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WO2025099672A1 - Systèmes et procédés de déchloration hydrolytique par micro-ondes de déchets plastiques mélangés - Google Patents

Systèmes et procédés de déchloration hydrolytique par micro-ondes de déchets plastiques mélangés Download PDF

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Publication number
WO2025099672A1
WO2025099672A1 PCT/IB2024/061107 IB2024061107W WO2025099672A1 WO 2025099672 A1 WO2025099672 A1 WO 2025099672A1 IB 2024061107 W IB2024061107 W IB 2024061107W WO 2025099672 A1 WO2025099672 A1 WO 2025099672A1
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chloride
reactor
plastic
hydrolytic
microwave
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Fabrice Cuoq
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SABIC Global Technologies BV
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SABIC Global Technologies BV
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J19/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
    • B01J19/08—Processes employing the direct application of electric or wave energy, or particle radiation; Apparatus therefor
    • B01J19/12—Processes employing the direct application of electric or wave energy, or particle radiation; Apparatus therefor employing electromagnetic waves
    • B01J19/122—Incoherent waves
    • B01J19/126—Microwaves
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J19/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
    • B01J19/18—Stationary reactors having moving elements inside
    • B01J19/20—Stationary reactors having moving elements inside in the form of helices, e.g. screw reactors
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J3/00—Processes of treating or compounding macromolecular substances
    • C08J3/28—Treatment by wave energy or particle radiation
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10B—DESTRUCTIVE DISTILLATION OF CARBONACEOUS MATERIALS FOR PRODUCTION OF GAS, COKE, TAR, OR SIMILAR MATERIALS
    • C10B53/00—Destructive distillation, specially adapted for particular solid raw materials or solid raw materials in special form
    • C10B53/07—Destructive distillation, specially adapted for particular solid raw materials or solid raw materials in special form of solid raw materials consisting of synthetic polymeric materials, e.g. tyres
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
    • C10G1/00—Production of liquid hydrocarbon mixtures from oil-shale, oil-sand, or non-melting solid carbonaceous or similar materials, e.g. wood, coal
    • C10G1/008—Controlling or regulating of liquefaction processes
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
    • C10G1/00—Production of liquid hydrocarbon mixtures from oil-shale, oil-sand, or non-melting solid carbonaceous or similar materials, e.g. wood, coal
    • C10G1/02—Production of liquid hydrocarbon mixtures from oil-shale, oil-sand, or non-melting solid carbonaceous or similar materials, e.g. wood, coal by distillation
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
    • C10G1/00—Production of liquid hydrocarbon mixtures from oil-shale, oil-sand, or non-melting solid carbonaceous or similar materials, e.g. wood, coal
    • C10G1/10—Production of liquid hydrocarbon mixtures from oil-shale, oil-sand, or non-melting solid carbonaceous or similar materials, e.g. wood, coal from rubber or rubber waste
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J2219/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
    • B01J2219/00049—Controlling or regulating processes
    • B01J2219/00051—Controlling the temperature
    • B01J2219/00139—Controlling the temperature using electromagnetic heating
    • B01J2219/00141—Microwaves
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J2219/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
    • B01J2219/00049—Controlling or regulating processes
    • B01J2219/00162—Controlling or regulating processes controlling the pressure
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2300/00—Characterised by the use of unspecified polymers
    • C08J2300/30—Polymeric waste or recycled polymer
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2327/00—Characterised by the use of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a halogen; Derivatives of such polymers
    • C08J2327/02—Characterised by the use of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a halogen; Derivatives of such polymers not modified by chemical after-treatment
    • C08J2327/04—Characterised by the use of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a halogen; Derivatives of such polymers not modified by chemical after-treatment containing chlorine atoms
    • C08J2327/06—Homopolymers or copolymers of vinyl chloride

Definitions

  • the present disclosure generally relates to systems and methods for processing plastic waste to remove chloride contaminants. More specifically, the present disclosure relates to systems and methods for performing a microwave-induced hydrolytic dechlorination of chloride- containing plastic, in which the hydrolytically dechlorinated plastic can be subsequently pyrolyzed to yield pyrolysis oil having a low chloride content.
  • Pyrolysis oil originates from the chemical recycling of mixed plastic waste (MPW).
  • MPW mixed plastic waste
  • pyrolysis oil can be formed by pyrolyzing MPW at sufficiently elevated temperatures (e.g., between 400 °C and 500 °C) under anaerobic conditions.
  • MPW often contains polyvinyl chloride (PVC), among other polymers.
  • PVC polyvinyl chloride
  • HC1 hydrogen chloride gas
  • the released HC1 is corrosive, which can lead to undesirable corrosion within the pyrolysis reactor.
  • the released HC1 can also react with other olefins to form organochloride species that remain in the pyrolysis oil product.
  • organochloride species may similarly release HC1 during thermal processing of the pyrolysis oil product, which can lead to corrosion issues when the pyrolysis oil is further processed.
  • MPW can be thermally treated to remove a portion of the chloride content prior to pyrolysis
  • thermal hydrodechlorination requires substantially high temperatures (e.g., 250 °C to 320 °C) and long reaction times, which is detrimental to the process. Accordingly, there remains a need for an improved technique for dechlorinating chloride-containing plastic prior to pyrolysis to yield pyrolysis oil having a substantially lower chloride content.
  • Embodiments include systems and methods for performing a microwave-induced hydrolytic dechlorination of chloride-containing plastic, before the hydrolytically dechlorinated plastic is subsequently pyrolyzed to form pyrolysis oil having a low chloride content.
  • One such system is a hydrolytic dechlorination reactor that includes an internal chamber configured to receive chloride-containing plastic and an aqueous fluid, in which the aqueous fluid containing steam, liquid water, an aqueous solution, or any combination thereof.
  • the hydrolytic dechlorination reactor also includes a microwave source operably coupled to the internal chamber and configured to supply microwaves to irradiate the chloride-containing plastic and the aqueous fluid for a hydrolytic dechlorination of the chloride-containing plastic and yield hydrolytically dechlorinated plastic.
  • the hydrolytically dechlorinated plastic contains at least 90% less chloride than the chloride-containing plastic.
