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WO2025208005A1 - Compositions d'hydrocarbures issues de la pyrolyse de plastiques post-consommation et/ou post-industriels et leurs procédés de production et d'utilisation - Google Patents

Compositions d'hydrocarbures issues de la pyrolyse de plastiques post-consommation et/ou post-industriels et leurs procédés de production et d'utilisation

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Publication number
WO2025208005A1
WO2025208005A1 PCT/US2025/021974 US2025021974W WO2025208005A1 WO 2025208005 A1 WO2025208005 A1 WO 2025208005A1 US 2025021974 W US2025021974 W US 2025021974W WO 2025208005 A1 WO2025208005 A1 WO 2025208005A1
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WO
WIPO (PCT)
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ppmv
gas
content
total
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
PCT/US2025/021974
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English (en)
Inventor
Jeffrey W. Gold
Connor Cudney
Sarah Engelhardt
Steven Adams
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Nexus Circular LLC
Original Assignee
Nexus Circular LLC
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Nexus Circular LLC filed Critical Nexus Circular LLC
Publication of WO2025208005A1 publication Critical patent/WO2025208005A1/fr
Pending legal-status Critical Current
Anticipated expiration legal-status Critical

Links

Classifications

    • 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
    • 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
    • C10G1/002—Production of liquid hydrocarbon mixtures from oil-shale, oil-sand, or non-melting solid carbonaceous or similar materials, e.g. wood, coal in combination with oil conversion- or refining 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
    • C10G11/00—Catalytic cracking, in the absence of hydrogen, of hydrocarbon oils
    • 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
    • C10G31/00—Refining of hydrocarbon oils, in the absence of hydrogen, by methods not otherwise provided for
    • C10G31/09—Refining of hydrocarbon oils, in the absence of hydrogen, by methods not otherwise provided for by filtration
    • 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
    • C10G45/00—Refining of hydrocarbon oils using hydrogen or hydrogen-generating compounds
    • C10G45/02—Refining of hydrocarbon oils using hydrogen or hydrogen-generating compounds to eliminate hetero atoms without changing the skeleton of the hydrocarbon involved and without cracking into lower boiling hydrocarbons; Hydrofinishing
    • 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
    • C10G50/00—Production of liquid hydrocarbon mixtures from lower carbon number hydrocarbons, e.g. by oligomerisation
    • 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
    • C10G9/00—Thermal non-catalytic cracking, in the absence of hydrogen, of hydrocarbon oils
    • 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
    • C10G2300/00—Aspects relating to hydrocarbon processing covered by groups C10G1/00 - C10G99/00
    • C10G2300/20—Characteristics of the feedstock or the products
    • C10G2300/201—Impurities
    • C10G2300/202—Heteroatoms content, i.e. S, N, O, P
    • 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
    • C10G2300/00—Aspects relating to hydrocarbon processing covered by groups C10G1/00 - C10G99/00
    • C10G2300/20—Characteristics of the feedstock or the products
    • C10G2300/201—Impurities
    • C10G2300/205—Metal content
    • 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
    • C10G2400/00—Products obtained by processes covered by groups C10G9/00 - C10G69/14
    • C10G2400/02—Gasoline
    • 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
    • C10G2400/00—Products obtained by processes covered by groups C10G9/00 - C10G69/14
    • C10G2400/08—Jet fuel
    • 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
    • C10G2400/00—Products obtained by processes covered by groups C10G9/00 - C10G69/14
    • C10G2400/10—Lubricating oil

Definitions

  • the disclosed subject matter relates to hydrocarbon based compositions derived from pyrolysis of a feedstock comprising post-consumer and/or post-industrial plastics and methods of making and use thereof.
  • a gas derived from pyrolysis of a feedstock comprising post-consumer and/or post-industrial plastics comprising post-consumer and/or post-industrial plastics.
  • the gas is produced at an industrial scale.
  • the gas comprises a mixture of different hydrocarbons, any of which can optionally be substituted, wherein 70% or more of the mixture (w/w) comprises Ci-Ce hydrocarbons.
  • the gas has: a total chloride content of 40,000 ppmv or less; a total bromide content of 2000 ppmv or less; a metalloids content of 500 ppmv or less; a total sulfur content of 5000 ppmv or less; an oxygenates content of 4000 ppmv or less; an atmospheric gas content of 30 mol% or less; or a combination thereof.
  • 80% or more or 90% or more of the mixture (w/w) comprises Ci-Ce hydrocarbons. In some examples, from 70% to 100% of the mixture (w/w) comprises Ci-Ce hydrocarbons.
  • 70% or more, 80% or more, or 90% or more of the mixture (w/w) comprises C1-C5 hydrocarbons. In some examples, from 70% to 100% of the mixture (w/w) comprises C1-C5 hydrocarbons. In some examples, 70% or more, 80% or more, or 90% or more of the mixture (w/w) comprises C2-C5 hydrocarbons. In some examples, from 70% to 100% of the mixture (w/w) comprises C2-C5 hydrocarbons.
  • the mixture (w/w) comprises C3-C5 hydrocarbons. In some examples, from 60% to 100% of the mixture (w/w) comprises C3-C5 hydrocarbons.
  • the mixture (w/w) comprises C1-C4 hydrocarbons. In some examples, from 60% to 100% of the mixture (w/w) comprises C1-C4 hydrocarbons.
  • the mixture comprises: 0-10% (e.g., 3-8%, 4-6%) Ci hydrocarbons, 5- 20% (e.g., 8-14%) C2 hydrocarbons, 10-45% (e.g., 20-35%) C3 hydrocarbons, and 20-45% (e.g., 20-30%) C4 hydrocarbons. In some examples, the mixture comprises: 0-10% Ci hydrocarbons, 20-50% C2 hydrocarbons, 20-50% C3 hydrocarbons, and 5-20% C4 hydrocarbons.
  • the mixture is substantially free hydrocarbons comprising 9 or more carbons. In some examples, the mixture is substantially free hydrocarbons comprising 8 or more carbons. In some examples, the mixture is substantially free hydrocarbons comprising 7 or more carbons. In some examples, the mixture is substantially free hydrocarbons comprising 6 or more carbons. In some examples, the mixture is substantially free of hydrocarbons comprising only 1 carbon. In some examples, the mixture is substantially free of hydrocarbons comprising 2 or less carbons.
  • the mixture comprises: 10 - 90 wt.% saturated hydrocarbons; 10 - 90 wt.% unsaturated (non-aromatic) hydrocarbons; and 0 - 2.5 wt.% (e.g., 0-0.5 wt.%) aromatic hydrocarbons.
  • the mixture comprises: 30 - 80 wt.% (e.g., 40-55 wt.%) saturated hydrocarbons; 20 - 70 wt.% (e.g., 25-45 wt.%) unsaturated (non-aromatic) hydrocarbons; and 0 - 2.5 wt.% (e.g., 0-0.5 wt.%) aromatic hydrocarbons.
  • the mixture comprises: 10 - 20 wt.% saturated hydrocarbons; 80 - 90 wt.% unsaturated (non- aromatic) hydrocarbons; and 0 - 2.5 wt.% (e.g., 0-0.5 wt.%) aromatic hydrocarbons. In some examples, the mixture is substantially free of aromatic hydrocarbons.
  • the gas has a number average molecular weight and/or a weight average molecular weight of from 15 to 75 Daltons. In some examples, the gas has a number average molecular weight and/or a weight average molecular weight of from 40 to 50 Daltons. In some examples, the gas has a number average molecular weight and/or a weight average molecular weight of from 30 to 45 Daltons.
  • the gas comprises 30 wt.% or less contaminants (e.g., 20 wt.% or less, 10 wt.% or less, 5 wt.% or less, or 1 wt.% or less), for example as determined using gas chromatography (GC).
  • contaminants e.g., 20 wt.% or less, 10 wt.% or less, 5 wt.% or less, or 1 wt.% or less
  • GC gas chromatography
  • the gas has a total chloride content of 40,000 ppmv or less (e.g., 20,000 ppmv or less; 10,000 ppmv or less; 5,000 ppmv or less; 1000 ppmv or less; 500 ppmv or less; 250 ppmv or less; 100 ppmv or less, 50 ppmv or less, 25 ppmv or less, 10 ppmv or less, 5 ppmv or less, 1 ppmv or less, 0.1 ppmv or less, or 0.01 ppmv or less), for example as determined using gas chromatography (GC).
  • GC gas chromatography
  • the gas has a total bromide content of 2000 ppmv or less (e.g., 1000 ppmv or less, 500 ppmv or less, 250 ppmv or less, 100 ppmv or less, 50 ppmv or less, 25 ppmv or less, 10 ppmv or less, 5 ppmv or less, 1 ppm or less, 0.1 ppm or less, or 0.01 ppm or less), for example as determined using gas chromatography (GC).
  • 2000 ppmv or less e.g., 1000 ppmv or less, 500 ppmv or less, 250 ppmv or less, 100 ppmv or less, 50 ppmv or less, 25 ppmv or less, 10 ppmv or less, 5 ppmv or less, 1 ppm or less, 0.1 ppm or less, or 0.01 ppm or less
  • GC gas chromatography
  • the gas has a metalloids content of 500 ppmv or less (e.g., 250 ppmv or less, 150 ppmv or less, 100 ppmv or less, 50 ppmv or less, 25 ppmv or less, 10 ppmv or less, 5 ppmv or less, 1 ppmv or less, 0.1 ppmv or less, or 0.01 ppmv or less), for examples, as determined using gas chromatography (GC).
  • ppmv or less e.g., 250 ppmv or less, 150 ppmv or less, 100 ppmv or less, 50 ppmv or less, 25 ppmv or less, 10 ppmv or less, 5 ppmv or less, 1 ppmv or less, 0.1 ppmv or less, or 0.01 ppmv or less
  • GC gas chromatography
  • the gas has a sulfur content of 5000 ppmv or less (e.g., 2500 ppmv or less, 2000 ppmv or less, 1000 ppmv or less, 500 ppmv or less, 100 ppmv or less, 10 ppmv or less, 5 ppmv or less, 2 ppm or less, 1 ppm or less, 0. 1 ppm or less, or 0.01 ppm or less), for example as determined using gas chromatography (GC).
  • GC gas chromatography
  • the gas has a total oxygenate (e.g., hydrocarbons substituted with an oxygen group) content of 1500 ppmv or less (e.g., 750 ppmv or less, 500 ppmv or less, 100 ppmv or less, 50 ppmv or less, 25 ppmv or less, 10 ppmv or less, 5 ppmv or less, 1 ppmv or less, 0.1 ppmv or less, or 0.01 ppmv or less), for example as determined using gas chromatography (GC).
  • ppmv or less e.g., 750 ppmv or less, 500 ppmv or less, 100 ppmv or less, 50 ppmv or less, 25 ppmv or less, 10 ppmv or less, 5 ppmv or less, 1 ppmv or less, 0.1 ppmv or less, or 0.01 ppmv or less
  • GC gas chromatography
  • the gas comprises 30 mol% or less (e.g., 20 mol% or less, 10 mol% or less, 5 mol% or less, or 1 mol% or less) atmospherics (e.g., N2, H2, CO2, CO, He, O2, O3, Ar, Ne, or a combination thereof), for example as determined using gas chromatography (GC).
  • mol% or less e.g., 20 mol% or less, 10 mol% or less, 5 mol% or less, or 1 mol% or less
  • atmospherics e.g., N2, H2, CO2, CO, He, O2, O3, Ar, Ne, or a combination thereof
  • GC gas chromatography
  • the gas has: a total chloride content of 40,000 ppmv or less; a metalloids content of 500 ppmv or less; an oxygenates content of 4000 ppmv or less; or a combination thereof. In some examples, the gas has: a total chloride content of 40,000 ppmv or less; a total bromide content of 2000 ppmv or less; a metalloids content of 500 ppmv or less; an oxygenates content of 4000 ppmv or less; or a combination thereof.
  • the gas has: a total chloride content of 40,000 ppmv or less; a metalloids content of 500 ppmv or less; a total sulfur content of 5000 ppmv or less; an oxygenates content of 4000 ppmv or less; or a combination thereof.
  • the gas has: a total chloride content of 40,000 ppmv or less; a total bromide content of 2000 ppmv or less; a metalloids content of 500 ppmv or less; a total sulfur content of 5000 ppmv or less; an oxygenates content of 4000 ppmv or less; or a combination thereof.
  • the gas has: a total chloride content of 40,000 ppmv or less; a metalloids content of 500 ppmv or less; and an oxygenates content of 4000 ppmv or less.
  • the gas has: a total chloride content of 40,000 ppmv or less; a total bromide content of 2000 ppmv or less; a metalloids content of 500 ppmv or less; and an oxygenates content of 4000 ppmv or less.
  • the gas has: a total chloride content of 40,000 ppmv or less; a metalloids content of 500 ppmv or less; a total sulfur content of 5000 ppmv or less; and an oxygenates content of 4000 ppmv or less.
  • the gas has: a total chloride content of 40,000 ppmv or less; a total bromide content of 2000 ppmv or less; a metalloids content of 500 ppmv or less; a total sulfur content of 5000 ppmv or less; and an oxygenates content of 4000 ppmv or less.
