondary Process Solid," refers to the original mineral-containing substance used as a conveying aid or medium. This includes various soils (whether or not they contain organic material) or commercial minerals like bentonite or calcium carbonate, either in dry form or as a slurry.

[0110] Using a mineral containing substance will improve the thermal and pressure stability during the hydrolysis. These solid phases result in a more stable reaction kinetics and improve safety under elevated conditions. In addition to the previously mentioned factors, the incorporation of a mineral phase can play an effective role in accelerating decontamination reactions during the hydrolysis stage. This effect arises from its acceptable specific surface area and the presence of functional groups on its surface. The higher the specific surface area of the mineral phase and the more active the functional groups present, the greater its contribution to enhancing the reaction efficiency.

[0111] 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 use water, heat, and pressure in multiple stages to transform organic waste and primary process solids (PPS) into valuable products such as liquid hydrocarbons in the naphtha and gasoil boiling point range, fuel, feed, gas, and others. Typically, PPS is first prepared as a slurry with solid processing solids (SPS) and water. This slurry is then pumped and heated in a hydrolysis reactor under steam pressure to start the hydrolysis process. During this process, heterogeneous bonds, such as carbon-oxygen, carbon-nitrogen, and carbon-sulfur, are broken, resulting in the separation of impurities from the plastic in the feed. Additionally, organic liquids and solid particles may undergo further reactions due to the elevated temperatures and pressures, leading to the breakdown of complex organic molecules into simpler ones through processes like hydrolysis. At this stage, a mixture of hydrolyzed PPS with a lower molecular weight than the original feedstock is produced. This process also produces separated water and smaller mineral particles. 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. Figure 1 presents a high-level block diagram illustrating exemplary embodiments of this invention, with further detailed depictions of processes and devices provided in the subsequent Figures and explained below. Embodiments of the current invention can manage and process a mixed stream of primary process solids (PPS) without the need for initial sorting into separate, pure streams. In certain embodiments shown in the Figures, the PPS (referred to herein as "raw material") may undergo an optional feed preparation stage (110) before entering the initial processing stage. During this step, the PPS is treated with a mixture of water and solid processing solids (SPS) to facilitate smooth conveying, as illustrated in Figures 1 and 3. Alternatively, the feed preparation stage (110) aims to enhance the flowability of the raw materials, improving their movement, heat transfer, and mixing in the subsequent processing stages. For some feedstocks, it may be necessary to reduce the viscosity of semi-solids to allow for continuous pumping or metering during the initial stage. In other cases, the materials may already be adequately sized and only need the addition of a suitable liquid component.

[0112] Feedstock preparation (110) is achieved through a process that includes mixing and optionally grinding (1004), either separately or combined with preheating. This preparatory phase may involve pretreating the waste, such as washing the Primary Process Solid (100) (PPS) after grinding (1004) to remove a significant portion of contaminants, including 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.

[0113] 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 address disruptions caused by variations in feedstock quantity, quality, composition, and / or initial particle size. In an alternative embodiment the resulting slurry (112) can be transferred through a piping system to on-site feed storage (320) tanks for later processing or introduced directly 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.

[0114] 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 described. The use of SPS (134) in slurrying, such as during feed preparation (110), also helps reduce friction and energy consumption. For optimal processing in the described embodiments, it is generally beneficial to maintain a slurry (112) moisture content of at least 20%, preferably above 30%, and ideally around or above 40%, primarily to address the viscosity limitations of the pumps used.

[0115] Those with ordinary skill in the field will recognize that the minimum moisture content threshold can be adjusted by using different pumping or conveying technologies, depending on the specific characteristics of the feedstock. The processes described demonstrate relatively high energy efficiency, as most of the water introduced into the system exits in liquid form rather than as vapor or gas. Whether or not additional solvents beyond water are required at this stage depends on the specific properties of the feedstock and the process conditions.

[0116] In accordance with embodiments of the current invention, incoming streams can be processed without prior separation of water and other contaminants, unlike conventional methods that often struggle with wet feedstock and prioritize their removal first. Instead, the embodiments of this invention utilize the water already present in the feedstock to further enhance efficiency, aiding in the removal of contaminants and toxic chemicals from organic streams. Feedstock preparation (110) and slurring can be carried out in a feedstock preparation (110) apparatus, as diagrammed in Figure 2.

[0117] As shown in Figure 6b, the preparation (110) and optional grinding (1004) of PPS (100) can be performed using the raw material preparation machine (110). After preparing the PPS (100), it is added to the feed stream and conveyed into the mixed storage tank (220) together with the pre-prepared SPS (134) slurry (112). The initial handling of PPS (100) can be performed using underflow buckets, conventional conveyors, bucket elevators, or other appropriate equipment under ambient conditions. In an alternative embodiment of the invention, the mixed storage tank (220) can include vibratory screens (1043) for fine sizing to remove dirt, loose debris, and other contaminants. For injecting the generated slurry (112) into the hydrolysis complex (230), it is advisable to use specialized high-pressure equipment, such as pumps. The required reduction in material size depends on the composition of the PPS (100); optimal particle sizes typically range from 0.1 mm to 100 mm, with a preference for 1 mm to 50 mm, and ideally from 5 mm to 30 mm.

[0118] For practical purposes, PPS (100) particles are typically sized between 6 to 26 mm to ensure efficient pumping with the SPS (134). The initial particle size usually depends on the capacity and capabilities of the equipment used. After the raw material preparation (110) step, the particle size should be optimized to suit the requirements of the subsequent treatments in the process. In alternative embodiments of the invention, the feed preparation (110) step may include adding or removing materials from the raw materials, essentially performing specific pretreatments to refine the plastic content. Experts in the field will also understand that certain feedstocks with high fluid content can be directly introduced into the hydrolysis stage (120) without affecting the objectives and advantages of the present invention.

[0119] 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 present in organic materials, rubber, polymers, engineering plastics, and PVC. These bonds are broken down, primarily forming gases or water-soluble gases or liquids, which facilitates their separation (130) from the hydrolyzed PPS (500) flow.