  • the hydrolytic dechlorination reactor includes an impeller operably coupled to the internal chamber and configured to mix the chloride-containing plastic and the aqueous fluid during microwave irradiation.
  • the hydrolytic dechlorination reactor includes a controller communicatively coupled to the microwave source and configured to provide control signals to control operation of the microwave source during the microwave irradiation.
  • the hydrolytic dechlorination reactor further includes at least one sensor operably coupled to the internal chamber of the hydrolytic dechlorination reactor and communicatively coupled to the controller to provide measurements of an internal chamber temperature, an internal chamber pressure, or a combination thereof, during the microwave irradiation.
  • the controller is configured to provide the control signals to the microwave source during the micro wave irradiation to maintain the internal chamber temperature between 150 °C and 220 °C, inclusive, to maintain the internal chamber pressure between 2 bar and 24 bar, inclusive, or a combination thereof.
  • the internal chamber of the hydrolytic dechlorination reactor is fluidly coupled to a scrubber that includes a caustic material and a caustic consumption sensor, in which the caustic consumption sensor communicatively coupled to the controller to provide measurements of caustic consumption of the scrubber during the microwave irradiation, and in which the controller is configured to provide the control signals to the microwave source to end the microwave irradiation for a batch of the chloride-containing plastic based at least in part on the caustic consumption of the scrubber.
  • the hydrolytic dechlorination reactor is part of a pyrolysis oil processing system.
  • the hydrolytic dechlorination reactor is operably coupled to a pyrolysis reactor configured to receive the hydrolytically dechlorinated plastic from the hydrolytic dechlorination reactor and to pyrolyze the hydrolytically dechlorinated plastic at a temperature between 400 °C and 500 °C to yield pyrolysis oil.
  • the hydrolytic dechlorination reactor is operably coupled to the pyrolysis reactor via an extruder, in which the extruder is configured to receive the hydrolytically dechlorinated plastic from the hydrolytic dechlorination reactor and to extrude and deliver the hydrolytically dechlorinated plastic to the pyrolysis reactor.
  • the extruder is a microwave-compatible extruder integrated into the internal chamber of the hydrolytic dechlorination reactor to facilitate continuous mode operation of the hydrolytic dechlorination reactor.
  • the aqueous fluid preferably contains steam.
  • One such method includes the steps of supplying a chloride-containing plastic and an aqueous fluid to an internal chamber of a microwave reactor, in which the aqueous fluid containing steam, liquid water, an aqueous solution, or any combination thereof.
  • the steps further include irradiating, using a microwave source of the microwave reactor, the chloride-containing plastic and the aqueous fluid for a hydrolytic dechlorination of the chloride-containing plastic and yield hydrolytically dechlorinated plastic.
  • the steps further include supplying the hydrolytically dechlorinated plastic to a pyrolysis reactor, and pyrolyzing the hydrolytically dechlorinated plastic in the pyrolysis reactor to produce pyrolysis oil.
  • contents of the internal chamber consist essentially of the chloride- containing plastic and water (H2O), and optionally a base selected from the group consisting of: sodium hydroxide (NaOH), potassium hydroxide (KOH), monoethanolamine (MEA), and diethylethanolamine (DEAE).
  • a temperature of the internal chamber during the hydrolytic dechlorination is between 150 °C and 220 °C, inclusive, and a pressure of the internal chamber during the hydrolytic dechlorination is between 2 bar and 24 bar, inclusive.
  • the chloride-containing plastic contains alkyl chlorides, and at least 75% of the alkyl chlorides in the chloride-containing plastic are converted into alkyl alcohols in the hydrolytically dechlorinated plastic via the hydrolytic dechlorination.
  • the chloride-containing plastic contains MPW, and wherein at least 80% of the alkyl chlorides in the chloride-containing plastic are converted into alkyl alcohols in the hydrolytically dechlorinated plastic via the hydrolytic dechlorination.
  • FIG. 1 is a diagrammatic representation of a pyrolysis oil production system that converts batches of MPW into pyrolysis oil having a reduced chloride content, according to an embodiment.
  • FIG. 2 is a diagrammatic representation of a pyrolysis oil production system that continuously converts a stream of MPW into a stream of pyrolysis oil having a reduced chloride content, according to an embodiment.
  • FIG. 3 is a diagrammatic representation of a process in which a chloride-containing plastic is hydrolytically dechlorinated and then pyrolyzed to yield pyrolysis oil with a reduced chloride content, according to an embodiment.
  • the present disclosure describes various embodiments related to systems and methods for performing a microwave-induced hydrolytic dechlorination of chloride-containing plastic to reduce the chloride content of the plastic, as well as the chloride content of pyrolysis oil subsequently generated from the hydrolytically dechlorinated plastic.
  • the description may use the phrases “in certain embodiments,” “in various embodiments,” “in an embodiment,” or “in embodiments,” which may each refer to one or more of the same or different embodiments.
  • the terms “comprising,” “including,” “having,” and the like, as used with respect to embodiments of the present disclosure are synonymous.
  • the term “plurality” as used herein refers to two or more items or components.
  • Embodiments include systems and methods for performing a microwave-induced hydrolytic dechlorination of chloride-containing plastic, before the hydrolytically dechlorinated plastic is subsequently pyrolyzed to form pyrolysis oil having a low chloride content.
  • One such system is a hydrolytic dechlorination reactor that includes an internal chamber configured to receive chloride-containing plastic and an aqueous fluid, in which the aqueous fluid containing steam, liquid water, an aqueous solution, or any combination thereof.
  • the hydrolytic dechlorination reactor also includes a microwave source operably coupled to the internal chamber and configured to supply microwaves to irradiate the chloride-containing plastic and the aqueous fluid for a hydrolytic dechlorination of the chloride-containing plastic and yield hydrolytically dechlorinated plastic.
  • the hydrolytically dechlorinated plastic contains at least 90% less chloride than the chloride-containing plastic.
  • the hydrolytic dechlorination reactor includes an impeller operably coupled to the internal chamber and configured to mix the chloride-containing plastic and the aqueous fluid during microwave irradiation.