  • the gas has: a total chloride content of 40,000 ppmv or less; a total bromide content of 2000 ppmv or less; a metalloids content of 500 ppmv or less; a total sulfur content of 5000 ppmv or less; an oxygenates content of 4000 ppmv or less; and an atmospheric gas content of 30 mol% or less.
  • the gas has: a total chloride content of 20,000 ppmv or less; a metalloids content of 150 ppmv or less; an oxygenates content of 2000 ppmv or less; or a combination thereof. In some examples, the gas has: a total chloride content of 20,000 ppmv or less; a total bromide content of 1000 ppmv or less; a metalloids content of 150 ppmv or less; an oxygenates content of 2000 ppmv or less; or a combination thereof.
  • the gas has: a total chloride content of 20,000 ppmv or less; a metalloids content of 150 ppmv or less; a total sulfur content of 2500 ppmv or less; an oxygenates content of 2000 ppmv or less; or a combination thereof.
  • the gas has: a total chloride content of 20,000 ppmv or less; a total bromide content of 1000 ppmv or less; a metalloids content of 150 ppmv or less; a total sulfur content of 2500 ppmv or less; an oxygenates content of 2000 ppmv or less; or a combination thereof.
  • the gas has: a total chloride content of 20,000 ppmv or less; a total bromide content of 1000 ppmv or less; a metalloids content of 150 ppmv or less; a total sulfur content of 2500 ppmv or less; an oxygenates content of 2000 ppmv or less; an atmospheric gas content of 15 mol% or less; or a combination thereof.
  • the gas has: a total chloride content of 20,000 ppmv or less; a metalloids content of 150 ppmv or less; and an oxygenates content of 2000 ppmv or less.
  • the gas has: a total chloride content of 20,000 ppmv or less; a total bromide content of 1000 ppmv or less; a metalloids content of 150 ppmv or less; and an oxygenates content of 2000 ppmv or less.
  • the gas has: a total chloride content of 20,000 ppmv or less; a metalloids content of 150 ppmv or less; a total sulfur content of 2500 ppmv or less; and an oxygenates content of 2000 ppmv or less.
  • the gas has: a total chloride content of 20,000 ppmv or less; a total bromide content of 1000 ppmv or less; a metalloids content of 150 ppmv or less; a total sulfur content of 2500 ppmv or less; and an oxygenates content of 2000 ppmv or less.
  • the gas has: a total chloride content of 20,000 ppmv or less; a total bromide content of 1000 ppmv or less; a metalloids content of 150 ppmv or less; a total sulfur content of 2500 ppmv or less; an oxygenates content of 2000 ppmv or less; and an atmospheric gas content of 15 mol% or less.
  • the gas has: a total chloride content of 4,000 ppmv or less; a metalloids content of 250 ppmv or less; an oxygenates content of 3000 ppmv or less; or a combination thereof. In some examples, wherein the gas has: a total chloride content of 4,000 ppmv or less; a total bromide content of 200 ppmv or less; a metalloids content of 250 ppmv or less; an oxygenates content of 3000 ppmv or less; or a combination thereof.
  • the gas has: a total chloride content of 400 ppmv or less; a metalloids content of 25 ppmv or less; an oxygenates content of 2500 ppmv or less; or a combination thereof. In some examples, the gas has: a total chloride content of 400 ppmv or less; a total bromide content of 100 ppmv or less; a metalloids content of 25 ppmv or less; an oxygenates content of 2500 ppmv or less; or a combination thereof.
  • the gas has: a total chloride content of 400 ppmv or less; a total bromide content of 100 ppmv or less; a metalloids content of 25 ppmv or less; a total sulfur content of 2000 ppmv or less; an oxygenates content of 2500 ppmv or less; or a combination thereof.
  • the gas has: a total chloride content of 400 ppmv or less; a total bromide content of 100 ppmv or less; a metalloids content of 25 ppmv or less; a total sulfur content of 2000 ppmv or less; and an oxygenates content of 2500 ppmv or less.
  • the gas has: a total chloride content of 40 ppmv or less; a metalloids content of 2.5 ppmv or less; an oxygenates content of 2000 ppmv or less; or a combination thereof. In some examples, the gas has: a total chloride content of 40 ppmv or less; a total bromide content of 10 ppmv or less; a metalloids content of 2.5 ppmv or less; an oxygenates content of 2000 ppmv or less; or a combination thereof.
  • the gas has: a total chloride content of 40 ppmv or less; a total bromide content of 10 ppmv or less; a metalloids content of 2.5 ppmv or less; a total sulfur content of 200 ppmv or less; an oxygenates content of 2000 ppmv or less; or a combination thereof.
  • the gas has: a total chloride content of 40 ppmv or less; a total bromide content of 10 ppmv or less; a metalloids content of 2.5 ppmv or less; a total sulfur content of 200 ppmv or less; and an oxygenates content of 2000 ppmv or less.
  • the gas has: a total chloride content of 20 ppmv or less; a metalloids content of 1 ppmv or less; an oxygenates content of 1800 ppmv or less; or a combination thereof. In some examples, the gas has: a total chloride content of 20 ppmv or less; a total bromide content of 1 ppmv or less; a metalloids content of 1 ppmv or less; an oxygenates content of 1800 ppmv or less; or a combination thereof.
  • the gas has: a total chloride content of 20 ppmv or less; a total bromide content of 1 ppmv or less; a metalloids content of 1 ppmv or less; a total sulfur content of 20 ppmv or less; an oxygenates content of 1800 ppmv or less; or a combination thereof.
  • the gas has: a total chloride content of 20 ppmv or less; a total bromide content of 1 ppmv or less; a metalloids content of I ppmv or less; a total sulfur content of 20 ppmv or less; and an oxygenates content of 1800 ppmv or less.
  • the gas is produced via pyrolysis in a volume of from 1,000 to 200,000,000 pounds per 5 to 90 days.
  • the pyrolysis includes a catalyst.
  • the method produces the gas at a yield of 5% or more, 10% or more, 25% or more, 50% or more, 60% or more, or 75% or more.
  • the gas is produced by pyrolysis and further includes hydrotreatment or further refining steps after pyrolysis.
  • the post-consumer and/or post-industrial plastics comprise polyethylene (e.g., LDPE, LLDPE, HDPE), polypropylene, polystyrene, or a combination thereof.
  • polyethylene e.g., LDPE, LLDPE, HDPE
  • polypropylene e.g., polypropylene, polystyrene, or a combination thereof.
  • the feedstock comprises 90% or more (e.g., 93% or more) by weight of polyethylene, polypropylene, polystyrene, or a combination thereof. In some examples, the feedstock comprises moisture at an amount of 20% or less (e.g., 10% or less, 15% or less, 5% or less, or 3% or less) by weight.
  • the feedstock comprises 10% or less (e.g., 5% or less, 2.5% or less, or 1% or less) by weight polyvinyl chloride (PVC), polyvinylidene chloride (PVDC), polyethylene terephthalate (PET), nylon, ethylene vinyl alcohol (EVOH), polycarbonate (PC), acrylonitrile butadiene styrene (ABS), rubber, thermosets, or a combination thereof.
  • the feedstock comprises 15% by weight or less (e.g., 10% by weight or less, 5% by weight or less, or 3% by weight or less) non-plastic materials such as metal, glass, wood, cotton, paper, cardboard, dirt, inorganics, etc.
  • the feedstock comprises films, such as single and/or multi-layered films.
  • the feedstock includes plastics with a plastic type classification # 2, 4, 5, 6, or a combination thereof.
  • the method further comprises one or more stages of cooling and/or compression.
  • the method further comprises one or more stages of cooling and/or condensation.
  • the method further comprises one or more post-treatment and/or contaminant removal stages.
  • the method further comprises fractionation.
  • compositions comprising any of the gases disclosed herein, the product of any of the methods disclosed herein, or a combination thereof.
  • articles of manufacture comprising any of the gases disclosed herein, the product of any of the methods disclosed herein, or a combination thereof.
  • compositions derived from any of the gases disclosed herein, the product of any of the methods disclosed herein, or a combination thereof are also disclosed herein. Also disclosed herein are methods of making said compositions. In some examples, the method comprises additional processing of the composition, such as refining, filtering, cracking, hydro treating, etc. in the production of chemicals and/or polymers.
  • the composition derived from any of the gases disclosed herein comprises a second gas.
  • the second gas has: a total chloride content of 40,000 ppmv or less; a total bromide content of 2000 ppmv or less; a metalloids content of 500 ppmv or less; a total sulfur content of 5000 ppmv or less; or a combination thereof.
  • the second gas has a higher total chloride content, total bromide content, metalloids content, total sulfur content, or a combination thereof, than the gas from which it was derived.
  • the second gas has a higher oxygenates and/or atmospherics content than the gas from which it was derived.
  • the second gas has an oxygenates content of 100,000 ppmv or less. In some examples, the second gas has an atmospheric gas content of 100 mol% or less. In some examples, the composition is derived via the methods further comprising one or more stages of cooling and/or compression, one or more stages of cooling and/or condensation, one or more post-treatment and/or contaminant removal stages, fractionation, or a combination thereof.
  • the composition comprises a lubricating oil, a mineral oil, a group III base oil, a fully refined paraffin wax, or a combination thereof.
  • the composition comprises a binder, a processing aid, or a combination thereof.
  • the composition comprises kerosene including cosmetic kerosene, white oils, high value paraffin and purified liquid fuels, or a combination thereof.
  • the composition comprises naphtha.
  • the composition comprises fuel.
  • the composition comprises liquefied petroleum gas (LPG), naphtha, kerosene, diesel and gas oil, or a combination thereof.
  • the composition comprises lube oil, gasoline, jet fuel, diesel fuel, or a combination thereof.
  • the article comprises packaging, film, and/or fibers for carpets and clothing, molded articles, and extruded pipes, or a combination thereof.
  • the article comprises a medical device.
  • the article comprises lubricant, candles, adhesives, packaging, rubber, cosmetics, fire logs, bituminous mixtures, superficial wear coatings, asphalt, sealing coatings, or a combination thereof.
  • the composition or article comprises asphalt, automotive fuel, aviation fuels, base oil, bitumen, cadalene, cutting fluid, diesel fuel, fuel oil, gasoline, heating oil, heavy fuel oil, hydrocarbon solvents, jet fuel, kerosene, ligroin, lubricant, mazut, microcrystalline wax, mineral oil, motor fuel, motor oil, naphtha, naphthenic acid, paraffin wax, petroleum benzine, petroleum ether, petroleum jelly, petroleum naphtha, petroleum resin, retene, or a combination thereof.
  • the composition or article comprises gasoline, jet fuel, diesel and other fuels, asphalt, heavy fuel oil, lubricants, paraffin wax, tar, asphalt, fertilizer, flooring, perfume, insecticide, petroleum jelly, soap, vitamin, amino acid, or a combination thereof.
  • the composition or article comprises wood-based composites such as oriented- strand board (OSB), particleboard, hardboard, medium density fiberboard, gypsum board, or a combination thereof.
  • the composition or article comprises fully refined paraffin which is used to produce candles, cosmetics, crayons, food packaging, paper and carton coatings, or a combination thereof.
  • the composition or article comprises a hydrocarbon feedstock for a petroleum refinery, a catalytic cracking system, a thermal cracking system, a polymerization system, or a combination thereof, for example used in the production of chemicals and/or polymers.
  • the method comprises using the composition as a hydrocarbon feedstock for a petroleum refinery, a catalytic cracking system, a thermal cracking system, a polymerization system, or a combination thereof, for example used in the production of chemicals and/or polymers.
  • the method comprises: feeding the composition into a petroleum refinery, a catalytic cracking system, a thermal cracking system, a polymerization system, or a combination thereof; and using the composition as a hydrocarbon feedstock for said petroleum refinery, catalytic cracking system, thermal cracking system, polymerization system, or a combination thereof; for example to thereby produce chemicals and/or polymers.
  • Figure 1 Schematic diagram of an example system and/or method as disclosed herein according to one implementation.
  • Figure 2 Schematic diagram of an example system and/or method as disclosed herein according to one implementation.
  • FIG. 1 Schematic diagram of an example system and/or method as disclosed herein according to one implementation.
  • Figure 6 Schematic perspective side view of an example single-screw extruder with an electrically heated barrel.
  • Figure 7 Cross-sectional view of the example single-screw extruder of Figure 6.
  • Figure 8 Schematic perspective side view of an example dual-screw extruder with an electrically heated barrel.
  • Figure 10 Schematic perspective side view of an example single-screw extruder with a gas/flame heated barrel.
  • Figure 11 Schematic perspective side view of an example single-screw extruder with an oil heated barrel.
  • Figure 12 Schematic perspective side view of an example single-screw extruder with an electrically heated barrel and a single vent.
  • Figure 13 Schematic perspective side view of an example single-screw extruder with an electrically heated barrel and two vents.
  • Figure 14 Schematic perspective side view of an example single-screw extruder with an electrically heated barrel and four vents.
  • Figure 15 Schematic perspective side view of an example single-screw extruder with an electrically heated barrel, two vents, and a vent stuffer.
  • Figure 16 Schematic perspective front view of an example vent stuffer.
  • Figure 17 Schematic side view of an example rotary kiln reactor.
  • Figure 18 Schematic top view of the example rotary kiln reactor of Figure 17.
  • Figure 19 Schematic side view of an example screw reactor.
  • Figure 20 Schematic top view of the example screw reactor of Figure 19.
  • Figure 21 Schematic side view of an example fluidized bed reactor.