[0120] The hydrolysis process has a minimal impact on polyolefins, although it may slightly reduce their molecular weight. After the hydrolysis stage (120), the reactor contents move to a complex, multi-component separation (130) step. In the second stage (240) of the separation process, various solid components such as SPS (134), light ash solids, heavy ash solids, minerals (containing inorganic elements like silicon, aluminum, iron, titanium, calcium, magnesium, sulphurand phosphorus), fixed carbon, and other carbonaceous materials with low hydrogen content are separated from the slurry as SPS (134). Additionally, organic and acidic gases produced during hydrolysis, along with steam, are also separated at this stage. The purified PPS (500) stream, now enriched in polyolefins and other polymers with reduced heteroatom content, is then directed to a unit for further processing.

[0121] In certain embodiments of the invention, bulk and mineral separation (130) at this stage of the process utilizes a combination of hydrocyclonic separation (130) and gravity discharge and / or particle size separation . The separated minerals or other solids can optionally be directed to storage for further handling. The hydrolysis stage (120) typically operates within a temperature range of 50 °C to 550 °C, with preferred ranges of 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. Temperature control is crucial to minimize or eliminate the formation of char, ash, resin, or other undesired reactions, ideally preventing coal or ash formation. In exemplary embodiments, the pressure during hydrolysis generally ranges from about 1 bar to 200 bar, with preferred ranges from 1.2 bar to 150 bar, more preferably from 1.5 bar to 100 bar, and most preferably from 2 bar to 80 bar, depending on the raw material. The duration of the hydrolysis step typically varies from about 1 minute to 1440 minutes, with preferred durations from 2 minutes to 600 minutes, more preferably from 5 minutes to 240 minutes, and most preferably from about 15 minutes to 180 minutes. Additionally, in some embodiments, the average pH of the material at this stage falls within the range of 4 to 8.5, preferably 5 to 8, more preferably from 5.5 to 7.5, and most ideally around 6.5. The duration of the process can vary based on the applied conditions; for example, it may be less than 15 minutes at higher temperatures or extend to over an hour at lower temperatures, as understood by those skilled in the field. 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.

[0122] In PPS (100), plastics can be softened or melted, rubber can be devulcanized, long- chain molecules can be fragmented, and solid materials such as fixed carbon and metals can be released. This reduction in viscosity also facilitates the separation (130) of bound insoluble solids (134), including minerals, fillers, composite materials, and fibrous materials, among others.

[0123] In an exemplary implementation of the hydrolysis stage (120), as depicted in Figure 3a and 6a, the Feed storage (320) provides a continuous feed stream to a high- pressure slurry pump (1006).

[0124] In an exemplary implementation of the hydrolysis stage (120), as depicted in Figure 6b, a high pressure slurry pump (1006) provides a continuous feed stream for the hydrolysis reactor. This pump pressurizes the slurry (112) of SPS (134) and PPS (100) and transfers it to the hydrolysis complex (230). The design of the hydrolysis reactor (1032) can incorporate standard technologies such as batch reactors, auger reactors, stirred reactors, extruders, or flow-through jacketed reactors, as the process operates at pressures exceeding atmospheric levels.

[0125] In hydrolysis, as generally depicted in Figure 1, the slurry (112) is introduced into the hydrolysis stage (120), where it is exposed to elevated temperatures and pressures. This process facilitates the removal of heteroatoms and the breakdown of long-chain molecules into shorter chains. The resulting reacted feed (122) comprises a mixture of renewable fuel / oil (149), separated water, PPS (100) with an increased melt flow index (MFI), and SPS (134). The composition of these components will be detailed further in relation to 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 instance, depending on the composition of PPS (100), such transformations may involve processes like deoxygenation, denitrogenation, desulfurization, dechlorination, decarbonylation, and decarboxylation. Additionally, it may include organic decontamination, partial depolymerization, isomerization, and cyclization of the polymer chains or their components.

[0126] The hydrolysis stage (120) establishes conditions that facilitate the removal of gaseous impurities such as ammonia, nitrogen oxides, HCI, carbon monoxide, carbon dioxide, and sulfur-containing gases. It also vents sulfur-containing gases produced from the breakdown of sulfur-containing components in the feedstock, which may include various rubbers and organic contaminants. The combination of heat, pressure, and processing time during this phase also ensures the destruction of any pathogens present in the waste. As a result, embodiments of this innovation can be used for the sterilization and processing of biological waste.

[0127] Because heterogeneous bonds involving elements like oxygen, sulfur, nitrogen, and chlorine typically have similar or lower bond energies compared to carbon-carbon bonds and often exhibit higher inherent reactivity due to covalent bond polarization, they are more prone to breaking under the elevated temperature and pressure conditions within the hydrolysis reactor (1032). The hydrolysis reactor (1032) is usually a batch reactor, a continuous stirred-tank reactor, an auger reactor, an extruder, or other types of reactors designed to maintain the required reaction conditions.

[0128] As a result, the hydrolysis process is highly effective at reducing contamination in the final products. Additionally, under these reactor conditions, engineering plastics are likely to break down into primary monomers, which can be easily separated from polyolefins due to their greater water solubility or because the removal of heteroatoms converts them into more polyolefin-like substances. 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.

[0129] In the hydrolysis reactor (1032), the pressure is preferably set to be close to the saturation pressure of the water present in the liquid mixture at the operating temperature. The saturation pressure is the pressure required at a specific temperature to prevent the water from boiling and is influenced by the presence and quantity of other gases in the purified feed slurry (112). The total pressure in the reactor is maintained above the vapor pressure of the water in the slurry (112) mixture to prevent preferential boiling of the water. Typically, the pressure is adjusted within a range of 0 to 15 bar, preferably about 0 to 7 bar above saturation, to facilitate the release of unwanted gases. Generally, the total pressure can vary between 1 and 200 bar, with a preference for 2 to 150 bar, more ideally between 3 and 100 bar, and most ideally between 6 and 80 bar.