  • the hydrolytic dechlorination reactor includes a controller communicatively coupled to the microwave source and configured to provide control signals to control operation of the microwave source during the microwave irradiation.
  • the hydrolytic dechlorination reactor further includes at least one sensor operably coupled to the internal chamber of the hydrolytic dechlorination reactor and communicatively coupled to the controller to provide measurements of an internal chamber temperature, an internal chamber pressure, or a combination thereof, during the microwave irradiation.
  • the controller is configured to provide the control signals to the microwave source during the micro wave irradiation to maintain the internal chamber temperature between 150 °C and 220 °C, inclusive, to maintain the internal chamber pressure between 2 bar and 22 bar, inclusive, or a combination thereof.
  • the internal chamber of the hydrolytic dechlorination reactor is fluidly coupled to a scrubber that includes a caustic material and a caustic consumption sensor, in which the caustic consumption sensor communicatively coupled to the controller to provide measurements of caustic consumption of the scrubber during the microwave irradiation, and in which the controller is configured to provide the control signals to the microwave source to end the microwave irradiation for a batch of the chloride-containing plastic based at least in part on the caustic consumption of the scrubber.
  • the hydrolytic dechlorination reactor is part of a pyrolysis oil processing system.
  • the hydrolytic dechlorination reactor is operably coupled to a pyrolysis reactor configured to receive the hydrolytically dechlorinated plastic from the hydrolytic dechlorination reactor and to pyrolyze the hydrolytically dechlorinated plastic at a temperature between 400 °C and 500 °C to yield pyrolysis oil.
  • the hydrolytic dechlorination reactor is operably coupled to the pyrolysis reactor via an extruder, in which the extruder is configured to receive the hydrolytically dechlorinated plastic from the hydrolytic dechlorination reactor and to extrude and deliver the hydrolytically dechlorinated plastic to the pyrolysis reactor.
  • the extruder is a microwave-compatible extruder integrated into the internal chamber of the hydrolytic dechlorination reactor to facilitate continuous mode operation of the hydrolytic dechlorination reactor.
  • the aqueous fluid preferably contains steam.
  • One such method includes the steps of supplying a chloride-containing plastic and an aqueous fluid to an internal chamber of a microwave reactor, in which the aqueous fluid contains steam, liquid water, an aqueous solution, or any combination thereof.
  • the steps further include irradiating, using a microwave source of the microwave reactor, the chloride-containing plastic and the aqueous fluid for a hydrolytic dechlorination of the chloride-containing plastic, thereby to yield hydrolytically dechlorinated plastic.
  • the steps further include supplying the hydrolytically dechlorinated plastic to a pyrolysis reactor, and pyrolyzing the hydrolytically dechlorinated plastic in the pyrolysis reactor to produce pyrolysis oil.
  • contents of the internal chamber consist essentially of the chloride- containing plastic and water (H2O), and optionally a base selected from the group consisting of: sodium hydroxide (NaOH), potassium hydroxide (KOH), monoethanolamine (MEA), and diethylethanolamine (DEAE).
  • a temperature of the internal chamber during the hydrolytic dechlorination is between 150 °C and 220 °C, inclusive, and a pressure of the internal chamber during the hydrolytic dechlorination is between 2 bar and 22 bar, inclusive.
  • the chloride-containing plastic contains alkyl chlorides, and at least 75% of the alkyl chlorides in the chloride-containing plastic are converted into alkyl alcohols in the hydrolytically dechlorinated plastic via the hydrolytic dechlorination.
  • the chloride-containing plastic contains MPW, and at least 80% of the alkyl chlorides in the chloride-containing plastic are converted into alkyl alcohols in the hydrolytically dechlorinated plastic via the hydrolytic dechlorination.
  • FIG. 1 is a diagrammatic representation of an embodiment of a pyrolysis oil production system 100 that converts batches of MPW 102 into pyrolysis oil 104 having a reduced chloride content.
  • the MPW 102 consists of one or more chloride-containing polymers, while in other implementations, the MPW 102 includes a mixture of chloride-containing polymers and other polymers.
  • chloride-containing polymers include polyvinyl chloride (PVC), poly vinylidene chloride (PVDC), chlorinated polyvinyl chloride (CPVC), other polychloroolefins, and mixtures thereof.
  • the embodiment of the pyrolysis oil production system 100 illustrated in FIG. 1 includes a microwave reactor 106 (e.g., a microwave-based hydrolytic dechlorination reactor) that enables a microwave-based hydrolytic dechlorination of batches chloride-containing polymers in the MPW 102 to yield hydrolytically dechlorinated mixed plastic waste (HD-MPW) 108 having a substantially lower chloride content.
  • the microwave reactor 106 receives a batch of MPW 102 and receives a supply or flow of an aqueous fluid 110.
  • the aqueous fluid 110 includes steam, liquid water, an aqueous solution, or any combination thereof.
  • the aqueous solution may include a water-soluble base, such as sodium hydroxide (NaOH), potassium hydroxide (KOH), monoethanolamine (MEA), di ethylethanolamine (DEAE), or any combination thereof.
  • a water-soluble base such as sodium hydroxide (NaOH), potassium hydroxide (KOH), monoethanolamine (MEA), di ethylethanolamine (DEAE), or any combination thereof.
  • the steam may have a temperature between 100 °C and 150 °C, which may pre-heat the MPW 102 to provide at least a portion of the activation energy to facilitate the hydrolytic dechlorination reaction.
  • the MPW 102 and the aqueous fluid 110 may be combined outside of the microwave reactor to form a slurry or suspension that is subsequently delivered to the microwave reactor 106.
  • the pyrolysis oil production system 100 includes a controller 112 that is communicatively coupled to various components of the pyrolysis oil production system 100 to receive monitoring data and to provide control signals to control operation of the system.
  • the controller 112 includes at least one processor 114 (e.g., a central processing unit (CPU), graphics processing unit (GPU), application-specific integrated circuit (ASIC)) and at least one memory 116 (e.g., random access memory (RAM), read-only memory (ROM), flash memory, solid state disk (SSD)).