  • Figure 22 Schematic top view of the example fluidized bed reactor of Figure 21.
  • Figure 23 Schematic side view of an example batch reactor.
  • FIG. 25 Schematic side view of an example continuously stirred reactor with external gas heating.
  • Figure 29 Schematic side view of an example continuously stirred reactor with external electrical heating and internal electric heating.
  • Figure 31 Schematic side view of an example molten material reactor.
  • Figure 35 Schematic side view of an example screw reactor with a recycle loop.
  • Figure 37 Schematic side view of an example batch reactor with a recycle loop.
  • Figure 39 Schematic side view of an example continuously stirred reactor with external gas heating, internal electric heating, and a recycle loop.
  • Figure 40 Schematic side view of an example continuously stirred reactor with external electric heating, internal electric heating, and a recycle loop.
  • Figure 42 Schematic side view of an example supercritical water reactor with a recycle loop.
  • Figure 43 Schematic side view of an example supercritical water reactor with a recycle loop.
  • Figure 47 Schematic diagram of an example system and/or method, such as an example product recovery system and/or method, as disclosed herein according to one implementation.
  • Figure 48 Schematic diagram of an example system and/or method, such as an example product recovery system and/or method, as disclosed herein according to one implementation.
  • Figure 49 Schematic diagram of an example system and/or method, such as an example product recovery system and/or method, as disclosed herein according to one implementation.
  • Figure 50 Schematic diagram of an example system and/or method, such as an example product recovery system and/or method, as disclosed herein according to one implementation.
  • Figure 51 Schematic diagram of a thermal cracking system.
  • Figure 53 Schematic side view of an example dual vent extruder.
  • Figure 54 Schematic side view of an example single-screw extruder with an electrically heated barrel, two vents, and the dual vent extruder screw of Figure 53.
  • compositions, methods, and systems described herein may be understood more readily by reference to the following detailed description of specific aspects of the disclosed subject matter and the Examples included therein.
  • Ranges can be expressed herein as from “about” one particular value, and/or to “about” another particular value. By “about” is meant within 5% of the value, e.g., within 4, 3, 2, or 1% of the value. When such a range is expressed, another aspect includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms another aspect. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint, and independently of the other endpoint.
  • substantially is meant within 5%, e.g., within 4%, 3%, 2%, or 1%.
  • references in the specification and concluding claims to parts by weight of a particular element or component in a composition denotes the weight relationship between the element or component and any other elements or components in the composition or article for which a part by weight is expressed.
  • X and Y are present at a weight ratio of 2:5, and are present in such ratio regardless of whether additional components are contained in the compound.
  • organic moieties mentioned when defining variable positions within the general formulae described herein are collective terms for the individual substituents encompassed by the organic moiety.
  • the prefix C n -C m preceding a group or moiety indicates, in each case, the possible number of carbon atoms in the group or moiety that follows.
  • Methods for producing a charge in a molecule, portion of a molecule, cluster of molecules, molecular complex, moiety, or atom are disclosed herein and can be accomplished by methods known in the art, e.g., protonation, deprotonation, oxidation, reduction, alkylation, acetylation, esterification, de-esterification, hydrolysis, etc.
  • the term “substituted” is contemplated to include all permissible substituents of organic compounds.
  • the permissible substituents include acyclic and cyclic, branched and unbranched, carbocyclic and heterocyclic, and aromatic and nonaromatic substituents of organic compounds.
  • Illustrative substituents include, for example, those described below.
  • the permissible substituents can be one or more and the same or different for appropriate organic compounds.
  • the heteroatoms, such as nitrogen can have hydrogen substituents and/or any permissible substituents of organic compounds described herein which satisfy the valencies of the heteroatoms.
  • alkyl groups include methyl, ethyl, propyl, 1-methyl-ethyl, butyl, 1-methyl-propyl, 2-methyl- propyl, 1 , 1 -dimethyl-ethyl, pentyl, 1-methyl-butyl, 2-methyl-butyl, 3-methyl-butyl, 2,2- dimethyl-propyl, 1-ethyl-propyl, hexyl, 1 , 1 -dimethyl-propyl, 1 ,2-dimethyl-propyl, 1 -methylpentyl, 2-methyl-pentyl, 3-methyl-pentyl, 4-methyl-pentyl, 1 , 1 -dimethyl -butyl, 1 ,2-dimethyl-butyl, 1,3-dimethyl-butyl, 2,2-dimethyl-butyl, 2,3-dimethyl-butyl, 3,3-dimethyl-butyl, 1-ethyl- butyl, 2-ethyl
  • Alkyl substituents can be unsubstituted or substituted with one or more chemical moieties.
  • the alkyl group can be substituted with one or more groups including, but not limited to, hydroxyl, halogen, acyl, alkyl, alkoxy, alkenyl, alkynyl, aryl, heteroaryl, aldehyde, amino, cyano, carboxylic acid, ester, ether, ketone, nitro, phosphonyl, silyl, sulfo-oxo, sulfonyl, sulfone, sulfoxide, or thiol, as described below, provided that the substituents are sterically compatible and the rules of chemical bonding and strain energy are satisfied.
  • Examples include ethenyl, 1 -propenyl, 2-propenyl, 1 -methylethenyl, 1-butenyl, 2-butenyl, 3-butenyl, 1 -methyl- 1- propenyl, 2-methyl-l -propenyl, 1 -methyl-2-propenyl, 2-methyl-2-propenyl, 1 -pentenyl, 2- pentenyl, 3-pentenyl, 4-pentenyl, 1 -methyl- 1-butenyl, 2-methyl- 1-butenyl, 3-methyl- 1-butenyl, 1 -methyl-2-butenyl, 2-methyl-2-butenyl, 3-methyl-2-butenyl, l-methyl-3-butenyl, 2-methyl-3-butenyl, 3-methyl-3-butenyl, 1 , 1 -dimethyl-2-propenyl, 1 ,2-dimethyl- 1 -propenyl, 1 ,2-dimethyl-2- propenyl, 1
  • Alkenyl substituents can be unsubstituted or substituted with one or more chemical moieties.
  • alkynyl represents straight-chained or branched hydrocarbon moieties containing a triple bond.
  • C2-C24 e.g., C2-C24, C2-C20, C2- Ci8, C2-C16, C2-C14, C2-C12, C2-C10, C2-C8, C2-C6, or C2-C4 alkynyl groups are intended.
  • Alkynyl groups can contain more than one unsaturated bond.
  • Alkynyl substituents can be unsubstituted or substituted with one or more chemical moieties.
  • suitable substituents include, for example, alkyl, alkoxy, alkenyl, alkynyl, aryl, heteroaryl, acyl, aldehyde, amino, cyano, carboxylic acid, ester, ether, halide, hydroxyl, ketone, nitro, phosphonyl, silyl, sulfo-oxo, sulfonyl, sulfone, sulfoxide, or thiol, as described below.
  • aryl refers to groups that include a monovalent aromatic carbocyclic group of from 3 to 50 carbon atoms.
  • Aryl groups can include a single ring or multiple condensed rings.
  • aryl groups include Ce-Cio aryl groups. Examples of aryl groups include, but are not limited to, benzene, phenyl, biphenyl, naphthyl, tetrahydronaphthyl, phenylcyclopropyl, phenoxybenzene, and indanyl.
  • aryl also includes “heteroaryl,” which is defined as a group that contains an aromatic group that has at least one heteroatom incorporated within the ring of the aromatic group.
  • heteroatoms include, but are not limited to, nitrogen, oxygen, sulfur, and phosphorus.
  • non-heteroaryl which is also included in the term “aryl,” defines a group that contains an aromatic group that does not contain a heteroatom.
  • the aryl substituents can be unsubstituted or substituted with one or more chemical moieties.
  • substituents include, for example, alkyl, alkoxy, alkenyl, alkynyl, aryl, heteroaryl, acyl, aldehyde, amino, cyano, carboxylic acid, ester, ether, halide, hydroxyl, ketone, nitro, phosphonyl, silyl, sulfo-oxo, sulfonyl, sulfone, sulfoxide, or thiol as described herein.
  • biasryl is a specific type of aryl group and is included in the definition of aryl. Biaryl refers to two aryl groups that are bound together via a fused ring structure, as in naphthalene, or are attached via one or more carbon-carbon bonds, as in biphenyl.
  • the cycloalkyl group and heterocycloalkyl group can be substituted with one or more groups including, but not limited to, alkyl, alkoxy, alkenyl, alkynyl, aryl, heteroaryl, acyl, aldehyde, amino, cyano, carboxylic acid, ester, ether, halide, hydroxyl, ketone, nitro, phosphonyl, silyl, sulfo-oxo, sulfonyl, sulfone, sulfoxide, or thiol as described herein.
  • Examples of cycloalkenyl groups include, but are not limited to, cyclopropenyl, cyclobutenyl, cyclopentenyl, cyclopentadienyl, cyclohexenyl, cyclohexadienyl, and the like.
  • the cycloalkenyl group and heterocycloalkenyl group can be substituted with one or more groups including, but not limited to, alkyl, alkoxy, alkenyl, alkynyl, aryl, heteroaryl, acyl, aldehyde, amino, cyano, carboxylic acid, ester, ether, halide, hydroxyl, ketone, nitro, phosphonyl, silyl, sulfo-oxo, sulfonyl, sulfone, sulfoxide, or thiol as described herein.
  • cyclic group is used herein to refer to either aryl groups, non-aryl groups (i.e., cycloalkyl, heterocycloalkyl, cycloalkenyl, and heterocycloalkenyl groups), or both.
  • Cyclic groups have one or more ring systems (e.g., monocyclic, bicyclic, tricyclic, polycyclic, etc.) that can be substituted or unsubstituted.
  • a cyclic group can contain one or more aryl groups, one or more non-aryl groups, or one or more aryl groups and one or more non-aryl groups.
  • acyl as used herein is represented by the formula -C(O)Z ] where Z 1 can be a hydrogen, hydroxyl, alkoxy, alkyl, alkenyl, alkynyl, aryl, heteroaryl, cycloalkyl, cycloalkenyl, heterocycloalkyl, or heterocycloalkenyl group described above.
  • Z 1 can be a hydrogen, hydroxyl, alkoxy, alkyl, alkenyl, alkynyl, aryl, heteroaryl, cycloalkyl, cycloalkenyl, heterocycloalkyl, or heterocycloalkenyl group described above.
  • acyl can be used interchangeably with “carbonyl.”
  • alkanol as used herein is represented by the formula Z'OH, where Z 1 can be an alkyl, alkenyl, alkynyl, aryl, heteroaryl, cycloalkyl, cycloalkenyl, heterocycloalkyl, or heterocycloalkenyl group described above.
  • amino as used herein are represented by the formula — NZ'Z 2 Z 3 , where Z 1 , Z 2 , and Z 3 can each be substitution group as described herein, such as hydrogen, an alkyl, alkenyl, alkynyl, aryl, heteroaryl, cycloalkyl, cycloalkenyl, heterocycloalkyl, or heterocycloalkenyl group described above.
  • cyclic anhydride as used herein is represented by the formula: where Z 1 can be an alkyl, alkenyl, alkynyl, aryl, heteroaryl, cycloalkyl, cycloalkenyl, heterocycloalkyl, or heterocycloalkenyl group described above.
  • carboxylic acid as used herein is represented by the formula — C(O)OH.
  • cyano as used herein is represented by the formula — CN.
  • esters as used herein is represented by the formula — OC(O)Z ] or — C(C))C)Z , where Z 1 can be an alkyl, alkenyl, alkynyl, aryl, heteroaryl, cycloalkyl, cycloalkenyl, heterocycloalkyl, or heterocycloalkenyl group described above.
  • ether as used herein is represented by the formula Z'OZ 2 , where Z 1 and Z 2 can be, independently, an alkyl, alkenyl, alkynyl, aryl, heteroaryl, cycloalkyl, cycloalkenyl, heterocycloalkyl, or heterocycloalkenyl group described above.
  • epoxy refers to a cyclic ether with a three atom ring and can represented by the formula: where Z 1 , Z 2 , Z 3 , and Z 4 can be, independently, an alkyl, alkenyl, alkynyl, aryl, heteroaryl, cycloalkyl, cycloalkenyl, heterocycloalkyl, or heterocycloalkenyl group described above.
  • ketone as used herein is represented by the formula Z'C(O)Z 2 , where Z 1 and Z 2 can be, independently, an alkyl, alkenyl, alkynyl, aryl, heteroaryl, cycloalkyl, cycloalkenyl, heterocycloalkyl, or heterocycloalkenyl group described above.
  • halide or “halogen” or “halo” as used herein refers to fluorine, chlorine, bromine, and iodine.
  • hydroxyl as used herein is represented by the formula — OH.
  • nitro as used herein is represented by the formula — NO2.
  • phosphonyl is used herein to refer to the phospho-oxo group represented by the formula — P(O)(OZ 1 )2, where Z 1 can be hydrogen, an alkyl, alkenyl, alkynyl, aryl, heteroaryl, cycloalkyl, cycloalkenyl, heterocycloalkyl, or heterocycloalkenyl group described above.
  • sil as used herein is represented by the formula — SiZ'Z 2 Z 3 , where Z 1 , Z 2 , and Z 3 can be, independently, hydrogen, alkyl, alkoxy, alkenyl, alkynyl, aryl, heteroaryl, cycloalkyl, cycloalkenyl, heterocycloalkyl, or heterocycloalkenyl group described above.