[0130] As shown in Figure 1, the reacted feed (122) from this stage generally consists of a mixture of reacted PPS (500), SPS (134), and a combination of reacted liquid and gas products. These products can be categorized into an oil phase, a water phase, a mixed oil-water phase, and a wet solid (mineral) phase. The water phase, oil phase, and mixed oil-water phase are typically rich in various dissolved organic materials. In one embodiment of the present invention, the initial stage of hydrolysis (referred to as stage 1 hydrolysis) can be carried out in a hydrolysis reactor (1032), as depicted in Figure 2.

[0131] This reactor may feature a multi-chamber design to ensure a narrow distribution of residence times for the materials in the slurry (112). Alternatively, the reactor could be configured as an auger reactor or an extruder in different embodiments. In some variations, the slurry (112) is pre-heated and / or pressurized in multiple stages before entering the reactor vessel, using a separate unit for storage, pressurizing, and heating. The reactor vessel might be equipped with baffles and a motorized stirrer with multiple blades to effectively mix the slurry (112) within each chamber simultaneously. For example, one embodiment might include a vessel with four chambers. It is essential that the reactor vessel is strong enough to withstand the pressure from the gas phase under operational conditions.

[0132] Referring to Figure 1, the reacted feed (122), which generally consists of hydrolyzed PPS (500), SPS (134), and reacted products, is introduced into the separation (130) stage. This stage separates the components into gases and steam (132), separated water (138), SPS (134), organic liquid (151), and the hydrolyzed PPS (500) stream. Various separation techniques, as described herein, can be employed to achieve this. The steam and gases (132) can be removed and redirected, for instance, to preheat the incoming slurry (112). The separation (130) step, which constitutes the second stage (240) of the process, may involve one or more sequential or simultaneous steps. In typical implementations, the reacted feed (122) first undergoes solid / liquid separation (130), followed by liquid / liquid separation (130). Although the order of these separations (130) can be adjusted, it is understood by those skilled in the field that changing the sequence might affect the overall efficiency of the separation (130) process. Solid particles, including minerals that were not removed during the initial hydrolysis stage (120), can be separated from the liquids by methods such as decanting. Renewable oil (149) and separated water can then be separated using techniques like centrifugation (1042) or gravity separation (1040'),- Once sufficiently isolated, the hydrocarbon liquid or unfinished oil (149) can be transferred to storage tanks for holding or further refined and processed into higher-value products.

[0133] In certain embodiments of the separation (130) stage, as illustrated in Figure 3a, the reacted feed (122) undergoes a process known as flashing to reduce pressure, which facilitates the reuse of excess heat from earlier heating stages. Flashing typically involves multiple stages of pressure reduction, often performed in two, three, or more stages. The primary goal of flashing is to utilize a vent (336) to vent the remaining steam and gases (132) associated with the reacted feed (122). This depressurization process is an efficient method for dehydration, as it removes water without requiring additional heat. The effective use of this excess heat is termed heat recovery (340), representing an advancement in the current process.

[0134] In an alternative embodiment as illustrated in Figure 3b, the reacted feed (122) undergoes a process known as flashing to reduce pressure, which facilitates the reuse of excess heat from earlier heating stages. Flashing typically involves multiple stages of pressure reduction, often performed in two, three, or more stages. The primary goal of flashing is to vent the remaining steam and gases (132) associated with the reacted feed (122).

[0135] After the reacted feed (122) has undergone flashing and heat recovery, the intermediate feed (400) typically contains at least one reacted liquid product, at least one reacted organic solid product, at least one reacted inorganic solid product, and water. The reacted liquid product usually includes hydrocarbon liquids, while the reacted organic solid product typically consists of plastics. The reacted inorganic solid product generally comprises minerals and / or rejected solids. The intermediate feed (400) is preferably largely free of gaseous products.

[0136] Figure 4a and figure 4b illustrates a series of separation (130) steps that can be applied to the intermediate feed (400). An advantage of the present invention is the capability to subject this intermediate feed (400), which is produced from the first hydrolysis stage (120), to one or more separation (130) stages. These stages are designed to remove SPS (134), minerals, and water from the feed before it proceeds to the third stage, which is the cracking (140) process. This multi-stage separation helps in purifying the feedstock by effectively isolating and removing unwanted solid and liquid components, thus enhancing the efficiency and effectiveness of the subsequent cracking stage. The process ensures that the feed entering the cracking reactor is more homogeneous and free from contaminants that could affect the quality of the final products.

[0137] In this embodiment (Figure 4b), the intermediate feed (400), which generally includes the hydrolyzed PPS (500) stream, water, and SPS (134) such as minerals or other contaminated solids, undergoes an initial separation (410). This step separates the majority of PPS (500), resulting in a mixture of rejected solids, water and SPS / remaining PPS (414)This solid / liquid separation (130) can be performed using a first centrifuge (1042) or other appropriate solid / liquid separation devices. The separated SPS (134) is then redirected to the SPS mixing tank.

[0138] In this embodiment (Figure 4b), the hydrolyzed PPS (500) and SPS (134) mixture undergoes a second separation (440) to isolate the SPS (134) and release the remaining separated PPS (500). This second separation (440) can be carried out using a second solid / liquid centrifuge (1042). In certain embodiment the second separation comprises a separation column (1040). In alternative embodiments the second separation comprises a gravity separation column (1040'), or another suitable separation device. In the embodiments comprising the gravity separation column (1040'), the separation (130) leverages differences in specific gravity to facilitate the centrifugal separation (130) of water and plastic from the mixture. In the embodiments comprising the separation column (1040) the separation (130) leverages differences in specific particle size to facilitate the centrifugal separation (130) of water and plastic from the mixture.