  • processor 114 e.g., a central processing unit (CPU), graphics processing unit (GPU), application-specific integrated circuit (ASIC)
  • RAM random access memory
  • ROM read-only memory
  • flash memory solid state disk (SSD)
  • the memory 116 stores instructions that are executed by the processor 114 to process measurement data collected by sensors disposed throughout the pyrolysis oil production system 100 to determine operational parameters of the system, and to provide suitable control signals to modify the operational parameters of the system to ensure that they remain within pre-defined ranges.
  • the controller 112 is communicatively coupled to provide control signals to a flow control valve 118 to control the flow of the aqueous fluid 110 into the microwave reactor 106, and is communicatively coupled to provide control signals to a delivery device 120 (e.g., an extruder, a conveyor belt, a hopper) to control the flow of MPW 102 into the microwave reactor 106.
  • a delivery device 120 e.g., an extruder, a conveyor belt, a hopper
  • the interior of the microwave reactor 106 includes a reaction chamber 122 that receives the MPW 102 and the aqueous fluid 110.
  • the microwave reactor 106 includes a microwave source 124 (e.g., a cavity magnetron) that is operably coupled to the reaction chamber 122 to supply microwaves to irradiate a mixture of the MPW 102 and the aqueous fluid 110 within the reaction chamber 122 to provide some or all of the activation energy to facilitate the hydrolytic dechlorination reaction.
  • a microwave source 124 e.g., a cavity magnetron
  • the microwave source 124 is a 300 watt (W) micro wave source, while higher wattage micro wave sources may be used to process larger batches of MPW 102.
  • the microwave reactor 106 includes an impeller 126 (e.g., a shredder impeller) that is operably coupled to the reaction chamber 122 to mix the MPW 102 and the aqueous fluid 110 and to break apart polymer aggregates during the hydrolytic dechlorination reaction.
  • an impeller 126 e.g., a shredder impeller
  • the reaction chamber 122 of the microwave reactor 106 is fluidly coupled to a scrubber 128 (e.g., an acid gas scrubber, a wet scrubber, a dry scrubber) designed to receive and neutralize HC1 released from the reaction chamber 122 during the hydrolytic dechlorination reaction.
  • a scrubber 128 e.g., an acid gas scrubber, a wet scrubber, a dry scrubber
  • the scrubber 128 is loaded with a caustic material (e.g., NaOH, KOH) that reacts with the HC1 to form water and a salt. While illustrated as a separate component in FIG. 1, in other embodiments, the scrubber 128 is integrated as a component of the microwave reactor 106.
  • the microwave reactor 106 is also communicatively coupled to the controller 112 to provide measurements and settings related to the operational parameters of the microwave reactor 106 to the controller 112, and to receive control signals from the controller 112 to modify the operational parameters of the micro wave reactor 106.
  • the controller 112 may be communicatively coupled to the impeller 126 to provide control signals to ensure that the mixing rate is within a predefined range.
  • the controller 112 may be communicatively coupled to one or more sensors 130 that are disposed within (or operably coupled to) the reaction chamber 122 and provide measurements related to the temperature, pressure, pH, or other relevant conditions within the reaction chamber 122.
  • the controller 112 is communicatively coupled to a caustic consumption sensor 132 of the scrubber 128 that measures when and how fast the caustic material is being consumed by HC1 being released from the reaction chamber 122 during the hydrolytic dechlorination reaction.
  • the controller 112 is also communicatively coupled to the microwave source 124 of the microwave reactor to provide control signals to activate the microwave source 124 to begin the hydrolytic dechlorination process for a batch of MPW 102, and to deactivate the microwave source 124 to conclude the hydrolytic dechlorination process for the batch of MPW 102.
  • the controller 112 may additionally provide control signals to activate and deactivate the microwave source 124 throughout the hydrolytic dechlorination process in accordance with a predefined duty cycle.
  • the controller 112 provides control signals to activate and deactivate the microwave source 124 based on the monitored operational parameters of the microwave reactor, such as the temperature within the reaction chamber 122, the pressure within the reaction chamber 122, an amount of time that has elapsed since activating the microwave source 124 to begin hydrolytic dechlorination process for a batch of MPW, a consumption rate of the caustic material of the scrubber 128, or any combination thereof.
  • the controller 112 may selectively activate and deactivate the micro wave source 124 during the hydrolytic dechlorination process to ensure that the temperature within the reaction chamber 122 remains below 250 °C, such as between 100 °C and 240 °C, between 130 °C and 230 °C, between 150 °C and 220 °C, or at a particular target temperature (e.g., 220 °C ⁇ 10%, 220 °C ⁇ 5%).
  • a particular target temperature e.g., 220 °C ⁇ 10%, 220 °C ⁇ 5%.
  • the controller 112 may selectively activate and deactivate the microwave source 124 during the hydrolytic dechlorination process to ensure that the pressure within the reaction chamber remains above 1 bar and below 25 bar, such as between 2 bar and 24 bar, between 3 bar and 23 bar, between 15 bar and 22 bar, between 18 bar and 21 bar, or at a particular target pressure (e.g., 20 bar ⁇ 10%, 20 bar ⁇ 5%).
  • a particular target pressure e.g., 20 bar ⁇ 10%, 20 bar ⁇ 5%.
  • the processor 114 of the controller 112 determines that a predetermined amount of time (e.g., 30 minutes, between 1 and 10 minutes) has elapsed since the microwave source 124 was activated at the beginning of a hydrolytic dechlorination process for a batch of MPW, and in response, deactivates the microwave source 124. In some embodiments, the processor 114 of the controller 112 deactivates the micro wave source 124 to conclude the hydrolytic dechlorination process for a batch of MPW in response to determining that the caustic consumption rate of the scrubber 128 has dropped below a predefined threshold value (e.g., below 1 milligram of caustic material per second or per minute).
  • a predetermined amount of time e.g., 30 minutes, between 1 and 10 minutes
  • the processor 114 of the controller 112 deactivates the micro wave source 124 to conclude the hydrolytic dechlorination process for a batch of MPW in response to determining that the pH of the water present in the reaction chamber is no longer decreasing due to formation of hydrochloric acid (HC1 aq.) from the HC1 gas generated by the hydrolytic dechlorination process.