  • an alkyl group comprising an amino group the amino group can be incorporated within the backbone of the alkyl group.
  • the amino group can be attached to the backbone of the alkyl group.
  • the nature of the group(s) that is (are) selected will determine if the first group is embedded or attached to the second group.
  • compositions such as Gases
  • Post-industrial or Pre-consumer plastics include materials derived from waste streams during a plastic manufacturing process.
  • Sources of post-consumer and/or post-industrial plastics include, but are not limited to, plastic resin producers; packaging converters; industrial, commercial, retail, and institutional facilities; households; and waste collectors.
  • gases derived from pyrolysis of a feedstock comprising post-consumer and/or post-industrial plastics are disclosed herein.
  • the gas can be produced via pyrolysis at an industrial scale.
  • the gas comprises hydrocarbons that are non-condensable at ambient temperature and ambient pressure.
  • the gas can have a number average molecular weight and/or a weight average molecular weight of 75 Daltons or less (e.g., 70 Daltons or less, 65 Daltons or less, 60 Daltons or less, 55 Daltons or less, 50 Daltons or less, 45 Daltons or less, 40 Daltons or less, 35 Daltons or less, 30 Daltons or less, 25 Daltons or less, or 20 Daltons or less).
  • the gas has a number average molecular weight and/or a weight average molecular weight of 50 Daltons or less.
  • the gas has a number average molecular weight and/or a weight average molecular weight of 45 Daltons or less.
  • Daltons from 25 to 75 Daltons, from 30 to 75 Daltons, from 35 to 75 Daltons, from 40 to 75
  • Daltons from 50 to 75 Daltons, from 55 to 75 Daltons, from 60 to 75 Daltons, from 20 to 70
  • Daltons from 25 to 65 Daltons, from 30 to 60 Daltons, from 30 to 45 Daltons, or from 40 to 50
  • the gas can have a number average molecular weight and/or a weight average molecular weight of from 40 to 50 Daltons. In some examples, the gas can have a number average molecular weight and/or a weight average molecular weight of from 30 to 45 Daltons.
  • the gas comprises a mixture of different hydrocarbons (e.g., linear, branched, cyclic, acyclic, saturated, unsaturated, aromatic, non-aromatic, etc.), any of which can optionally be substituted.
  • hydrocarbons e.g., linear, branched, cyclic, acyclic, saturated, unsaturated, aromatic, non-aromatic, etc.
  • the gas comprises a mixture of different hydrocarbons, any of which can optionally be substituted, and 70% or more of the mixture (w/w) comprises Ci-Q> hydrocarbons (e.g., 71% or more, 72% or more, 73% or more, 74% or more, 75% or more, 76% or more, 77% or more, 78% or more, 79% or more, 80% or more, 81% or more, 82% or more, 83% or more, 84% or more, 85% or more, 86% or more, 87% or more, 88% or more, 89% or more, 90% or more, 91% or more, 92% or more, 93% or more, 94% or more, 95% or more, 96% or more, 97% or more, 98% or more, or 99% or more).
  • Ci-Q> hydrocarbons e.g., 71% or more, 72% or more, 73% or more, 74% or more, 75% or more, 76% or more, 77% or more, 78% or more, 79% or more,
  • Ci-C 6 hydrocarbons can range from any of the minimum values described above to any of the maximum values described above.
  • the gas comprises a mixture of different hydrocarbons, any of which can optionally be substituted, and from 70% to 100% of the mixture (w/w) comprises Ci-Ce hydrocarbons (e.g., from 70% to 85%, from 85% to 100%, from 70% to 80%, from 80% to 90%, from 90% to 100%, from 70% to 95%, from 70% to 90%, from 75% to 100%, from 80% to 100%, from 75% to 95%, or from 80% to 90%).
  • Ci-Ce hydrocarbons e.g., from 70% to 85%, from 85% to 100%, from 70% to 80%, from 80% to 90%, from 90% to 100%, from 70% to 95%, from 70% to 90%, from 75% to 100%, from 80% to 100%, from 75% to 95%, or from 80% to 90%).
  • the gas comprises a mixture of different hydrocarbons, any of which can optionally be substituted, and 100% or less of the mixture (w/w) comprises C1-C5 hydrocarbons (e.g., 99% or less, 98% or less, 97% or less, 96% or less, 95% or less, 94% or less, 93% or less, 92% or less, 91% or less, 90% or less, 89% or less, 88% or less, 87% or less, 86% or less, 85% or less, 84% or less, 83% or less, 82% or less, 81% or less, 80% or less, 79% or less, 78% or less, 77% or less, 76% or less, 75% or less, 14% or less, 73% or less, 72% or less, or 71 % or less).
  • C1-C5 hydrocarbons e.g., 99% or less, 98% or less, 97% or less, 96% or less, 95% or less, 94% or less, 93% or less, 92% or less, 91%
  • the amount of the mixture comprising C1-C5 hydrocarbons can range from any of the minimum values described above to any of the maximum values described above.
  • the gas comprises a mixture of different hydrocarbons, any of which can optionally be substituted, and from 70% to 100% of the mixture (w/w) comprises C1-C5 hydrocarbons (e.g., from 70% to 85%, from 85% to 100%, from 70% to 80%, from 80% to 90%, from 90% to 100%, from 70% to 95%, from 70% to 90%, from 75% to 100%, from 80% to 100%, from 75% to 95%, or from 80% to 90%).
  • the gas comprises a mixture of different hydrocarbons, any of which can optionally be substituted, and 80% or more of the mixture (w/w) comprises C1-C5 hydrocarbons. In some examples, the gas comprises a mixture of different hydrocarbons, any of which can optionally be substituted, and from 80% to 100% of the mixture (w/w) comprises Ci- C5 hydrocarbons. In some examples, the gas comprises a mixture of different hydrocarbons, any of which can optionally be substituted, and 90% or more of the mixture (w/w) comprises C1-C5 hydrocarbons. In some examples, the gas comprises a mixture of different hydrocarbons, any of which can optionally be substituted, and from 90% to 100% of the mixture (w/w) comprises Ci- C5 hydrocarbons.
  • the gas comprises a mixture of different hydrocarbons, any of which can optionally be substituted, and 70% or more of the mixture (w/w) comprises C2-C5 hydrocarbons (e.g., 71% or more, 72% or more, 73% or more, 74% or more, 75% or more, 76% or more, 77% or more, 78% or more, 79% or more, 80% or more, 81% or more, 82% or more, 83% or more, 84% or more, 85% or more, 86% or more, 87% or more, 88% or more, 89% or more, 90% or more, 91% or more, 92% or more, 93% or more, 94% or more, 95% or more, 96% or more, 97% or more, 98% or more, or 99% or more).
  • C2-C5 hydrocarbons e.g., 71% or more, 72% or more, 73% or more, 74% or more, 75% or more, 76% or more, 77% or more, 78% or more, 79% or more,
  • the gas comprises a mixture of different hydrocarbons, any of which can optionally be substituted, and 100% or less of the mixture (w/w) comprises C2-C5 hydrocarbons (e.g., 99% or less, 98% or less, 97% or less, 96% or less, 95% or less, 94% or less, 93% or less, 92% or less, 91% or less, 90% or less, 89% or less, 88% or less, 87% or less, 86% or less, 85% or less, 84% or less, 83% or less, 82% or less, 81% or less, 80% or less, 79% or less, 78% or less, 77% or less, 76% or less, 75% or less, 74% or less, 73% or less, 72% or less, or 71% or less).
  • C2-C5 hydrocarbons e.g., 99% or less, 98% or less, 97% or less, 96% or less, 95% or less, 94% or less, 93% or less, 92% or less, 91% or less, 90%
  • the amount of the mixture comprising C2-C5 hydrocarbons can range from any of the minimum values described above to any of the maximum values described above.
  • the gas comprises a mixture of different hydrocarbons, any of which can optionally be substituted, and from 70% to 100% of the mixture (w/w) comprises C2-C5 hydrocarbons (e.g., from 70% to 85%, from 85% to 100%, from 70% to 80%, from 80% to 90%, from 90% to 100%, from 70% to 95%, from 70% to 90%, from 75% to 100%, from 80% to 100%, from 75% to 95%, or from 80% to 90%).
  • the gas comprises a mixture of different hydrocarbons, any of which can optionally be substituted, and 100% or less of the mixture (w/w) comprises C3-C5 hydrocarbons (e.g., 99% or less, 98% or less, 97% or less, 96% or less, 95% or less, 94% or less, 93% or less, 92% or less, 91% or less, 90% or less, 89% or less, 88% or less, 87% or less, 86% or less, 85% or less, 84% or less, 83% or less, 82% or less, 81% or less, 80% or less, 79% or less, 78% or less, 77% or less, 76% or less, 75% or less, 74% or less, 73% or less, 72% or less,
  • the amount of the mixture comprising C3-C5 hydrocarbons can range from any of the minimum values described above to any of the maximum values described above.
  • the gas comprises a mixture of different hydrocarbons, any of which can optionally be substituted, and from 60% to 100% of the mixture (w/w) comprises C3-C5 hydrocarbons (e.g., from 70% to 80%, from 80% to 100%, from 60% to 70%, from 70% to 80%, from 80% to 90%, from 90% to 100%, from 60% to 95%, from 60% to 90%, from 60% to 85%, from 60% to 75%, from 65% to 100%, from 70% to 100%, from 75% to 100%, from 80% to 100%, from 85% to 100%, from 65% to 95%, or from 70% to 90%).
  • C3-C5 hydrocarbons e.g., from 70% to 80%, from 80% to 100%, from 60% to 70%, from 70% to 80%, from 80% to 90%, from 90% to 100%, from 60% to 95%, from 60% to 90%, from 60% to 85%, from 60% to 75%, from 65% to 100%, from 70% to 100%, from 75% to 100%, from 80% to 100%, from 85% to 100%, from 65%
  • the gas comprises a mixture of different hydrocarbons, any of which can optionally be substituted, and 70% or more of the mixture (w/w) comprises C3-C5 hydrocarbons. In some examples, the gas comprises a mixture of different hydrocarbons, any of which can optionally be substituted, and from 70% to 100% of the mixture (w/w) comprises C3- C5 hydrocarbons. In some examples, the gas comprises a mixture of different hydrocarbons, any of which can optionally be substituted, and 80% or more of the mixture (w/w) comprises C3-C5 hydrocarbons.
  • the gas comprises a mixture of different hydrocarbons, any of which can optionally be substituted, and from 80% to 100% of the mixture (w/w) comprises C3- C5 hydrocarbons. In some examples, the gas comprises a mixture of different hydrocarbons, any of which can optionally be substituted, and 90% or more of the mixture (w/w) comprises C3-C5 hydrocarbons. In some examples, the gas comprises a mixture of different hydrocarbons, any of which can optionally be substituted, and from 90% to 100% of the mixture (w/w) comprises C3- C5 hydrocarbons.
  • the gas comprises a mixture of different hydrocarbons, any of which can optionally be substituted, and 60% or more of the mixture (w/w) comprises C1-C4 hydrocarbons (e.g., 61% or more, 62% or more, 63% or more, 64% or more, 65% or more, 66% or more, 67% or more, 68% or more, 69% or more, 70% or more, 71% or more, 72% or more, 73% or more, 74% or more, 75% or more, 76% or more, 77% or more, 78% or more, 79% or more, 80% or more, 81% or more, 82% or more, 83% or more, 84% or more, 85% or more, 86% or more, 87% or more, 88% or more, 89% or more, 90% or more, 91% or more, 92% or more, 93% or more, 94% or more, 95% or more, 96% or more, 97% or more, 98% or more, or 99% or more).
  • C1-C4 hydrocarbons
  • the gas comprises a mixture of different hydrocarbons, any of which can optionally be substituted, and 100% or less of the mixture (w/w) comprises C1-C4 hydrocarbons (e.g., 99% or less, 98% or less, 97% or less, 96% or less, 95% or less, 94% or less, 93% or less, 92% or less, 91% or less, 90% or less, 89% or less, 88% or less, 87% or less, 86% or less, 85% or less, 84% or less, 83% or less, 82% or less, 81% or less, 80% or less, 79% or less, 78% or less, 77% or less, 76% or less, 75% or less, 74% or less, 73% or less, 72% or less,
  • the amount of the mixture comprising C1-C4 hydrocarbons can range from any of the minimum values described above to any of the maximum values described above.
  • the gas comprises a mixture of different hydrocarbons, any of which can optionally be substituted, and from 60% to 100% of the mixture (w/w) comprises C1-C4 hydrocarbons (e.g., from 70% to 80%, from 80% to 100%, from 60% to 70%, from 70% to 80%, from 80% to 90%, from 90% to 100%, from 60% to 95%, from 60% to 90%, from 60% to 85%, from 60% to 75%, from 65% to 100%, from 70% to 100%, from 75% to 100%, from 80% to 100%, from 85% to 100%, from 65% to 95%, or from 70% to 90%).