[0139] The separated SPS (134) typically contains dissolved small organic molecules resulting from the breakdown of engineering plastics, PVC, and other organic contaminants, as well as ash, chloride, and other impurities. By removing these impurities before the thermal cracking (140) reactions, especially in the thermalchemical processes described later, this invention ensures that the final products are less contaminated. This enhancement not only improves the combustibility of the fuels produced but also reduces impurities in both fuel and chemical applications. After separation, the SPS (134) is sent to the SPS mixing tank (1028), where the water undergoes continuous treatment in a water waste treatment process (WWTP) before being returned to the tank. It should be noted that the present invention is not limited to a two-step separation (130) process, nor is it constrained by the order of the separation (130) steps. The invention can accommodate various scenarios where the separation of the intermediate feed (400) into products such as hydrolyzed PPS (500), SPS (134), inorganic rejected solids, and water may occur in either a single step or multiple steps. Referring to the exemplary apparatus shown in Figure 2, the flashing of the reacted feed (122) in the second stage (240) can be performed using one or more flash vessels equipped with vents. Ideally, the pressure inside the flash vessel is significantly lower than that within the hydrolysis complex (230). For instance, the pressure in the flash vessel might be around 20 bar, while the hydrolysis reactor (1032) operates at approximately 50 bar. Various types of equipment can be used to facilitate the separation (130) of materials from the first- stage hydrolysis reactor (1032). This separation (130) produces a mixture comprising 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 assist in heating the feed after preheating.

[0140] Solids or particulates like SPS (134) can be separated from the hydrolyzed PPS (500) using appropriate equipment, such as centrifuges (1042), hydrocyclones, or static tanks. The separated SPS (134) is then returned to the SPS mixing tank (1028), where it is used as a medium for transferring PPS (100) back to the hydrolysis reactor (1032) for further processing. The hydrolyzed PPS (500), after being separated from SPS, inorganic residues, and water, is introduced into the cracking unit (260) via the extruder (252) at a temperature range of 20 to 450 °C, preferably of 100 to 425 °C, more preferably of 150 to 400 °C.

[0141] Extruders play a crucial role in the chemical recycling of plastics, offering significant advantages in the process of melting and transferring recycled materials. They provide precise control over temperature and pressure, ensuring that the plastics are uniformly melted without causing thermal degradation, which is essential for maintaining the chemical structure needed for effective recycling. The continuous and consistent operation of extruders in the present invention also allows for the controlled and efficient breakdown of polymers into their monomers or other chemical forms, facilitating their reuse in the production of new plastics. Additionally, extruders can handle various plastic types and contaminants, making them versatile tools in the chemical recycling process. Their integration with in-line filtration and reaction systems further enhances the purity and quality of the recycled output, making them indispensable for advancing the circular economy in the plastics industry.

[0142] Based on the outlined principles, a skilled practitioner might integrate various equipment into the second separation (440) process, including centrifuges (1042), hydrocyclones, distillation towers (1051'), filtration devices, screens, or other suitable apparatus. Distillation is especially useful for removing very fine carbon solids from the intermediate feed (400). Additionally, further pressure reduction enhances steam recovery and assists in the solid / liquid separation (130), facilitating the recovery of SPS (134) and other rejected inorganic solids.

[0143] The PPS (500) stream, designated for conversion into end products such as hydrocarbons in the naphtha and / or gasoil boiling point range (144) and hydrocarbon gases, is fed into a high-temperature reactor operating under moderate pressure. This method follows established industry practices and expert recommendations for processing plastics into desired chemical products and fuel components. In some embodiments, residual fractions or heavy oils (152) that are not suitable for specialty or generic chemical applications may be directed to an extruder (252) or a cracking reactor (260), as depicted in Figure 2. In specific embodiments these residual fractions, including waxes collected from the bottom of the distillation towers (1051') , are transferred to the extruder (252) or cracking reactor (260) for further processing.

[0144] In a more preferred embodiment these residual fractions, including waxes collected from the bottom of the quench column (1051) , are transferred to the extruder (252) or cracking reactor (260) for further processing

[0145] In some embodiments, the residual fractions, heavy oils (152) and waxes can be used for energy recovery, for example for electricity or heat generation.

[0146] 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.

[0147] Alternatively, in some embodiments, as illustrated in Figure 5, the cracking (140) stage can be further refined using a thermal-chemical platform. For example, the hydrolyzed PPS (500) stream might be processed through established cracking methods to produce fuel gas (146), carbon solids (142), and hydrocarbons in the naphtha and gasoil boiling point range (144). Additional thermal-chemical processes, such as vis-breaking, hydrotreating, hydroprocessing, reforming, hydrocracking, catalytic cracking, gasifying, and pyrolyzing, may be employed to modify the boiling point distribution of the resulting hydrocarbon mixture. Although gasifying and pyrolyzing PPS (100) streams have historically posed challenges, the consistent quality of the output from the second stage (240) separation (130) in the described embodiments facilitates more effective application of these treatments.

[0148] In Figure 5, during the exemplary cracking (140) stage within a thermal-chemical platform, the hydrolyzed PPS (500) is subjected to conditions that promote reactions such as thermal cracking (140), catalytic cracking (140), or other established processes in the field. Additionally, any reacted solid products present in the plastic may also be introduced into the cracking reactor (260).

[0149] In the cracking reactor (260), the hydrolyzed PPS (500), when exposed to high temperatures and moderate pressures, is converted into a range of valuable materials. This typically includes carbon solids (142) and a mixture of hydrocarbons, which are generally released as hydrocarbon vapor and gases (148).

[0150] 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, CO, CO2, hydrogen or other gases or the mixtures thereof. Various apparatuses can be utilized to facilitate the cracking (140) stage. The cracking (140) reactions typically occur within a temperature range of approximately 250 °C to 800 °C, with a preferred range of about 300 °C to 750 °C, a more preferred range of about 350 °C to 700 °C, and an optimal range of about 400 °C to 600 °C. The reaction duration generally spans from about 1 minute to 360 minutes, with a preferred duration of 2 to 240 minutes, a more preferred duration of 3 to 180 minutes, and an optimal duration of 5 to 120 minutes. Different components within the products experience varying times in the cracking reactor (260); for example, vapors move through quickly, while liquids remain exposed for a longer period.

[0151] The output from the cracking (140) stage comprises two main components: a mixture of hydrocarbon vapor and gases (148) and carbon solids (142). The hydrocarbon vapor and gases (148) include CO2, CO, nitrogen-containing compounds, sulfur-containing compounds, and oil (149) vapor. Carbon solids (142) resemble high-quality coke. The conditions within the cracking (140) stage are precisely controlled to maximize the purity of both the carbon solids (142) and the hydrocarbon vapor and gas (148) mixture. Rapid quenching of the hot vapors is essential to prevent secondary reactions and minimize the formation of carbon char after the vapor exits the cracking reactor (260).