  • the operational parameters of the microwave reactor 106 are manually set and adjusted by a human operator.
  • the solid HD-MPW 108 and an aqueous phase are removed from the reaction chamber 122.
  • the HD-MPW 108 contains substantially less chloride content than the MPW 102.
  • the chloride content of the HD-MPW 108 is at least 50% below, at least 60% below, at least 70% below, at least 75% below, at least 80% below, at least 85% below, or at least 90% below, or between 75% and 95% below the chloride content of the MPW 102. It is further presently recognized that, unlike other reactions dechlorination reactions, the disclosed hydrolytic dechlorination process specifically results in alkyl chlorides being converted into alkyl alcohols.
  • hydrodechlorination reaction also known as dehydrochlorination reaction
  • an alkyl chloride loses both a proton and a chloride group to form an alkene (also known as an olefin).
  • the disclosed hydrolytic dechlorination process requires the presence of the aqueous fluid 110 to form a nucleophilic hydroxide species (-OH), which performs a substitution reaction to displace chloride from the alkyl chloride structure, resulting in the alkyl alcohol, as illustrated in Scheme 1.
  • -OH nucleophilic hydroxide species
  • the presence of the alkyl alcohols in the HD- MPW 108 desirably decreases the rate of coke formation within the pyrolysis reactor compared to the olefin products of other dechlorination processes.
  • the HD- MPW 108 may be washed with water to remove HC1 entrained in the HD-MPW 108.
  • the aqueous fluid 110 extracted from the reaction chamber 122 at the conclusion of the hydrolytic dechlorination process may contain HC1 (aq.) and/or chloride salts (e.g., sodium chloride (NaCl), potassium chloride (KC1), monoethanolamino chloride, diethylethanolamino chloride, or combinations thereof) formed from at least a portion of the chloride liberated from the MPW 102.
  • chloride salts e.g., sodium chloride (NaCl), potassium chloride (KC1), monoethanolamino chloride, diethylethanolamino chloride, or combinations thereof
  • the remaining aqueous fluid 110 and/or the wash water is suitably neutralized using acid and/or base and disposed.
  • the remaining aqueous fluid 110 and/or the wash water is delivered to a purification unit having one or more water purification stages (e.g., activated carbon stages, ion-exchange resin stages) to suitably remove the HC1 aq. and/or chloride salts from these fluids, and the purified water can be recycled to form at least a portion of the aqueous fluid 110 for a subsequent hydrolytic dechlorination process, desirably reducing water consumption of the microwave reactor 106 and the pyrolysis oil production system 100.
  • water purification stages e.g., activated carbon stages, ion-exchange resin stages
  • the pyrolysis oil production system 100 includes an extruder 134 that is coupled to the reaction chamber 122 of the microwave reactor 106.
  • the extruder 134 is designed to remove the HD-MPW 108 from the reaction chamber 122, extrude the HD-MPW 108, and deliver the extruded HD-MPW 108 to a pyrolysis reactor 136 of the pyrolysis oil production system 100.
  • the extruder 134 is communicatively coupled to the controller 112 to receive control signals to activate and deactivate the extruder 134 for each batch of the HD-MPW 108, and to modify operational parameters (e.g., an extrusion rate, extruder screw speed, extruder screw pressure, air gap) of the extruder 134.
  • operational parameters e.g., an extrusion rate, extruder screw speed, extruder screw pressure, air gap
  • the operational parameters of the extruder 134 are manually set and adjusted by a human operator.
  • the pyrolysis reactor 136 is designed to receive the HD-MPW 108 from the extruder 134 and to pyrolyze the HD-MPW 108 at temperatures ranging from 400 °C to 500 °C under anaerobic conditions to yield pyrolysis oil 104 having a low chloride content.
  • the chloride content of the pyrolysis oil 104 is at least 50% below, at least 60% below, at least 70% below, at least 75% below, at least
  • the chloride content of the pyrolysis oil 104 is less than 10 parts-per- million by weight (ppmw), less than 100 ppmw, or between 1 ppmw and 10 ppmw.
  • the lower chloride content of the HD-MPW 108 desirably reduces or eliminates the formation of HC1 and the associated corrosion issues within the pyrolysis reactor 136.
  • the additional alkyl alcohols within the HD-MPW 108 desirably reduces the rate of coke formation within the pyrolysis reactor, enabling the pyrolysis reactor 136 to operate for long periods of time without being taken offline for decoking.
  • the pyrolysis reactor 136 is communicatively coupled to the controller 112 to receive control signals to activate and deactivate pyrolysis reactor 136 for each batch of the extruded HD-MPW 108, and to modify operational parameters (e.g., pyrolysis temperature, heating rate, hold time) of the pyrolysis reactor 136.
  • the operational parameters of the pyrolysis reactor 136 are manually set and adjusted by a human operator.
  • the resulting pyrolysis oil 104 may then advance to a refinery or a steam cracker system for further processing, wherein the lower chloride content reduces or eliminates the formation of HC1 and the associated corrosion issues.
  • both the reaction chamber 122 of the microwave reactor 106 and the pyrolysis reactor 136 of the pyrolysis oil production system 100 perform their respective hydrolytic dechlorination and pyrolysis functions under anerobic conditions. This may be achieved in different ways in various embodiments.
  • the MPW 102 and the aqueous fluid 110 are degassed to remove dissolved or adsorbed atmospheric oxygen before being introduced into the reaction chamber 122.
  • the MPW 102 is maintained in an inert atmosphere (e.g., a nitrogen (N2) atmosphere) within the reaction chamber 122 of the microwave reactor 106, and the HD-MPW 108 remains under the inert atmosphere as it traverses the extruder 134 to reach the pyrolysis reactor 136, ensuring anerobic conditions throughout the pyrolysis oil production system 100.
  • the MPW 102 and/or the HD-MPW 108 is only under anerobic and/or inert atmosphere within the reaction chamber 122 of the microwave reactor 106 and the pyrolysis reactor 136.
  • the MPW 102 is not pre-heated and the microwave source 124 provides all the activation energy to drive the hydrolytic dechlorination reaction.