  • C1-C4 hydrocarbons e.g., from 70% to 80%, from 80% to 100%, from 60% to 70%, from 70% to 80%, from 80% to 90%, from 90% to 100%, from 60% to 95%, from 60% to 90%, from 60% to 85%, from 60% to 75%, from 65% to 100%, from 70% to 100%, from 75% to 100%, from 80% to 100%, from 85% to 100%, from 65%
  • the gas comprises a mixture of different hydrocarbons, any of which can optionally be substituted, and 70% or more of the mixture (w/w) comprises C1-C4 hydrocarbons. In some examples, the gas comprises a mixture of different hydrocarbons, any of which can optionally be substituted, and from 70% to 100% of the mixture (w/w) comprises Ci- C4 hydrocarbons. In some examples, the gas comprises a mixture of different hydrocarbons, any of which can optionally be substituted, and 80% or more of the mixture (w/w) comprises C1-C4 hydrocarbons.
  • the gas comprises a mixture of different hydrocarbons, any of which can optionally be substituted, and from 80% to 100% of the mixture (w/w) comprises Ci- C4 hydrocarbons. In some examples, the gas comprises a mixture of different hydrocarbons, any of which can optionally be substituted, and 90% or more of the mixture (w/w) comprises C1-C4 hydrocarbons. In some examples, the gas comprises a mixture of different hydrocarbons, any of which can optionally be substituted, and from 90% to 100% of the mixture (w/w) comprises Ci- C4 hydrocarbons.
  • the gas comprises a mixture of different hydrocarbons, any of which can optionally be substituted, and 0% or more of the mixture (w/w) can comprise Ci hydrocarbons (e.g., 1% or more, 2% or more, 3% or more, 4% or more, 5% or more, 6% or more, 7% or more, 8% or more, or 9% or more).
  • Ci hydrocarbons e.g., 1% or more, 2% or more, 3% or more, 4% or more, 5% or more, 6% or more, 7% or more, 8% or more, or 9% or more.
  • the gas comprises a mixture of different hydrocarbons, any of which can optionally be substituted, and 10% or less of the mixture (w/w) can comprise Ci hydrocarbons (e.g., 9% or less, 8% or less, 7% or less, 6% or less, 5% or less, 4% or less, 3% or less, 2% or less, or 1% or less).
  • Ci hydrocarbons e.g., 9% or less, 8% or less, 7% or less, 6% or less, 5% or less, 4% or less, 3% or less, 2% or less, or 1% or less.
  • the amount of the mixture comprising Ci hydrocarbons can range from any of the minimum values described above to any of the maximum values described above.
  • the gas can comprise a mixture of different hydrocarbons, any of which can optionally be substituted, and from 0% to 10% of the mixture (w/w) can comprise Ci hydrocarbons (e.g., from 0% to 5%, from 5% to 10%, from 0% to 2%, from 2% to 4%, from 4% to 6%, from 6% to 8%, from 8% to 10%, from 0% to 8%, from 0% to 6%, from 0% to 4%, from 1% to 10%, from 2% to 10%, from 4% to 10%, from 6% to 10%, from 1% to 9%, or from 3% to 8%).
  • Ci hydrocarbons e.g., from 0% to 5%, from 5% to 10%, from 0% to 2%, from 2% to 4%, from 4% to 6%, from 6% to 8%, from 0% to 6%, from 0% to 4%, from 1% to 10%, from 2% to 10%, from 4% to 10%, from 6% to 10%, from 1% to 9%,
  • the gas can comprise a mixture of different hydrocarbons, any of which can optionally be substituted, and from 3% to 8% of the mixture (w/w) can comprise Ci hydrocarbons, the gas can comprise a mixture of different hydrocarbons, any of which can optionally be substituted, and from 4% to 6% of the mixture (w/w) can comprise Ci hydrocarbons.
  • the gas comprises a mixture of different hydrocarbons, any of which can optionally be substituted, and 50% or less of the mixture (w/w) can comprise C2 hydrocarbons (e.g., 49% or less, 48% or less, 47% or less, 46% or less, 45% or less, 44% or less, 43% or less, 42% or less, 41% or less, 40% or less, 39% or less, 38% or less, 37% or less, 36% or less, 35% or less, 34% or less, 33% or less, 32% or less, 31% or less, 30% or less, 29% or less, 28% or less, 27% or less, 26% or less, 25% or less, 24% or less, 23% or less, 22% or less, 21% or less, 20% or less, 19% or less, 18% or less, 17% or less, 16% or less, 15% or less, 14% or less, 13% or less, 12% or less, 11 % or less, 10% or less, 9% or less, 8% or less, %
  • the amount of the mixture comprising C2 hydrocarbons can range from any of the minimum values described above to any of the maximum values described above.
  • the gas can comprise a mixture of different hydrocarbons, any of which can optionally be substituted, and from 5% to 50% of the mixture (w/w) can comprise C2 hydrocarbons (e.g., from 5% to 25%, from 25% to 45%, from 5% to 15%, from 15% to 25%, from 25% to 35%, from 35% to 50%, from 5% to 45%, from 5% to 40%, from 5% to 35%, from 5% to 30%, from 5% to 20%, from 5% to 10%, from 10% to 50%, from 15% to 50%, from 20% to 50%, from 30% to 50%, from 40% to 50%, from 10% to 45%, or from 8% to 14%).
  • the gas can comprise a mixture of different hydrocarbons, any of which can optionally be substituted, and from 5% to 20% of the mixture (w/w) can comprise C2 hydrocarbons. In some examples, the gas can comprise a mixture of different hydrocarbons, any of which can optionally be substituted, and from 8% to 14% of the mixture (w/w) can comprise C2 hydrocarbons. In some examples, the gas can comprise a mixture of different hydrocarbons, any of which can optionally be substituted, and from 20% to 50% of the mixture (w/w) can comprise C2 hydrocarbons.
  • the gas comprises a mixture of different hydrocarbons, any of which can optionally be substituted, and 10% or more of the mixture (w/w) can comprise C3 hydrocarbons (e.g., 1 1% or more, 12% or more, 13% or more, 14% or more, 15% or more, 16% or more, 17% or more, 18% or more, 19% or more, 20% or more, 21% or more, 22% or more, 23% or more, 24% or more, 25% or more, 26% or more, 27% or more, 28% or more, 29% or more, 30% or more, 31% or more, 32% or more, 33% or more, 34% or more, 35% or more, 36% or more, 37% or more, 38% or more, 39% or more, 40% or more, 41% or more, 42% or more, 43% or more, 44% or more, 45% or more, 46% or more, 47% or more, 48% or more, or 49% or more).
  • C3 hydrocarbons e.g., 1
  • the gas comprises a mixture of different hydrocarbons, any of which can optionally be substituted, and 50% or less of the mixture (w/w) can comprise C3 hydrocarbons (e.g., 49% or less, 48% or less, 47% or less, 46% or less, 45% or less, 44% or less, 43% or less, 42% or less, 41% or less, 40% or less, 39% or less, 38% or less, 37% or less, 36% or less, 35% or less, 34% or less, 33% or less, 32% or less, 31% or less, 30% or less, 29% or less, 28% or less, 27% or less, 26% or less, 25% or less, 24% or less, 23% or less, 22% or less, 21 % or less, 20% or less, 19% or less, 18% or less, 17% or less, 16% or less, 15% or less, 14% or less, 13% or less, 12% or less, or 11 % or less).
  • C3 hydrocarbons e.g., 4
  • the amount of the mixture comprising C3 hydrocarbons can range from any of the minimum values described above to any of the maximum values described above.
  • the gas can comprise a mixture of different hydrocarbons, any of which can optionally be substituted, and from 10% to 50% of the mixture (w/w) can comprise C3 hydrocarbons (e.g., from 10% to 30%, from 30% to 50%, from 10% to 15%, from 15% to 20%, from 20% to 25%, from 25% to 30%, from 30% to 35%, from 35% to
  • the gas can comprise a mixture of different hydrocarbons, any of which can optionally be substituted, and from 20% to 50% of the mixture (w/w) can comprise C3 hydrocarbons. In some examples, the gas can comprise a mixture of different hydrocarbons, any of which can optionally be substituted, and from 20% to 35% of the mixture (w/w) can comprise C3 hydrocarbons.
  • the gas comprises a mixture of different hydrocarbons, any of which can optionally be substituted, and 5% or more of the mixture (w/w) can comprise C4 hydrocarbons (e.g., 6% or more, 7% or more, 8% or more, 9% or more, 10% or more, 11% or more, 12% or more, 13% or more, 14% or more, 15% or more, 16% or more, 17% or more, 18% or more, 19% or more, 20% or more, 21% or more, 22% or more, 23% or more, 24% or more, 25% or more, 26% or more, 27% or more, 28% or more, 29% or more, 30% or more, 31% or more, 32% or more, 33% or more, 34% or more, 35% or more, 36% or more, 37% or more, 38% or more, 39% or more, 40% or more, 41% or more, 42% or more, 43% or more, or 44% or more).
  • C4 hydrocarbons e.g., 6% or
  • the gas comprises a mixture of different hydrocarbons, any of which can optionally be substituted, and 45% or less of the mixture (w/w) can comprise C4 hydrocarbons (e.g., 44% or less, 43% or less, 42% or less, 41% or less, 40% or less, 39% or less, 38% or less, 37% or less, 36% or less, 35% or less, 34% or less, 33% or less, 32% or less, 31% or less, 30% or less, 29% or less, 28% or less, 27% or less, 26% or less, 25% or less, 24% or less, 23% or less, 22% or less, 21% or less, 20% or less, 19% or less, 18% or less, 17% or less, 16% or less, 15% or less, 14% or less, 13% or less, 12% or less, 1 1% or less, 10% or less, 9% or less, 8% or less, 7% or less, or 6% or less).
  • C4 hydrocarbons e.g., 44%
  • the amount of the mixture comprising C4 hydrocarbons can range from any of the minimum values described above to any of the maximum values described above.
  • the gas can comprise a mixture of different hydrocarbons, any of which can optionally be substituted, and from 5% to 45% of the mixture (w/w) can comprise C4 hydrocarbons (e.g., from 5% to 25%, from 25% to 45%, from 5% to 15%, from 15% to 25%, from 25% to 35%, from 35% to 45%, from 5% to 40%, from 5% to 35%, from 5% to 30%, from 5% to 20%, from 5% to 10%, from 10% to 45%, from 15% to 45%, from 20% to 45%, from 30% to 45%, from 35% to 45%, from 40% to 45%, from 10% to 40%, or from 9% to 14%).
  • the gas can comprise a mixture of different hydrocarbons, any of which can optionally be substituted, and from 5% to 20% of the mixture (w/w) can comprise C4 hydrocarbons. In some examples, the gas can comprise a mixture of different hydrocarbons, any of which can optionally be substituted, and from 20% to 45% of the mixture (w/w) can comprise C4 hydrocarbons. In some examples, the gas can comprise a mixture of different hydrocarbons, any of which can optionally be substituted, and from 20% to 30% of the mixture (w/w) can comprise C4 hydrocarbons.
  • the gas comprises a mixture of different hydrocarbons, any of which can optionally be substituted, and the mixture comprises: 0-10% (e.g., 3-8%, 4-6%) Ci hydrocarbons, 5-20% (e.g., 8-14%) C2 hydrocarbons, 10-45% (e.g., 20-35%) C3 hydrocarbons, and 20-45% (e.g., 20-30%) C4 hydrocarbons.
  • the gas comprises a mixture of different hydrocarbons, any of which can optionally be substituted, and the mixture comprises: 3-8% (e.g., 4-6%) Ci hydrocarbons, 8-14% C2 hydrocarbons, 20-35% C3 hydrocarbons, and 20- 30% C4 hydrocarbons.
  • the gas comprises a mixture of different hydrocarbons, any of which can optionally be substituted, and the mixture comprises: 4-6% Ci hydrocarbons, 8-14% C2 hydrocarbons, 20-35% C3 hydrocarbons, and 20-30% C4 hydrocarbons.
  • the gas comprises a mixture of different hydrocarbons, any of which can optionally be substituted, and the mixture comprises: 0-10% Ci hydrocarbons, 20-50% C2 hydrocarbons, 20-50% C3 hydrocarbons, and 5-20% C4 hydrocarbons.
  • the gas comprises a mixture of different hydrocarbons, any of which can optionally be substituted, and the mixture is substantially free of hydrocarbons comprising 9 or more carbons. In some examples, the gas comprises a mixture of different hydrocarbons, any of which can optionally be substituted, and the mixture is substantially free of hydrocarbons comprising 8 or more carbons. In some examples, the gas comprises a mixture of different hydrocarbons, any of which can optionally be substituted, and the mixture is substantially free of hydrocarbons comprising 7 or more carbons. In some examples, the gas comprises a mixture of different hydrocarbons, any of which can optionally be substituted, and the mixture is substantially free of hydrocarbons comprising 6 or more carbons.
  • the gas comprises a mixture of different hydrocarbons, any of which can optionally be substituted, and the mixture is substantially free of hydrocarbons comprising only 1 carbon. In some examples, the gas comprises a mixture of different hydrocarbons, any of which can optionally be substituted, and the mixture is substantially free of hydrocarbons comprising 2 or less carbons.
  • the gas comprises a mixture of different hydrocarbons, any of which can optionally be substituted, and the mixture comprises saturated hydrocarbons (e.g., linear, branched, and/or cyclic alkanes), unsaturated (non-aromatic) hydrocarbons (e.g., linear, branched, and/or cyclic alkenes and/or alkynes), and aromatic hydrocarbons.