[0152] In an exemplary setup, rapid quenching of vapors can be accomplished by channeling them into a water-filled drum or by utilizing multiple quenching stages with thermal fluids and cooling media. Implementing multiple quenching steps can enhance the recovery of hydrocarbons in the naphtha and / or gasoil boiling point range (144) from the hydrolyzed PPS (500). Alternatively, vapors with lower boiling points can be quenched using incoming hydrocarbon liquids, which also aids in energy recovery.

[0153] In thermal-chemical platforms used for the cracking (140) stage, temperatures typically range from approximately 250 °C to 800 °C, with a preferred range of 300 °C to 750 °C, more preferably 350 °C to 700 °C, and most ideally 400 °C to 600 °C. These temperatures facilitate the breakdown of PPS (500) into hydrocarbons or the cracking (140) of hydrocarbon molecules into lower molecular weight compounds, which generally occurs at temperatures of 400-650 °C or above. According to established methods, hydrocarbon cracking (140) usually takes place at temperatures exceeding 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 approximately 0.1 bar and 30 bar, preferably between 0.5 bar and 25 bar, and most ideally between 1 bar and 20 bar in one embodiment. 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.

[0154] An example of the cracking (140) stage is depicted in Figure 5. Carbon solids (142) generated by the cracking reactor (260) are initially routed to a carbon solids cooler (630) to allow the carbon to cool and lose residual heat. After cooling, the carbon solids (142) undergo passivation, such as controlled air dosing, to reduce or eliminate the risk of self-heating when exposed to air. The passivated carbon is then transferred to carbon storage (540) for future use. The mixture of hydrocarbon vapor and gases (148) produced by the cracking reactor (260) is directed to a cooler (850) or condenser, which separates the mixture into fuel gas (146) and hydrocarbon oil (149). Following separation, the hydrocarbon oil (149) is divided into components like liquid hydrocarbons (144) and heavy oil (152) compounds (including wax). Any heavy compounds are recycled back to the cracking reactor (260), while the liquid hydrocarbons (144) are isolated.

[0155] Although the process described in this invention can be performed within a defined range of parameters, adjustments to operating conditions such as temperature and pressure can be made to enhance yield and efficiency. These adjustments are demonstrated for various types of feedstock. It is important to note that the operating parameters can be modified to suit different raw materials or specific process requirements, while still adhering to the core principles of the invention. This process can handle a wide range of plastic waste streams, including PPS (100), (micro)plastics collected from waterways, flowing and stationary water bodies, residues left after mechanical separation of plastics, as well as pre-consumer, preindustrial, post-consumer and post-industrial plastic waste, and plastic-containing packaging materials, among others.

[0156] 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.

[0157] As a result, the composition balance of these main components can affect various operational parameters of the processing steps in this invention. Additionally, the temperature range used during the initial reactions and subsequent processing steps can be adjusted to favor the production of specific products, such as light hydrocarbons like circular naphtha (144), over other pathways, thus enhancing the economic value of the resulting products.

[0158] 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. For PPS (100) feedstocks with substantial polyolefin content, such as polyethylene and polypropylene, it is advantageous to remove contaminants like polyesters, polyamides, polyurethanes, engineering plastics, PVC, rubber, paper, and minerals either during the feed preparation (110) stage or prior to it.

[0159] 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.

[0160] Shredder residue generally comprises about 50% combustible material and 50% noncombustible (inert) material. It may also include substances such as brake fluid, gasoline, engine oil , windshield washer fluids, antifreeze (ethylene glycol), FREON™ refrigerants, and occasionally polychlorinated biphenyls (PCBs), which can be introduced during the shredding of electronics and old appliances with intact capacitors. Additionally, shredder residue may contain heavy metals such as lead, mercury, and cadmium. The moisture content of shredder residue can vary depending on whether the shredding method is wet or dry and how much rain exposure it has had during storage. While shredder residue is typically regarded as "dry," it can still have up to 15% moisture by weight.

[0161] Similarly, MSW, tires, and mixed plastics used as feedstock may have attributes in common with shredder residue. However, MSW introduces additional considerations due to its diverse batch content, which might include animal by-products. These byproducts can undergo premature reactions, such as the hydrolysis of fats and proteins, if the temperature exceeds their decomposition limits, especially when the moisture content is high. Such premature hydrolysis can result in the formation of stable emulsions that are difficult to break down in later process stages. In certain cases, a two-step decomposition reaction may be employed to effectively address the specific content of the feedstock.

[0162] 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:

[0163] Solvents and Modifications

[0164] Depending on the composition of the raw feed, specific modifications may enhance processing efficiency. For example, adding an organic solvent to dense hydrocarbon feedstocks— such as plastics, rubber, tires, and foam— can increase the organic content and improve the yield of usable liquid mixtures. Additionally, incorporating acids or alkaline materials may be useful for controlling pH levels during processing. When the raw feedstock includes plastics, either alone or as part of shredder residue (SR) or municipal solid waste (MSW), it has been found that a hydrocarbon oil (149) produced by the process itself functions as a highly effective solvent, outperforming other known solvents in the field. As a result, some of the hydrocarbons produced by the process can be reintroduced into the raw feed or used in earlier stage reactions. In exemplary embodiments, these hydrocarbons typically have a boiling range between 50 °C and 400 °C, preferably between 100 °C and 350 °C. The hydrocarbon solvent may be preheated before being applied to the shredder residue, MSW, and tires or mixed plastics feedstock. Alternatively, in other embodiments, the hydrocarbons are applied directly to the feedstock, and the mixture is then heated to a temperature between 100 °C and 350 °C, preferably between 200 °C and 350 °C. Using the final stage oil (149) product eliminates the recurring costs associated with other solvents and their replenishment. In some embodiments of the present invention, either the full range of constituents in the oil (149) or a selected portion is used to dissolve tires, shredder residue, MSW, and / or mixed plastics.