  • one or more microwave-enhancing additives such as silica (SiOx), alumina (AkOy), silicon carbide (SiC), boron carbide (BxC), and/or carbonaceous materials (e.g., coke, carbon black), may be mixed with the MPW 102 and the aqueous fluid 110 within the reaction chamber 122 to increase the hydrolytic dechlorination rate and/or reduce the power or duty cycle of the microwave source for the hydrolytic dechlorination reaction.
  • the reaction mixture within the reaction chamber 122 may be free of such microwave-enhancing additives, which can reduce the complexity and the operational cost of the pyrolysis oil production system 100, while also reducing the possibility of these additives undesirably being carried over into the pyrolysis oil 104.
  • the HD- MPW 108 is generally not sorted to separate out different types of plastic, or portions of the HD- MPW 108 that were more or less effectively dechlorinated, which reduces the complexity, reduces the operational cost, and increases the pyrolysis oil yield of the pyrolysis oil production system 100.
  • FIG. 2 is a diagrammatic representation of another embodiment of a pyrolysis oil production system 200, which continuously converts a stream of MPW 202 into a stream of pyrolysis oil 204 having a reduced chloride content.
  • the embodiment of the pyrolysis oil production system 100 of FIG. 1 enables batch-mode operation, in which batches of MPW 102 are converted into batches of HD-MPW 108 that are subsequently converted into batches of pyrolysis oil 104.
  • the pyrolysis oil production system 200 of FIG. 2 includes a micro wave extruder 206 (e.g., a micro wave-based hydrolytic dechlorination reactor) having a reach on/extrusion chamber 222 that is operably coupled to a microwave source 224 (e.g., a cavity magnetron).
  • a micro wave extruder 206 e.g., a micro wave-based hydrolytic dechlorination reactor
  • a microwave source 224 e.g., a cavity magnetron
  • the reach on/extrusion chamber 222 receives the stream of the MPW 202 and the stream of the aqueous fluid 210, and the microwave extruder 206 simultaneously extrudes and irradiates the MPW 202 with microwaves from the microwave source 224 under anerobic conditions to motivate a hydrolytic dechlorination of the MPW 202, yielding a stream of HD-MPW 208 having reduced chloride content.
  • the stream of MPW 202 and the stream of aqueous fluid 210 may be combined outside of the microwave extruder 206 to form a slurry or suspension that is subsequently delivered to the reach on/extrusion chamber 222 of the microwave extruder 206.
  • the aqueous fluid specifically includes steam.
  • the pyrolysis oil production system 200 includes a controller 212 that is communicatively coupled to various components of the pyrolysis oil production system 200 to receive monitoring data and to provide control signals to control operation of the system, as discussed above.
  • the controller 212 includes at least one processor 214 and at least one memory 216.
  • the controller 212 can be communicatively coupled to provide control signals to a flow control valve 218 to control the flow rate of the stream of aqueous fluid 210 into the microwave reactor 106, and can be communicatively coupled to provide control signals to a delivery device 220 (e.g., an extruder, a conveyor belt, a hopper) to control the stream of MPW 202 into the micro wave extruder 206.
  • a delivery device 220 e.g., an extruder, a conveyor belt, a hopper
  • the reaction/extrusion chamber 222 of the microwave extruder 206 includes extrusion elements 234 (e.g., one or more screws) that extrude the MPW 202 and aqueous fluid 210.
  • the extrusion elements 234 mix the MPW 202 and the aqueous fluid 210 together and break apart polymer aggregates during the hydrolytic dechlorination reaction. Since the extrusion elements 234 of the microwave extruder 206 are exposed to microwave irradiation during operation, the extrusion elements 234 do not include metal, and can instead be made from a ceramic material in certain embodiments.
  • the reaction/extrusion chamber 222 is fluidly coupled to a scrubber 228, as discussed above.
  • the micro wave reactor 106 is also communicatively coupled to the controller 212 to provide measurements and settings related to the operational parameters of the microwave extruder 206 to the controller 212, and to receive control signals from the controller 212 to modify the operational parameters of the microwave extruder 206.
  • the controller 212 may be communicatively coupled to a motor that drives the extrusion elements 234 to provide control signals to ensure that the extrusion parameters (e.g., an extrusion rate, extruder screw speed, extruder screw pressure, air gap) are within predefined ranges.
  • the controller 212 may be communicatively coupled to one or more sensors 230 that are disposed within (or operably coupled to) the reaction/extrusion chamber 222 and provide measurements related to the temperature, pressure, pH, and so forth, within the reaction/extrusion chamber 222.
  • the controller 212 is communicatively coupled to a caustic consumption sensor 232 of the scrubber 228 that measures when and how fast caustic material of the scrubber 228 is being consumed by HC1 being released from the reaction/ extrusion chamber 222 during the hydrolytic dechlorination reaction.
  • the controller 212 may also be communicatively coupled to the microwave source 224 of the microwave extruder 206 to provide control signals to activate and deactivate the microwave source 224 throughout the hydrolytic dechlorination process.
  • the controller 212 provides control signals to activate and deactivate the microwave source 224 based on the monitored operational parameters of the micro wave reactor, such as the temperature within the reaction/extrusion chamber 222, the pressure within the reaction/extrusion chamber 222, an extrusion rate of the extrusion elements 234 of the microwave extruder 206, an amount of time that has elapsed since activating the microwave source 224, a consumption rate of the caustic material of the scrubber 228, or any combination thereof.
  • the monitored operational parameters of the micro wave reactor such as the temperature within the reaction/extrusion chamber 222, the pressure within the reaction/extrusion chamber 222, an extrusion rate of the extrusion elements 234 of the microwave extruder 206, an amount of time that has elapsed since activating the microwave source 224, a consumption rate of the caustic material of the scrubber 228, or any combination thereof.
  • the controller 212 may selectively activate and deactivate the microwave source 224 during the hydrolytic dechlorination process to ensure that the temperature within the reaction/extrusion chamber 222 remains below 250 °C, such as between 100 °C and 240 °C, between 130 °C and 230 °C, between 150 °C and 220 °C, or at a particular target temperature (e.g., 220 °C ⁇ 10%, 220 °C ⁇ 5%).