  • saturated hydrocarbons e.g., linear, branched, and/or cyclic alkanes
  • unsaturated (non-aromatic) hydrocarbons e.g., linear, branched, and/or cyclic alkenes and/or alkynes
  • aromatic hydrocarbons e.g., aromatic hydrocarbons.
  • the gas comprises a mixture of different hydrocarbons, any of which can optionally be substituted, and the mixture comprises 10 wt.% or more saturated hydrocarbons (e.g., 15 wt.% or more, 20 wt.% or more, 25 wt.% or more, 30 wt.% or more, 35 wt.% or more, 40 wt.% or more, 45 wt.% or more, 50 wt.% or more, 55 wt.% or more, 60 wt.% or more, 65 wt.% or more, 70 wt.% or more, 75 wt.% or more, 80 wt.% or more, or 85 wt.% or more).
  • saturated hydrocarbons e.g., 15 wt.% or more, 20 wt.% or more, 25 wt.% or more, 30 wt.% or more, 35 wt.% or more, 40 wt.% or more, 45 wt.% or more
  • the gas comprises a mixture of different hydrocarbons, any of which can optionally be substituted, and the mixture comprises 90 wt.% or less saturated hydrocarbons (e.g., 85 wt.% or less, 80 wt.% or less, 75 wt.% or less, 70 wt.% or less, 65 wt.% or less, 60 wt.% or less, 55 wt.% or less, 50 wt.% or less, 45 wt.% or less, 40 wt.% or less, 35 wt.% or less, 30 wt.% or less, 25 wt.% or less, 20 wt.% or less, or 15 wt.% or less).
  • saturated hydrocarbons e.g. 85 wt.% or less, 80 wt.% or less, 75 wt.% or less, 70 wt.% or less, 65 wt.% or less, 60 wt.% or less, 55 wt.% or less,
  • the amount of the mixture comprising saturated hydrocarbons can range from any of the minimum values described above to any of the maximum values described above.
  • the gas can comprise a mixture of different hydrocarbons, any of which can optionally be substituted, and from 10 wt.% to 90 wt.% of the mixture can comprise saturated hydrocarbons (e.g., from 10 wt.% to 50 wt.%, from 50 wt.% to 90 wt.%, from 10 wt.% to 20 wt.%, from 20 wt.% to 30 wt.%, from 30 wt.% to 40 wt.%, from 40 wt.% to 50 wt.%, from 50 wt.% to 60 wt.%, from 60 wt.% to 70 wt.%, from 70 wt.% to 80 wt.%, from 80 wt.% to 90 wt.%, from 10 wt.% to 80 wt.%, from 10 w
  • the gas can comprise a mixture of different hydrocarbons, any of which can optionally be substituted, and from 30 wt.% to 80 wt.% of the mixture can comprise saturated hydrocarbons. In some examples, the gas can comprise a mixture of different hydrocarbons, any of which can optionally be substituted, and from 40 wt.% to 55 wt.% of the mixture can comprise saturated hydrocarbons. In some examples, the gas can comprise a mixture of different hydrocarbons, any of which can optionally be substituted, and from 10 wt.% to 20 wt.% of the mixture can comprise saturated hydrocarbons.
  • the gas comprises a mixture of different hydrocarbons, any of which can optionally be substituted, and the mixture comprises 10 wt.% or more unsaturated (nonaromatic) hydrocarbons (e.g. 15 wt.% or more, 25 wt.% or more, 30 wt.% or more, 35 wt.% or more, 40 wt.% or more, 45 wt.% or more, 50 wt.% or more, 55 wt.% or more, 60 wt.% or more, 65 wt.% or more, 70 wt.% or more, 75 wt.% or more, 80 wt.% or more, or 85 wt.% or more).
  • unsaturated (nonaromatic) hydrocarbons e.g. 15 wt.% or more, 25 wt.% or more, 30 wt.% or more, 35 wt.% or more, 40 wt.% or more, 45 wt.% or more, 50
  • the amount of the mixture comprising unsaturated (non-aromatic) hydrocarbons can range from any of the minimum values described above to any of the maximum values described above.
  • the gas can comprise a mixture of different hydrocarbons, any of which can optionally be substituted, and from 10 to 90 wt.% of the mixture can comprise unsaturated (non-aromatic) hydrocarbons (e.g., from 10 wt.% to 50 wt.%, from 50 wt.% to 90 wt.%, from 10 wt.% to 20 wt.%, from 20 wt.% to 30 wt.%, from 30 wt.% to 40 wt.%, from 40 wt.% to 50 wt.%, from 50 wt.% to 60 wt.%, from 60 wt.% to 70 wt.%, from 70 wt.% to 80 wt.%, from 80 wt.% to 90 wt.%, from 10 w
  • the gas can comprise a mixture of different hydrocarbons, any of which can optionally be substituted, and from 20 to 70 wt.% of the mixture can comprise unsaturated (non-aromatic) hydrocarbons. In some examples, the gas can comprise a mixture of different hydrocarbons, any of which can optionally be substituted, and from 25 to 45 wt.% of the mixture can comprise unsaturated (non-aromatic) hydrocarbons. In some examples, the gas can comprise a mixture of different hydrocarbons, any of which can optionally be substituted, and from 80 to 90 wt.% of the mixture can comprise unsaturated (non-aromatic) hydrocarbons.
  • the gas comprises a mixture of different hydrocarbons, any of which can optionally be substituted, and the mixture comprises 0 wt.% or more aromatic hydrocarbons (e.g., 0.1 wt.% or more, 0.2 wt.% or more, 0.3 wt.% or more, 0.4 wt.% or more, 0.5 wt.% or more, 0.6 wt.% or more, 0.7 wt.% or more, 0.8 wt.% or more, 0.9 wt.% or more, 1 wt.% or more, 1.25 wt.% or more, 1.5 wt.% or more, 1.75 wt.% or more, 2 wt.% or more, or 2.25 wt.% or more).
  • aromatic hydrocarbons e.g., 0.1 wt.% or more, 0.2 wt.% or more, 0.3 wt.% or more, 0.4 wt.% or more, 0.5 wt.% or more
  • the gas comprises a mixture of different hydrocarbons, any of which can optionally be substituted, and the mixture comprises 2.5 wt.% or less aromatic hydrocarbons (e.g., 2.25 wt.% or less, 2 wt.% or less, 1.75 wt.% or less, 1.5 wt.% or less, 1.25 wt.% or less, 1 wt.% or less, 0.9 wt.% or less, 0.8 wt.% or less, 0.7 wt.% or less, 0.6 wt.% or less, 0.5 wt.% or less, 0.4 wt.% or less, 0.3 wt.% or less, or 0.2 wt.% or less).
  • aromatic hydrocarbons e.g., 2.25 wt.% or less, 2 wt.% or less, 1.75 wt.% or less, 1.5 wt.% or less, 1.25 wt.% or less, 1 wt.% or less, 0.9
  • the amount of the mixture comprising aromatic hydrocarbons can range from any of the minimum values described above to any of the maximum values described above.
  • the gas can comprise a mixture of different hydrocarbons, any of which can optionally be substituted, and from 0 to 2.5 wt.% of the mixture can comprise aromatic hydrocarbons (e.g., from 0 to 1.25 wt.%, from 1.25 to 2.5 wt.%, from 0 to 0.5 wt.%, from 0.5 to 1 wt.%, from 1 to 1.5 wt.%, from 1.5 to 2 wt.%, from 2 to 2.5 wt.%, from 0 to 2 wt.%, from 0 to 1.5 wt.%, from 0 to 1 wt.%, from 0.5 to 2.5 wt.%, from 1 to 2.5 wt.%, from 1.5 to 2.5 wt.%, from 0.25 to 2.25 wt.%, or from 0.5 to 2 wt.%).
  • the gas can comprise a mixture of different hydrocarbons, any of which can optionally be substituted, and from 0 to 0.5 wt.% of the mixture can comprise aromatic hydrocarbons.
  • the gas can comprise a mixture of different hydrocarbons, any of which can optionally be substituted, and the mixture can be substantially free of aromatic hydrocarbons.
  • the gas comprises a mixture of different hydrocarbons, any of which can optionally be substituted, and the mixture comprises 10 - 90 wt.% saturated hydrocarbons; 10 - 90 wt.% unsaturated (non-aromatic) hydrocarbons; and 0 - 2.5 wt.% aromatic hydrocarbons.
  • the gas comprises a mixture of different hydrocarbons, any of which can optionally be substituted, and the mixture comprises 30 - 80 wt.% (e.g., 40-55 wt.%) saturated hydrocarbons; 20 - 70 wt.% (e.g., 25-45 wt.%) unsaturated (non-aromatic) hydrocarbons; and 0 - 2.5 wt.% (e.g., 0-0.5 wt.%) aromatic hydrocarbons.
  • the gas comprises a mixture of different hydrocarbons, any of which can optionally be substituted, and the mixture comprises 40-55 wt.% saturated hydrocarbons; 25-45 wt.% unsaturated (nonaromatic) hydrocarbons; and 0-0.5 wt.% aromatic hydrocarbons.
  • the gas comprises a mixture of different hydrocarbons, any of which can optionally be substituted, and the mixture comprises 10 - 20 wt.% saturated hydrocarbons; 80 - 90 wt.% unsaturated (non-aromatic) hydrocarbons; and 0 - 2.5 wt.% aromatic hydrocarbons.
  • the gas can include one or more contaminants.
  • Contaminants can, for example, comprise an alkali metal, an alkaline earth metal, a transition metal, a basic metal, a semimetal, a nonmetal, a halogen, a salt or compound thereof, an atmospheric gas, an oxygenate, or a combination thereof.
  • contaminants include, but are not limited to, hydrogen, helium, lithium, sodium, potassium, beryllium, magnesium, calcium, strontium, titanium, vanadium, manganese, iron, cobalt, nickel, copper, zinc, molybdenum, aluminum, titanium, silicon, tin, nitrogen, phosphorus, arsenic, antimony, oxygen, sulfur, selenium, fluorine, chlorine, bromine, compounds thereof, and combinations thereof.
  • the gas includes a contaminant comprising atmospherics, chloride, bromide, metalloids, sulfur (e.g., sulfur and/or compounds thereof), oxygenates (e.g., hydrocarbons substituted with an oxygen containing group), or a combination thereof.
  • Contaminants are introduced during plastic formulation and manufacturing processes during the first life of plastic in conjunction with the source and collection method of the plastics.
  • contaminants can be found in the gas as a result of the pyrolysis process itself.
  • Compounds such as carbon dioxide and carbon monoxide may not be present in the input feedstock materials or residue that can be attached to the plastics, but can form in the reactors during the pyrolysis (e.g., depolymerization) process as the longer chain molecules are broken down and elements of those materials recombine inside the reactor.
  • Elements like oxygen can be driven off its parent material and then recombine with other materials to form gas contaminants (such as CO ) under the heated conditions within the reactor environment.
  • Other contaminants such as nitrogen can be cleaved from a wide range of plastic products, and, due to its inert nature, can remain uncombined with other chemicals but rather enters the gas phase and becomes a contaminant to the exiting gas stream.
  • chloride sources in used plastics can comprise PVDC layers.
  • PVDC is often used as a layer or coating in food and pharmaceutical packaging applications because it provides excellent barrier properties against moisture, UV light, acids, salts, and detergents as well as having good transparency.
  • PVDC is forecasted to increase at 3.2% annually through 2028 in the US.
  • Packaging converters produce a range of monolayer and multi-layer packaging. Both types can become mixed in recycled streams.
  • Post-consumer sources will contain higher volumes of materials containing chloride sources that can be difficult to differentiate and remove through standard sorting techniques.
  • bromine compounds are widely used as flame retardants in plastics. These substances help reduce flammability hazards in a wide range of electronic and non-electronic devices and plastic items that can get hot during use, such as computers, televisions, and other electronic equipment and appliances along with coffee stirrers and thermos cups. Brominated flame retardants can also be added to everyday items like picture frames, toys, cosmetic jewelry, clothes hangers and holiday decorations.
  • Nitrogen sources in used plastics can, for example, be derived from depolymerization (e.g., pyrolysis) of nylon (e.g., Nylon 6 (PA-6), Nylon-66 (PA-66) in used plastic sources, often from food and industrial packaging materials.
  • nylon e.g., Nylon 6 (PA-6), Nylon-66 (PA-66) in used plastic sources, often from food and industrial packaging materials.
  • Nylon is used in multi-layer flexible packing films to protect oxygen-sensitive foods or when excellent oil and grease resistance and high mechanical strength are required, such as for processed meats and fish, and cheese and other dairy products.
  • Nylon also provides a wide cold to hot temperature range (e.g., -60°C to 150°C), which enables foods to move through freezer to the microwave/oven without packaging degradation.
  • nylon is often used as a reinforcing layer to provide high mechanical strength and excellent abrasion and puncture resistance (for example, in polypropylene supersacks that contain a nylon interlayer or straps).
  • Nitrogen can also come from protein (food) residue on plastics that arises from the amino acids in decomposed protein. Postconsumer sources will contain higher volumes of materials containing nitrogen sources that can be difficult to differentiate and remove through standard sorting techniques.
  • Silicon sources in used plastics can, for example, comprise silica desiccant packages.
  • silicon products are widely used as release agents in a wide variety of materials and equipment, leaving residue on plastic surfaces.
  • Silicon is also an additive that can be added to a wide range of materials to change the appearance, extrusion properties, and/or end-product characteristics; this applies to films as well as two-dimensional plastics.