[0165] For example, all of the hydrocarbon oil (149) produced in the initial batch can be recirculated back into the input tire feedstock. Alternatively, in other embodiments, only the final-stage heavy oil (152) product is redirected in this way. If only a portion of the constituents is used, the solvent can be separated into its components during either the hydrocarbon oil (149) finishing step or the first stage of the process. Utilizing the hydrocarbon oil (149) produced as a solvent can increase the economic viability of this process compared to traditional methods. Since this oil (149) might not be immediately available for processing the first batch of feedstock, an alternative solvent may be used initially to help break down the feedstock.

[0166] Effective solvents for enhancing the processing of dense hydrocarbon feedstocks, such as plastics and rubber, include toluene or other so-called aromatic compounds. Other suitable solvents can also be identified by experts in the field. During the initial hydrolysis stage for processing tires and mixed plastics, adding extra water can help in removing chlorine or other halogen-containing materials.

[0167] In certain embodiments, the hydrocarbon vapor and gases (148) produced from the cracking stage (140) are primarily composed of hydrocarbon gases, with the possibility of minor impurities of non-hydrocarbon gases. These hydrocarbon gases include fuel gas (146), while the hydrocarbon vapors can be readily condensed into liquids or oils (149). The fuel gas (146) has a high calorific value and can be redistributed within the process to provide heating energy at various stages or used to generate electricity or other forms of energy for internal or external use. Oil (149) generally consists of hydrocarbons with carbon chains of 30 or fewer carbon atoms, similar to the lighter components in fuel oils (149) like naphtha and / or gasoil (144), making it commercially viable for sale. Heavy oil (152), which includes wax or waxy components, can be redirected to the cracking reactor (140) for further processing. It is important to note that the specific composition of oil (149), naphtha and / or gasoil (144) and heavy oil (152) is affected by both the type of feedstock used and the reaction conditions during the conversion and oil finishing steps. As a result, these streams may include paraffins, a-olefins, naphthenes, aromatics, and other components. For example, the composition varies depending on whether the feedstock is waste plastic or tires. Oil (149), naphtha and / or gasoil (144) and heavy oil (152) derived from feedstocks with a high plastic content typically contains more olefins and di-olefins, whereas oil (149), naphtha and / or gasoil (144) and heavy oil (152) from tires usually has aromatics, naphthenes, and sulfur compounds. If desired, these olefins can be removed through saturation or various post-treatment techniques known to experts in the field.

[0168] Equipment

[0169] The apparatuses for implementing the processes described in the embodiments of the present invention can be assembled using standard components familiar to process and chemical engineers. These apparatuses are generally constructed from materials that can withstand high temperatures and exposure to water, while meeting corrosion resistance requirements. Typically, carbon steel is used for the main structure, while 316L stainless steel or other corrosion -resistant alloys are utilized for components that come into contact with extreme pH conditions.

[0170] Specialized metals, such as Hastelloy, titanium, tantalum, and various hardened steels, cladding, surface treatment, coating, etc., may also be used for components requiring enhanced resistance to acids or specific conditions, but these are not necessary for achieving the core objectives of the invention.

[0171] Experts in the field will recognize that a variety of reactors, tanks, separators, conveyors, and other equipment can be used for this invention. For example, different types of filters with openings smaller than the size of suspended solid particles can be utilized for solids that do not significantly deform under stress. Moreover, clarifiers, settling chambers, and simple cyclones are effective when there is a significant density difference between solid particles and the fluid. When the size or density difference is smaller, devices that use centrifugal forces become more beneficial.

[0172] Handling of Problematic Waste

[0173] The processes described in this invention are well-suited for handling challenging waste materials. A notable advantage is that during feed preparation (110), downstream feed storage, and hydrolysis (e.g., feed storage (320) as shown in Figure 3a), the system effectively removes gaseous impurities, including ammonia, nitrous oxides, carbon monoxide, carbon dioxide, and sulfur-containing gases. Hydrolysis can generate sulfur-containing gases as a result of breaking down sulfur- rich components in the PPS (100), particularly from vulcanized rubber that contains sulfur bridges between rubber chains. Common sulfur-containing gases include hydrogen sulfide (H2S) and mercaptans (alkyl-sulfur compounds) such as methyl mercaptan. Additionally, sulfur-rich salts like calcium sulfide (CaS) may be produced and are typically separated in subsequent stages.

[0174] The hydrolysis of chlorinated and / or brominated organics in the mixture breaks down carbon-halide and oxygen-halide bonds, causing metals and halides to migrate into the water phase. This makes the current invention particularly suitable for recycling PVC and treating waste containing PCBs and PBDEs. As waste management experts know, PVC is about 58% chlorine by weight, which makes it susceptible to releasing toxic substances like dioxins when incinerated or processed with conventional methods. A key advantage of using water in this process is that the hydrogen ions in water react with chloride and halogen ions from PVC, resulting in soluble products such as hydrochloric acid. This chemical is relatively harmless, commercially valuable, and commonly used in cleaners and solvents while being largely free of contaminants and debris.

[0175] Efficiency

[0176] In the embodiments of this invention, high energy efficiency is achieved through countercurrent heat exchange and the effective use of moisture in the feedstock. This moisture assists in the optional sizing and conveying of materials throughout the system. A significant portion of the energy in these systems is dedicated to heating liquid water in the initial process steps. After hydrolysis, the process generates steam through flashing, which is then separated and redirected to preheat incoming feed, thereby recycling energy within the system. Although energy efficiency may vary depending on the composition of the raw feed, test runs have demonstrated that the process achieves at least 30% energy efficiency, preferably above 50% energy efficiency, more preferably above 75% energy efficiency and ideally above 90% energy efficiency. The use of water in hydrolysis, which can be released as steam along with other gases, enhances energy recovery efficiency. Water and steam serve as effective heat exchange mediums and can be redirected to the pre-hydrolysis heating stages using one or more compact condensers, which improve overall efficiency. As a result, the steam and gases (132) released from the reacted feed (122) are ideally used to help heat the incoming feed and maintain the temperature of the hydrolysis reactor (1032), reducing energy loss during the process. In some cases, steam can also be directly injected back into the incoming feed or into one or more reactors. The following examples are provided to offer detailed insights into implementing and utilizing the present invention for those skilled in the field. These examples are intended to illustrate various applications and should not be construed as limiting the scope of the invention or implying that they represent the only or exhaustive experiments conducted.