  • a particular target temperature e.g., 220 °C ⁇ 10%, 220 °C ⁇ 5%.
  • the controller 212 may selectively activate and deactivate the microwave source 224 during the hydrolytic dechlorination process to ensure that the pressure within the reaction/extrusion chamber 222 remains above 1 bar and below 25 bar, such as between 2 bar and 24 bar, between 3 bar and 23 bar, between 15 bar and 22 bar, between 18 bar and 21 bar, or at a particular target pressure (e.g., 20 bar ⁇ 10%, 20 bar ⁇ 5%).
  • a particular target pressure e.g., 20 bar ⁇ 10%, 20 bar ⁇ 5%.
  • the controller 212 can provide control signals to modify the extrusion rate of the microwave extruder 206 and/or the duty cycle of the microwave source 224 to ensure that the stream of MPW 202 experiences a consistent duration of exposure to the microwave irradiation (e.g., consistent contact time), such that the resulting stream of HD- MPW 208 demonstrates a consistent reduction in the amount of chloride content.
  • the processor 214 of the controller 212 can provide control signals to modify the extrusion rate of the micro wave extruder 206 and/or the duty cycle of the micro wave source 224 in response to determining that the caustic consumption rate of the scrubber 228 has dropped below a predefined threshold value (e.g., below 1 milligram of caustic material per second or per minute).
  • the processor 214 of the controller 212 can provide control signals to modify the extrusion rate of the microwave extruder 206 and/or the duty cycle of the micro wave source 224 in response to determining that the pH of the water present in the reaction/extrusion chamber 222 is no longer decreasing due to formation of HC1 aq.
  • microwave extruder 206 and/or other components of the pyrolysis oil production system 200 are monitored by a human operator, and certain processing steps can be manually performed or triggered by the human operator.
  • the stream of extruded HD-MPW 208 and the aqueous phase exit the reaction/extrusion chamber 222.
  • the stream of HD-MPW 208 is washed with water to remove adsorbed HC1 and/or HC1 aq.
  • the aqueous phase and/or wash water is purified and recycled for form at least part of the aqueous fluid, as discussed above.
  • the stream of extruded HD-MPW 208 is directed into the pyrolysis reactor 236, which pyrolyzes the HD-MPW 208, as set forth above.
  • the lower chloride content of the HD-MPW 208 desirably reduces or eliminates the formation of HC1 and the associated 1 corrosion issues within the pyrolysis reactor 236. Additionally, as noted, and it is believed that the additional alkyl alcohols within the HD-MPW 208 desirably reduces the rate of coke formation within the pyrolysis reactor, enabling the pyrolysis reactor 236 to operate for extended periods of time without being taken offline for decoking. In some embodiments, the resulting pyrolysis oil 204 may then advance to a refinery or a steam cracker system for further processing, wherein the lower chloride content reduces or eliminates the formation of HC1 and the associated corrosion issues with that equipment.
  • FIG. 3 is a diagrammatic representation of an embodiment of a process 300 in which a chloride-containing plastic (e.g., MPW 102, 202; PVC) is hydrolytically dechlorinated and then pyrolyzed to yield pyrolysis oil with a lower chloride content, relative to the chloride content of pyrolysis oil formed directly from the chloride-containing plastic without hydrolytic dechlorination.
  • a chloride-containing plastic e.g., MPW 102, 202; PVC
  • FIG. 3 is discussed with reference to elements illustrated in FIGS. 1 and 2.
  • the process 300 of FIG. 3 can be performed using the embodiment of the batch-mode pyrolysis oil production system 100 illustrated in FIG. 1 or using the embodiment of the continuous-mode pyrolysis oil production system 200 illustrated in FIG. 2.
  • the process 300 is implemented as computer-executable instructions stored in the memory 116 and executed by the processor 114 of controller 112 of FIG. 1, or stored in the memory 216 and executed by the processor 214 of controller 212 of FIG. 2, wherein the steps of the process 300 are performed in response to control signals provided to the various components of the pyrolysis oil production system 100, 200. In other embodiments, one or more of the steps of the process 300 may be triggered or performed manually by a human operator.
  • the process 300 begins with the step 302 of supplying the chloride-containing plastic and an aqueous fluid (e.g., aqueous fluid 110, 210) to an internal chamber of a micro wave reactor.
  • the controller 112, 212 executes stored instructions to provide suitable control signals to the delivery device 120, 220 and/or the flow control valve 118, 218 to cause the chloride-containing plastic and the aqueous fluid to be delivered to an internal chamber (e.g., the reaction chamber 122, the reach on/extrusion chamber 222) of a hydrolytic dechlorination reactor (e.g., the microwave reactor 106, the microwave extruder 206).
  • a hydrolytic dechlorination reactor e.g., the microwave reactor 106, the microwave extruder 206.
  • the chloride- containing plastic and the aqueous fluid are supplied to the reaction chamber 122 of the microwave reactor 106 in batches, while a stream of the chloride- containing plastic and a stream the aqueous fluid are continuously supplied to the reach on/extrusion chamber 222 of the micro wave extruder 206 for the embodiment of the pyrolysis oil production system 200 illustrated in FIG. 2.
  • the process 300 continues with the step 304 of irradiating, using a microwave source of the hydrolytic dechlorination reactor, the chloride- containing plastic and the aqueous fluid to facilitate a hydrolytic dechlorination of the chloride- containing plastic to yield hydrolytically dechlorinated plastic.
  • the controller 112, 212 executes stored instructions to provide suitable control signals to activate the microwave source 124 of the microwave reactor 106 of FIG. 1, or the microwave source 224 of the microwave extruder 206 of the FIG. 2, to drive the hydrolytic dechlorination reaction.
  • the controller 112, 212 may provide control signals to conditionally activate and deactivate the microwave source 124, 224 to maintain the parameters (e.g., temperature, pressure, pH, reaction time) of the hydrolytic dechlorination reaction within predefined ranges.