  • Post-consumer sources will contain higher volumes of materials containing silicon sources that can be difficult to differentiate and remove through standard sorting techniques.
  • Silicon dioxide can be applied in a very thin coating to plastics, specifically polyethylene, polypropylene, and/or polystyrene, to act as a barrier layer to improve the shelf life of oxygen and moisture sensitive food.
  • This thin coating can be applied by a vacuum or plasma deposition process; the barrier layer and the plastic forms a covalent bond.
  • the S1O2 barrier coatings are chemically inert and enable benefits in rigid and flexible food packaging applications, including, but not limited to, reducing oxygen and moisture permeability of plastics, ensuring aroma protection and retention of the smell and taste of contents, not sensitive to fluctuations in temperature and humidity, well-suited for pasteurization and sterilization processes, and can increase shelf life of foods without the addition of preservatives.
  • the SiC coatings are thin, e.g. significantly thinner than a human hair, and therefore have a negligible impact on the packing weight. For this reason, coated packaging is considered a mono-material that can be mechanically recycled. Recyclability initiatives are promoting the use of SiO coatings as a replacement for PVDC and Nylon barriers in flexible and rigid packaging. Although these guidelines are intended for mechanically recycled plastics, several packaging forms and formulations are better suited for pyrolysis-based advanced recycling.
  • Si O coatings have the potential to be the “gift that keeps on giving”, especially when used in rigid and flexible polyethylene and polypropylene plastics that are mechanically recycled initially, which, after a few cycles, will then eventually become the used plastic feedstocks for advanced recycling; the silicon is predicted to accumulate and carry forward into each successive application.
  • Phosphorus-containing flame retardants are widely used in plastics where its rapid oxidation consumes all the oxygen present, thereby stopping the fire.
  • Plastics commonly containing these flame retardants include, but are not limited to, engineered plastics, polyurethane foams, polyamides (e.g., nylon) and glass-fiber reinforced nylon, polyethylene and EVA co-polymers, and intumescent coatings on foams and polypropylene textiles.
  • Phosphate esters are also used as flame retardant plasticizers in PVC, high impact polystyrene (HIPS), polycarbonate (PC), and acrylonitrile butadiene styrene (ABS).
  • Phosphorus sources also include agricultural applications, such as residual glyphosate in HDPE containers and residual phosphorus fertilizers on ground-level films (e.g., mulch films). Post-consumer sources will contain higher volumes of materials containing phosphorus sources that can be difficult to differentiate and remove through standard sorting techniques.
  • Sources of sulfur, calcium, sodium, iron, phosphorus, or a combination thereof are additives, surface residues, and residual contamination of the incoming post-consumer and/or post-industrial plastics.
  • a wash step can potentially remove certain surface residues, but would add cost and complexity to the advanced (e.g., pyrolysis based) recycling process. Accordingly, post-consumer sources will contain higher volumes of materials containing sources of sulfur, calcium, sodium, iron, phosphorus, or a combination thereof that can be difficult to differentiate and remove through standard sorting techniques.
  • Copper alloys are commonly and increasingly used to create molds for plastic injection molding processes due to their high thermal conductivity that removes hot spots, reduces warpage and reduces cycle time, ease of machining by a variety of processes, and corrosion resistance to water, cooling fluids and the plastics being injected. Copper alloys often contain nickel and silicon. Plastics manufactured in copper alloy molds can have residual amounts of copper, nickel, and silicon on their surface. In addition, the plating of plastic with nickel and copper can be an effective means of protecting a substrate against corrosion from environmental exposure and make it more resistant to damage from chemicals used in the manufacturing process. In some instances, the plating on plastic can increase the hardness, strength, and wear resistance of the substrate. The presence of copper and nickel on the surface of both preconsumer and post-consumer sources can be difficult to differentiate and remove through standard sorting techniques.
  • arsenic sources used in plastics derive from additives and catalysts .
  • antimony is ubiquitous in manufactured products, and in particular in plastics where it is used extensively as a flame retardant synergist for brominated compounds, as a pigment for color compounds and as a catalyst in the manufacturing of plastics, notably in polyethylene terephthalate (PET), a food contact plastic used extensively for single-use water and beverage bottles and food trays.
  • PET polyethylene terephthalate
  • oxygen sources can include, but are not limited to atmospheric gas (air) entrainment in the feedstock (e.g., semi-molten feedstock from the extruder); decomposition of certain feedstock materials such as crosslinked polymers and thermoset (for example, PET plastics can be C10H8O4); decomposition of water, which could come in with feedstock or atmospheric gases (e.g., air); decompositions of contaminants in the feedstock, such as TiO (a common pigmentation agent), SiC (silica), etc.; impure N2 gas, commonly used as a purge gas; any variety of oxygenated molecules such as alcohols and other compounds; and combinations thereof.
  • atmospheric gas air
  • decomposition of certain feedstock materials such as crosslinked polymers and thermoset (for example, PET plastics can be C10H8O4)
  • decomposition of water which could come in with feedstock or atmospheric gases (e.g., air)
  • decompositions of contaminants in the feedstock such as TiO (a common pigmentation agent), SiC (silica
  • the gas can comprise 30 wt.% or less contaminants (e.g., 29 wt.% or less, 28 wt.% or less, 27 wt.% or less, 26 wt.% or less, 25 wt.% or less, 24 wt.% or less, 23 wt.% or less, 22 wt.% or less, 21 wt.% or less, 20 wt.% or less, 19 wt.% or less, 18 wt.% or less, 17 wt.% or less, 16 wt.% or less, 15 wt.% or less, 14 wt.% or less, 13 wt.% or less, 12 wt.% or less, 11 wt.% or less, 10 wt.% or less, 9 wt.% or less, 8 wt.% or less, 7 wt.% or less, 6 wt.% or less, 5 wt.% or less, 4 wt.% or
  • the gas can comprise 0 wt.% or more contaminants (e.g., 0.1 wt.% or more, 0.25 wt.% or more, 0.5 wt.% or more, 1 wt.% or more, 2 wt.% or more, 3 wt.% or more, 4 wt.% or more, 5 wt.% or more, 6 wt.% or more, 7 wt.% or more, 8 wt.% or more, 9 wt.% or more, 10 wt.% or more, 11 wt.% or more, 12 wt.% or more, 13 wt.% or more, 14 wt.% or more, 15 wt.% or more, 16 wt.% or more, 17 wt.% or more, 18 wt.% or more, 19 wt.% or more, 20 wt.% or more, 21 wt.% or more, 22 wt.% or more, 23 w
  • the contaminant content of the gas can range from any of the minimum values described above to any of the maximum values described above.
  • the gas can comprise from 0 wt.% to 30 wt.% contaminants (e.g., from 0 to 15 wt.%, from 15 to 30 wt.%, from 0 to 10 wt.%, from 10 to 20 wt.%, from 20 to 30 wt.%, from 0 to 25 wt.%, from 0 to 20 wt.%, from 0 to 5 wt.%, or from 0 to 1 wt.%).
  • the gas can comprise 20 wt.% or less contaminants.
  • the gas can comprise 10 wt.% or less contaminants.
  • the gas has a total chloride content or 40,000 ppmv or less (e.g., 35,000 ppmv or less; 30,000 ppmv or less; 25,000 ppmv or less; 20,000 ppmv or less; 15,000 ppmv or less; 10,000 ppmv or less; 9,000 ppmv or less; 8,000 ppmv or less; 7,000 ppmv or less; 6,000 ppmv or less; 5,000 ppmv or less; 4,000 ppmv or less; 3,000 ppmv or less; 2,000 ppmv or less; 1,000 ppmv or less; 900 ppmv or less; 800 ppmv or less; 700 ppmv or less; 600 ppmv or less; 500 ppmv or less; 450 ppmv or less; 400 ppmv or less; 350 ppmv or less; 300 ppmv or less; 250 ppmv or less; 200 ppmv or less; 175 ppmv or
  • the gas has a total chloride content of 0 ppmv or more (e.g., 0.001 ppmv or more; 0.0025 ppmv or more; 0.005 ppmv or more; 0.0075 ppmv or more; 0.01 ppmv or more; 0.025 ppmv or more; 0.05 ppmv or more; 0.075 ppmv or more; 0.1 ppmv or more; 0.25 ppmv or more; 0.5 ppmv or more; 0.75 ppmv or more; 1 ppmv or more; 1.5 ppmv or more; 2 ppmv or more; 2.5 ppmv or more; 3 ppmv or more; 3.5 ppmv or more; 4 ppmv or more; 4.5 ppmv or more; 5 ppmv or more; 6 ppmv or more; 7 ppmv or more; 8 ppmv or more; 9 ppmv or more; 10 ppmv or more (e.
  • the total chloride content of the gas can range from any of the minimum values described above to any of the maximum values described above.
  • the gas can have a total chloride content of from 0 to 40,000 ppmv (e.g., from 0 to 20,000 ppmv; from 20,000 to 40,000 ppmv; from 0 to 400 ppmv; from 400 to 4000 ppmv; from 4000 to 40,000 ppmv; from 0.001 to 30,000 ppmv; from 0.001 to 20,000 ppmv; from 0.001 to 10,000 ppmv; from 0.001 to 5000 ppmv; from 0.001 to 2500 ppmv; from 0.001 to 1000 ppmv; from 0.001 to 500 ppmv; from 0.001 to 250 ppmv; from 0.001 to 200 ppmv; from 0.001 to 150 ppmv; from 0.001 to 50 ppmv; from 0.001 to 25 ppmv; from 0.001 to 10 ppm
  • the gas has a total chloride content of 20,000 ppmv or less. In some examples, the gas has a total chloride content of 10,000 ppmv or less. In some examples, the gas has a total chloride content of 5,000 ppmv or less. In some examples, the gas has a total chloride content of 1000 ppmv or less. In some examples, the gas has a total chloride content of 500 ppmv or less. In some examples, the gas has a total chloride content of 250 ppmv or less. In some examples, the gas has a total chloride content of 100 ppmv or less. In some examples, the gas has a total chloride content of 50 ppmv or less.
  • the gas has a total chloride content of 25 ppmv or less. In some examples, the gas has a total chloride content of 10 ppmv or less. In some examples, the gas has a total chloride content of 5 ppmv or less. In some examples, the gas has a total chloride content of 1 ppmv or less. In some examples, the gas has a total chloride content of 0.1 ppmv or less. In some examples, the gas has a total chloride content of or 0.01 ppmv or less. In some examples, the gas can be substantially free of chlorides. The total chloride content of the gas can be determined by any suitable method, such as those known in the art.
  • the total chloride content of the gas can be determined using gas chromatography (GC) (e.g., GC-TCD, GC-FID, GC-MS, GC-ICP-MS, GC-TOF-MS, etc.).
  • GC gas chromatography
  • the gas has a total bromide content of 2000 ppmv or less (e.g., 1900 ppmv or less, 1800 ppmv or less, 1700 ppmv or less, 1600 ppmv or less, 1500 ppmv or less, 1400 ppmv or less, 1300 ppmv or less, 1200 ppmv or less, 1100 ppmv or less, 1000 ppmv or less, 950 ppmv or less, 900 ppmv or less, 850 ppmv or less, 800 ppmv or less, 750 ppmv or less, 700 ppmv or less, 650 ppmv or less, 600 ppmv or less, 550 ppmv or less, 500 ppmv or less, 475 ppmv or less, 450 ppmv or less, 425 ppmv or less, 400 ppmv or less, 375 ppmv or less, 350 ppmv or less, 325 ppmv or
  • the gas can have a total bromide content of 0 ppmv or more (e.g., 0.001 ppmv or more, 0.0025 ppmv or more, 0.005 ppmv or more, 0.0075 ppmv or more, 0.01 ppmv or more, 0.025 ppmv or more, 0.05 ppmv or more, 0.075 ppmv or more, 0.
  • the total bromide content of the gas can range from any of the minimum values described above to any of the maximum values described above.
  • the gas can have a total bromide content of from 0 to 2000 ppmv (e.g., from 0 to 1000 ppmv, from 1000 to 2000 ppmv, from 0 to 500 ppmv, from 500 to 1000 ppmv, from 1000 to 1500 ppmv, from 1500 to 2000 ppmv, from 0.001 to 2000 ppmv, from 0.001 to 1750 ppmv, from 0.001 to 1500 ppmv, from 0.001 to 1250 ppmv, from 0.001 to 1000 ppmv, from 0.001 to 750 ppmv, from 0.001 to 500 ppmv, from 0.001 to 475 ppmv, from 0.001 to 450 ppmv, from 0.001 to 425 ppmv, from 0.001 to 400 ppmv, from 0.001 to 375 ppmv, from
  • the gas has a total bromide content of 1000 ppmv or less. In some examples, the gas has a total bromide content of 500 ppmv or less. In some examples, the gas has a total bromide content of 250 ppmv or less. In some examples, the gas has a total bromide content of 100 ppmv or less. In some examples, the gas has a total bromide content of 50 ppmv or less. In some examples, the gas has a total bromide content of 25 ppmv or less. In some examples, the gas has a total bromide content of 10 ppmv or less. In some examples, the gas has a total bromide content of 5 ppmv or less.
  • the gas has a total bromide content of 1 ppm or less. In some examples, the gas has a total bromide content of 0.1 ppm or less. In some examples, the gas has a total bromide content of 0.01 ppm or less. In some examples, the gas can be substantially free of bromides.