[0177] While accuracy in the quantities and conditions used (e.g., amounts, temperature, etc.) has been a focus, it is important to consider that some experimental errors and variations may be present.

[0178] Example 1 — Operating Plant Plastic Waste

[0179] A full-scale, commercial installation has been built with a system similar to the one shown in Figure 6a and figure 6b for processing waste plastics. At maximum capacity, the plant is designed to produce over 10 cubic metric tons of oil (149) per day from an average input of about 15 tons of plastic feedstock (100). The resulting oil (149) is a high-quality, environmentally friendly product comparable to naphtha and / or gasoil (144). Additionally, the plant generates approximately 2 tons of char and 3 tons of gaseous hydrocarbon gas each day. This design can also be adapted for plants with a capacity of more than a thousand tons of feedstock.

[0180] Figure 6a and figure 6b illustrates a commercial-scale application of the described invention, designed for processing PPS (100), particularly plastic waste streams high in polyolefinic content. Initially, the PPS (100) is received and may be temporarily stored. During the PPS preparation (210) phase, the raw solid feed is passed through one or more metal detectors (1002) to detect and remove any metal particles that could potentially damage downstream equipment. Following this, the material undergoes particle sizing through grinding (1004) with a counter-rotating drum crusher, which reduces the particle size to approximately 25 mm.

[0181] 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).

[0182] After particle sizing and mixing with SPS (134), the feedstock attains adequate flowability for pumping into the pressurized hydrolysis reactor (1032). Conveyors may be required for transport before reaching this stage. Throughout the process, various pumps are used to move and pressurize the feedstock according to the specified process parameters. Appropriate pumps can be chosen from commercially available processing equipment based on the guidelines outlined here. The hydrolysis reactor (1032) generally operates at pressures ranging from approximately 10 bar to 100 bar, depending on the target operating temperature within the reactor. The temperature typically falls between about 150 °C and 300 °C, though it is usually at least 250 °C. The reactor may be configured as a stirred tank reactor, potentially incorporating hydraulic stages or baffles to enhance mixing and processing efficiency.

[0183] Vapors, including non-condensable gases such as light hydrocarbons, CO2, some water vapor, and other gases, are expelled from the top section of the hydrolysis reactor (1032). These vapors can be partially condensed, with the resulting liquids and non-condensable gases either processed further or discarded. Additionally, these vapors may be combined with similar vapors as described earlier.

[0184] 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.

[0185] The reacted feed (122) from the hydrolysis reactor (1032) is channeled to the second stage of separation (240) for processing. This feed is introduced into a high-pressure flash vessel (1036) through a control valve. In this stage, the high-pressure flash vessel separates the components of the reacted feed. Notably, the usable waste steam generated in this process is typically recycled as thermal energy throughout the plant, enhancing overall energy efficiency.

[0186] In one embodiment, the pressure in the high-pressure flash tank is reduced through a control valve from above 10 bar in the hydrolysis reactor (1032) to approximately 8-10 bar. Mixing may be utilized within the high-pressure flash tank. Alternative pressure settings can be chosen in the high-pressure flash vessel to generate thermal energy at specific pressures and temperatures, particularly if the waste heat is intended for use elsewhere in the plant.

[0187] 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.

[0188] The reacted feed (122) from the high-pressure flash vessel (1036) is then transferred to a low-pressure flash vessel (1038). In some configurations, this step may involve an intermediate medium-pressure flash tank before reaching the low- pressure vessel. The pressure in the low-pressure flash vessel is reduced to between 0 bar(g) and about 1.5 bar(g). During this process, waste steam and non- condensable gases are removed from the top of the vessel and are subsequently condensed and treated as needed. Following this, the reacted feed (122) is directed to a decanting and dewatering apparatus. In this stage, SPS (134) and inorganic solid particles are separated using standard commercial equipment, such as a centrifugal decanter, a centrifugal basket centrifuge (1042), a hydrocyclone, or a settling tank. The separated SPS (134) and solid particles are then transferred to the SPS tanker for further handling.

[0189] The separated PPS (500) is transferred to a centrifuge (1042) along with some of the water collected during the dewatering process. In the centrifuge, the remaining water and any solid particles are separated from the plastic stream. The separated water and solids are then redirected back to the SPS mixing tank (1028).

[0190] The separated PPS (500) stream is directed to the extruder (252), from where it is injected to the cracker reactor (260) once melted using specialized pumps. The temperature of the extruder (252) may vary depending on process conditions, typically ranging between 150 °C and 400 °C.

[0191] The cracker reactor (260) typically operates at temperatures ranging from 400 °C to 600 °C, depending on the composition, percentage, and molecular weight of the incoming hydrolyzed PPS (500). This reactor may be an extruder, an auger reactor, a continuous stirred-tank reactor, a fluidized bed reactor, or another suitable type that facilitates both the heating and movement of the solid material. The reactor pressure can be adjusted between 1 and 15 bar; higher pressures generally lead to a lower molecular weight of the liquid hydrocarbon (144) product and an increase in gas (both condensable and non-condensable) and carbon solids (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.

[0192] The gaseous products, including hydrocarbon vapor and gas (148), discharged from the reactor proceed to the condensation (139) phase. Here, through multiple stages of distillation, flash drum(1052') and / or overhead accumulations processes (1053), membrane or molecular sieves, and compression, the fuel gas (146) is thoroughly separated and typically used for energy production within the plant. Concurrently, the condensed oil (149) undergoes further separation () in a distillation tower (1051') or multiple towers. Heavy oil (152), including any wax or waxy products, is extracted from the bottom and redirected to the extruder (252) and / or the cracker (260). In some cases, heavy oil can be used as fuel in the boiler for electricity or heat generation. Lighter liquid compounds with specific properties are separated and packaged as naphtha and / or gasoil (144), which are then used as feedstocks for chemical plants, such as steam cracking facilities or other chemical or refining conversion plants requiring liquid hydrocarbon feedstocks.