  • the controller 112, 212 may additionally or alternatively provide control signals to other components of the hydrolytic dechlorination reactor 106, 206, such as the impeller 126 illustrated in FIG. 1 and the extrusion elements 234 illustrated in FIG. 2, to maintain the parameters of the hydrolytic dechlorination reaction within predefined ranges.
  • the process 300 continues with the step 306 of supplying the hydrolytically dechlorinated plastic to a pyrolysis reactor.
  • the controller 112 can provide control signals to activate the extruder 134 to extract the HD-MPW 108 from the reaction chamber 122 of the microwave reactor 106 and transfer it to the pyrolysis reactor 136.
  • the controller 212 can provide control signals to activate the extrusion elements 234 throughout the hydrolytic dechlorination reaction to continuously transfer the stream of HD-MPW 208 from the reach on/extrusion chamber 222 of the micro wave extruder 206 to the pyrolysis reactor 236.
  • the hydrolytically dechlorinated plastic is maintained under anerobic conditions (e.g., inert atmosphere, oxygen-free atmosphere) as it is transferred to the pyrolysis reactor 136, 236.
  • the process 300 concludes with the step 308 of pyrolyzing the hydrolytically dechlorinated plastic in the pyrolysis reactor to produce pyrolysis oil.
  • the pyrolysis oil 104, 204 includes substantially less chloride content as a result of the hydrolytic dechlorination reaction, which reduces or eliminates the formation of corrosive HC1, as well as additional organochloride species, within the pyrolysis reactor 136, 236 when pyrolyzing the HD-MPW 108, 208.
  • the lower chloride content of the pyrolysis oil limits or eliminates corrosion of refinery equipment that typically results from HC1 being released as the pyrolysis oil is heated during the refinement process.
  • the pyrolysis oil 104, 204 is subsequently processed by a steam cracker to convert hydrocarbons in the pyrolysis oil into smaller hydrocarbons (e.g., olefins, such as ethylene and propylene), the lower chloride content of the pyrolysis oil limits or eliminates corrosion of the steam cracker that typically results from HC1 being released as the pyrolysis oil is heated during the steam cracking process.
  • a steam cracker to convert hydrocarbons in the pyrolysis oil into smaller hydrocarbons (e.g., olefins, such as ethylene and propylene)
  • the lower chloride content of the pyrolysis oil limits or eliminates corrosion of the steam cracker that typically results from HC1 being released as the pyrolysis oil is heated during the steam cracking process.
  • the pyrolysis oil 104, 204 is subsequently combusted as fuel in an engine (e.g., an internal combustion engine, a gas turbine engine)
  • the lower chloride content of the pyrolysis oil limits or eliminates corrosion of engine components (e.g., combustion chambers, pistons, seals) that typically results from HC1 being released as the pyrolysis oil is combusted, while also limiting or eliminating chloride-containing exhaust gases from the exhaust of the engine.
  • a set of batch hydrolytic dechlorination experiments were performed using an embodiment of the microwave reactor 106 illustrated in FIG. 1, as presented in Table 1.
  • the chloride-containing plastic was either PVC or MPW
  • the aqueous fluid was either demineralized water or a solution with 6000 part-per-million-by-weight (ppmw) NaOH in demineralized water.
  • Demineralized water was used for these experiments to prevent the introduction of chloride salts (e.g., NaCl) into the reaction mixture.
  • the micro wave source of the microwave reactor was a 300 W micro wave source, and the mixture of the aqueous fluid and the chloride-containing plastic was irradiated for 30 minutes to a maximum temperature of 220 °C at a pressure of 20.5 bar.
  • the plastic was analyzed by X-ray fluorescence (XRF), and the resulting chloride signal was compared to that of the chloride- containing plastic prior to the hydrolytic dechlorination process.
  • the hydrolysis rate ranged from 76% to 92%. It is believed that increasing the reaction time, increasing the power of the microwave source, decreasing the batch size, and/or implementing one or more water washing steps after the reaction will further increase the hydrolysis rate (e.g., up to 95%, up to 99%, up to

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Abstract

L'invention concerne des procédés et des systèmes destinés à effectuer une déchloration hydrolytique induite par micro-ondes de plastique contenant du chlorure, avant que le plastique déchloré de manière hydrolytique ne soit ensuite pyrolysé pour former de l'huile de pyrolyse présentant une faible teneur en chlorure. Un tel procédé comprend les étapes consistant à fournir un plastique contenant du chlorure et un fluide aqueux à une chambre interne d'un réacteur à micro-ondes, le fluide aqueux contenant de la vapeur, de l'eau liquide, une solution aqueuse, ou toute combinaison de celles-ci. Les étapes consistent en outre à irradier, au moyen d'une source de micro-ondes du réacteur à micro-ondes, le plastique contenant du chlorure et le fluide aqueux pour une déchloration hydrolytique du plastique contenant du chlorure et produire du plastique déchloré de manière hydrolytique. Dans certaines mises en œuvre, les étapes consistent en outre à fournir le plastique déchloré de manière hydrolytique à un réacteur de pyrolyse, et à pyrolyser le plastique déchloré de manière hydrolytique dans le réacteur de pyrolyse pour produire de l'huile de pyrolyse.
PCT/IB2024/061107 2023-11-08 2024-11-08 Systèmes et procédés de déchloration hydrolytique par micro-ondes de déchets plastiques mélangés Pending WO2025099672A1 (fr)

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US20220168702A1 (en) * 2019-04-05 2022-06-02 Pyrowave Inc. Microwave pyrolysis reactor
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US20230117658A1 (en) * 2020-02-10 2023-04-20 Eastman Chemical Company Compositions from the chemical recycling of plastic-derived streams and uses thereof
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OSADA FUMIO ET AL: "Dechlorination of polyvinyl chloride in NaOH/ethylene glycol solution by microwave heating", JOURNAL OF MATERIAL CYCLES AND WASTE MANAGEMENT, SPRINGER JAPAN, TOKYO, vol. 11, no. 1, 1 January 2009 (2009-01-01), pages 19 - 22, XP037109743, ISSN: 1438-4957, [retrieved on 20090212], DOI: 10.1007/S10163-008-0213-5 *
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