[0193] To further illustrate the transformation of feedstock components through the described processes, yield evaluation studies were conducted to trace these components. For instance, these studies have demonstrated that chlorine from PVC in the raw feed predominantly ends up mostly as chlorine in the (waste) water stream. Approximately 99% or more of the chlorine is removed through HCI emission. Similarly, more than 99% of other heterogeneous atoms, such as oxygen, nitrogen, and sulfur, are transferred directly to the water stream. As a result, the content of these heterogeneous atoms in the final liquid hydrocarbons (144) falls within acceptable ranges for typical industrial applications.

[0194] Example 2 — The produced oil (149)

[0195] Due to the hydrolysis conducted through the process, the resulting liquid hydrocarbons (144) from different plastic sources demonstrate relatively uniform quality. This hydrolysis step effectively removes most of the heterogeneities associated with polyesters, polyamides, polyurethanes, other engineering plastics, PVC, and biomass within the PPS (100). Chemical recycling processes, including hydrolysis, are highly effective at removing contaminants. However, the quality and quantity of the produced liquid hydrocarbons (144) are significantly influenced by the proportion of polyolefins in the primary feed. Higher polyolefin content generally results in higher-quality and greater quantities of liquid hydrocarbons (144). Impurities from compounds such as primary sugars and fats on plastic surfaces can affect the final product. These impurities can be effectively addressed through basic washing procedures, thereby enhancing the overall quality of the product.

[0196] 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

[0197] Example 3 — Benchtop Conversion of PPS (100)

[0198] Using a benchtop setup similar to the one depicted in Figure 7 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.

[0199] Example 4 — Benchtop Conversion of waste plastics

[0200] In a pilot run, approximately 5 kg of PPS (100) feedstock was size-reduced to 25 mm pieces and introduced into a Parr reactor equipped with a mechanical stirrer. The feedstock consisted of a mixture of polyethylene, polypropylene, polystyrene, polyethylene terephthalate, PVC, and minerals. To prepare the feed, about 15% SPS (134) and 30% water were mixed with the plastic, thoroughly stirred, and then transferred to the reactor. The reactor was sealed, and heating was commenced. The raw feed underwent the first stage of hydrolysis at 250 °C and 50 bar for a duration of 1 hour. To maintain constant reactor pressure, approximately half of the total water in the reactor is evaporated, along with about 1 to 5% of the plastic in the form of polar and non-polar organic compounds resulting from the hydrolysis of PPS (100). The reactor output is partially condensed , producing various components such as CO, CO2, HCI, sulfur compounds, light hydrocarbon gases, and other gases. Some byproducts of the hydrolysis dissolve in water, while others accumulate on the surface. Non-condensable gases are directed to a flare for disposal.

[0201] Once the reactor has been cooled, the primary process solid (PPS) (100) is extracted and then reintroduced into the reactor after undergoing washing and separation (130) from soil and water. It is reintroduced with 5 to 15% water to maintain a constant pressure of 15 bar, while the reactor temperature is carefully regulated at 450 °C. The products resulting from the cracking (140) of hydrolyzed PPS (500) are subsequently cooled in a condenser. Liquid products are collected, and non- condensable compounds are directed to the flare for disposal. Table 1 provides the characteristics of circular naphtha (144) produced using various plastic percentage combinations in the PPS (100), with testing methods specified by ASTM codes.

Claims

35CLAIMS1. A method of upcycling synthetic and organic waste, comprising the steps of:• Preparation (110) of the primary process solid (100) into a slurry (112) with the 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 the primary process solid (100) into the mixed storage tank (220) along with the SPS slurry (112),• Subjecting the slurry (112) to hydrolysis (120) in a hydrolysis reactor(1032),• Conducting separation (130) after hydrolysis to remove 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) through an extruder (252).

2. A method of upcycling according to claim 1, wherein the primary process solid (100) is plastic or rubber waste.

3. A method of upcycling according to claim 1, wherein the primary process solid (100) is selected from the group consisting of polyethylene, polypropylene, polystyrene, PET, polyester, polycarbonate, PVC, textiles, minerals, biomass, fats, rubber, tires, polyurethane, polyamide, synthetic plastics, natural plastics, or mixtures thereof.

4. A method of upcycling according to claim 1, wherein the secondary process solid (134) is a mineral-containing substance, preferably including various types of soil, bentonite, calcium carbonate, silicates, alumino-silicates, alkali metal compounds, alkali earth metal compounds, and transition or metal compounds.

5. A method of upcycling according to claim 1, wherein the temperature during the hydrolysis (120) of the slurry (112) ranges from 50 °C to 550 °C, preferably from 80 °C to 500 °C, more preferably from 100 °C to 450 °C, and most preferably from 125 °C to approximately 400 °C.

6. A method of upcycling according to claim 1, wherein the pressure during the hydrolysis (120) of the slurry (112) ranges from 1 bar to 200 bar, preferably from 1.2 bar to 150 bar, more preferably from 1.5 bar to 100 bar, and most preferably from 2 bar to 80 bar.

367. A method of upcycling according to claim 1, wherein the hydrolysis period (120) of the slurry (112) ranges from 1 minute to 1440 minutes, preferably from 2 minutes to 600 minutes, more preferably from 5 minutes to 240 minutes, and most preferably from approximately 15 minutes to 180 minutes.

8. A method of upcycling according to claim 1, wherein the slurry (112) has a moisture content of at least 20%, preferably over 30%, and most preferably above 40%.

9. A method of upcycling according to claim 1, wherein the mixed storage tank (220) is equipped with a vibratory screen (1043) for fine sizing to remove contamination.

10. A method of upcycling according to claim 1, wherein the hydrolysis reactor (1032) features a multi-chamber design.

11. A method of upcycling according to claim 1, wherein the hydrolysis reactor (1032) is selected from a batch reactor, a continuous stirred-tank reactor, an auger reactor, or any other reactor type that facilitates the heating and mixing of the solid material.

12. A method of upcycling according to claim 1, wherein the thermal conversion reactor (260) is selected from an auger reactor, a batch reactor, an extruder, a continuous stirred-tank reactor, a fluidized bed reactor, or any other reactor type that supports the heating and movement of the solid material.

Images