  • the total bromide content of the gas can be determined using any suitable method, such as those known in the art. For example, the total bromide content of the gas can be determined using gas chromatography (GC) (e.g., GC-TCD, GC-FID, GC-MS, GC-ICP-MS, GC-TOF-MS, etc.). In some examples, the gas can comprise metalloids.
  • GC gas chromatography
  • metalloids include, but are not limited to, silicon and compounds thereof such as silanes, arsenic and compounds thereof such as arsine, phosphorous and compounds thereof such as phosphines, antimony and compounds thereof such as stibine, etc.
  • the gas can have a metalloid content of 500 ppmv or less (e.g., 475 ppmv or less, 450 ppmv or less, 425 ppmv or less, 400 ppmv or less, 375 ppmv or less, 350 ppmv or less, 325 ppmv or less, 300 ppmv or less, 275 ppmv or less, 250 ppmv or less, 225 ppmv or less, 200 ppmv or less, 175 ppmv or less, 150 ppmv or less, 125 ppmv or less, 100 ppmv or less, 75 ppmv or less, 50 ppmv or less, 45 ppmv or less, 40 ppmv or less, 35 ppmv or less, 30 ppmv or less, 25 ppmv or less, 20 ppmv or less, 15 ppmv or less, 10 ppmv or less, 9 ppmv or less, 8 ppmv or
  • ppmv or less 1.5 ppmv or less, 1 ppmv or less, 0.75 ppmv or less, 0.5 ppmv or less, 0.25 ppmv or less, 0.1 ppmv or less, 0.075 ppmv or less, 0.05 ppmv or less, 0.025 ppmv or less, 0.01 ppmv or less, 0.0075 ppmv or less, or 0.005 ppmv or less).
  • the gas can have a metalloid content of 0 ppmv or more (e.g., 0.001 ppmv or more, 0.0025 ppmv or more, 0.005 ppmv or more, 0.0075 ppmv or more, 0.01 ppmv or more, 0.025 ppmv or more, 0.05 ppmv or more, 0.075 ppmv or more, 0.1 ppmv or more, 0.25 ppmv or more, 0.5 ppmv or more, 0.75 ppmv or more, 1 ppmv or more, 1.5 ppmv or more, 2 ppmv or more, 2.5 ppmv or more, 3 ppmv or more,
  • ppmv or more 4 ppmv or more, 4.5 ppmv or more, 5 ppmv or more, 6 ppmv or more, 7 ppmv or more, 8 ppmv or more, 9 ppmv or more, 10 ppmv or more, 15 ppmv or more, 20 ppmv or more, 25 ppmv or more, 30 ppmv or more, 35 ppmv or more, 40 ppmv or more, 45 ppmv or more, 50 ppmv or more, 75 ppmv or more, 100 ppmv or more, 125 ppmv or more, 150 ppmv or more, 175 ppmv or more, 200 ppmv or more, 225 ppmv or more, 250 ppmv or more, 275 ppmv or more, 300 ppmv or more, 325 ppmv or more, 350 ppmv or more, 375 ppmv or more, 400 ppmv or more,
  • the metalloid content of the gas can range from any of the minimum values described above to any of the maximum values described above.
  • the gas can have a metalloid content of from 0 ppmv to 500 ppmv (e.g., from 0 to 250 ppmv, from 250 to 500 ppmv, from 0 to 125 ppmv, from 125 to 250 ppmv, from 250 to 375 ppmv, from 375 to 500 ppmv, from 0 to 100 ppmv, from 100 to 200 ppmv, from 200 to 300 ppmv, from 300 to 400 ppmv, from 400 to 500 ppmv, from 0.001 to 450 ppmv, from 0.001 to 400 ppmv, from 0.001 to 350 ppmv, from 0.001 to 300 ppmv, from 0.001 to 250 ppmv, from 0.001 to 225 ppmv, from 0.001 to 200 ppmv, from 0.001 to 175 ppmv,
  • the gas has a metalloids content of 250 ppmv or less. In some examples, the gas has a metalloids content of 150 ppmv or less. In some examples, the gas has a metalloids content of 100 ppmv or less. In some examples, the gas has a metalloids content of 50 ppmv or less. In some examples, the gas has a metalloids content of 25 ppmv or less. In some examples, the gas has a metalloids content of 10 ppmv or less. In some examples, the gas has a metalloids content of 5 ppmv or less. In some examples, the gas has a metalloids content of 1 ppmv or less.
  • the gas has a metalloids content of 0.1 ppmv or less. In some examples, the gas has a metalloids content of 0.01 ppmv or less. In some examples, the gas can be substantially free of metalloids.
  • the metalloid content of the gas can be determined using any suitable method, such as those known in the art. For example, the metalloid content of the gas can be determined using gas chromatography (GC) (e.g., GC-TCD, GC-FID, GC-MS, GC-ICP-MS, GC-TOF-MS, etc.).
  • GC gas chromatography
  • the gas can comprise a sulfur content.
  • a “sulfur content” can include sulfur or any compounds thereof, such as sulfides, thiols, sulfones, mercaptans, etc.
  • sulfur compounds that can contribute to the sulfur content include, but are not limited to, hydrogen sulfide , carbonyl sulfide, ethyl mercaptan, ethyl mercaptan, dimethyl sulfide, carbon disulfide, dimethyl disulfide, etc.
  • the gas can have a sulfur content of 5000 ppmv or less (e.g., 4750 ppmv or less, 4500 ppmv or less, 4250 ppmv or less, 4000 ppmv or less, 3750 ppmv or less, 3500 ppmv or less, 3250 ppmv or less, 3000 ppmv or less, 2750 ppmv or less, 2500 ppmv or less, 2250 ppmv or less, 2000 ppmv or less, 1900 ppmv or less, 1800 ppmv or less, 1700 ppmv or less, 1600 ppmv or less, 1500 ppmv or less, 1400 ppmv or less, 1300 ppmv or less, 1200 ppmv or less, 1100 ppmv or less, 1000 ppmv or less, 950 ppmv or less, 900 ppmv or less, 850 ppmv or less, 800 ppmv or less,
  • the gas can have a sulfur content of 0 ppmv or more (e.g., 0.001 ppmv or more, 0.0025 ppmv or more, 0.005 ppmv or more, 0.0075 ppmv or more, 0.01 ppmv or more, 0.025 ppmv or more, 0.05 ppmv or more, 0.075 ppmv or more, 0.
  • the sulfur content of the gas can range from any of the minimum values described above to any of the maximum values described above.
  • the gas can have a sulfur content of from 0 to 5000 ppmv (e.g., from 0 to 2500 ppmv, from 2500 to 5000 ppmv, from 0 to 1000 ppmv, from 1000 to 2000 ppmv, from 2000 to 3000 ppmv, from 3000 to 4000 ppmv, from 4000 to 5000 ppmv, from 0.001 to 4500 ppmv, from 0.001 to 4000 ppmv, from 0.001 to 3500 ppmv, from 0.001 to 3000 ppmv, from 0.001 to 2500 ppmv, from 0.001 to 1500 ppmv, from 0.001 to 1000 ppmv, from 0.001 to 500 ppmv, from 0.001 to 250 ppmv, from 0.001 to 100 ppmv, from 0.001 to 50 ppmv, from 0.00
  • the gas has a sulfur content of 2500 ppmv or less. In some examples, the gas has a sulfur content of 2000 ppmv or less. In some examples, the gas has a sulfur content of 1000 ppmv or less. In some examples, the gas has a sulfur content of 500 ppmv or less. In some examples, the gas has a sulfur content of 100 ppmv or less. In some examples, the gas has a sulfur content of 10 ppmv or less. In some examples, the gas has a sulfur content of 5 ppmv or less. In some examples, the gas has a sulfur content of 2 ppm or less.
  • the gas has a sulfur content of 1 ppm or less. In some examples, the gas has a sulfur content of 0.1 ppm or less. In some examples, the gas has a sulfur content of 0.01 ppm or less). In some examples, the gas is substantially free of sulfur.
  • the sulfur content of the gas can be determined using gas chromatography (GC) (e.g., GC-TCD, GC-FID, GC-MS, GC-ICP-MS, GC-TOF-MS, etc.), ASTM D5453, and/or Wavelength Dispersive X-Ray Fluorescence Spectrometry.
  • GC gas chromatography
  • the gas can comprise oxygenates.
  • oxygenates comprise hydrocarbons substituted with an oxygen containing group. Examples of oxygenates include, but are not limited to, methanol, formic acid, acetic acid, acetaldehyde, vinyl acetate, acetonitrile, acetone, ethanol, isopropanol, methyl ethyl ketone, butanone, etc.
  • the gas has a total oxygenate content of 4000 ppmv or less (e.g., 3750 ppmv or less, 3500 ppmv or less, 3250 ppmv or less, 3000 ppmv or less, 2750 ppmv or less, 2500 ppmv or less, 2250 ppmv or less, 2000 ppmv or less, 1750 ppmv or less, 1500 ppmv or less, 1400 ppmv or less, 1300 ppmv or less, 1200 ppmv or less, 1100 ppmv or less, 1000 ppmv or less, 950 ppmv or less, 900 ppmv or less, 850 ppmv or less, 800 ppmv or less, 750 ppmv or less, 700 ppmv or less, 650 ppmv or less, 600 ppmv or less, 550 ppmv or less, 500 ppmv or less, 475 ppmv or less,
  • the gas has a total oxygenate content of 0 ppmv or more (e.g., 0.001 ppmv or more, 0.0025 ppmv or more, 0.005 ppmv or more, 0.0075 ppmv or more, 0.01 ppmv or more, 0.025 ppmv or more, 0.05 ppmv or more, 0.075 ppmv or more, 0.1 ppmv or more, 0.25 ppmv or more, 0.5 ppmv or more, 0.75 ppmv or more, 1 ppmv or more, 1.5 ppmv or more, 2 ppmv or more, 2.5 ppmv or more, 3 ppmv or more, 3.5 ppmv or more, 4 ppmv or more, 4.5 ppmv or more, 5 ppmv or more, 6 ppmv or more, 7 ppmv or more, 8 ppmv or more, 9 ppmv or more, 10 ppmv or more (e.
  • the total oxygenate content of the gas can range from any of the minimum values described above to any of the maximum values described above.
  • the gas can have a total oxygenate content of from 0 to 4000 ppmv (e.g., from 0 to 2000 ppmv, from 2000 to 4000 ppmv, from 0 to 1000 ppmv, from 1000 to 2000 ppmv, from 2000 to 3000 ppmv, from 3000 to 4000 ppmv, from 0.001 to 3500 ppmv, from 0.001 to 3000 ppmv, from 0.001 to 2500 ppmv, from 0.001 to 2000 ppmv, from 0.001 to 1500 ppmv, from 0.001 to 1250 ppmv, from 0.001 to 1000 ppmv, from 0.001 to 500 ppmv, from 0.001 to 250 ppmv, from 0.001 to 100 ppmv, from 0.001 to 50 ppmv, from 0.001 to 25 ppmv, from
  • the gas has a total oxygenate content of 750 ppmv or less. In some examples, the gas has a total oxygenate content of 500 ppmv or less. In some examples, the gas has a total oxygenate content of 100 ppmv or less. In some examples, the gas has a total oxygenate content of 50 ppmv or less. In some examples, the gas has a total oxygenate content of 25 ppmv or less. In some examples, the gas has a total oxygenate content of 10 ppmv or less. In some examples, the gas has a total oxygenate content of 5 ppmv or less.
  • the gas has a total oxygenate content of 1 ppmv or less. In some examples, the gas has a total oxygenate content of 0.1 ppmv or less. In some examples, the gas has a total oxygenate content of 0.01 ppmv or less. In some examples, the gas can be substantially free of oxygenates.
  • the oxygenates content of the gas can be determined by any suitable method, such as those known in the art. For example, the oxygenates content of the gas can be determined using gas chromatography (GC) (e.g., GC-TCD, GC-FID, GC-MS, GC-ICP-MS, GC-TOF-MS, etc.).
  • GC gas chromatography
  • the gas can comprise atmospheric gases (e.g., atmospherics).
  • atmospheric gases include non-hydrocarbon components of the Earth’s ambient atmosphere. Examples of atmospherics include, but are not limited to, N2, H2, CO2, CO, He, O2, O3, Ar, Ne, and combinations thereof.
  • the gas can comprise 30 mol% or less atmospherics (e.g., 29 mol% or less, 28 mol% or less, 27 mol% or less, 26 mol% or less, 25 mol% or less, 24 mol% or less, 23 mol% or less, 22 mol% or less, 21 mol% or less, 20 mol% or less, 19 mol% or less, 18 mol% or less, 17 mol% or less, 16 mol% or less, 15 mol% or less, 14 mol% or less, 13 mol% or less, 12 mol% or less, 11 mol% or less, 10 mol% or less, 9 mol% or less, 8 mol% or less, 7 mol% or less, 6 mol% or less, 5 mol% or less, 4 mol% or less, 3 mol% or less, 2 mol% or less, 1 mol% or less, 0.5 mol% or less, 0.25 mol% or less, or 0.1 mol% or less).
  • atmospherics e.g
  • the gas can comprise 0 mol% or more atmospherics (e.g., 0.1 mol% or more, 0.25 mol% or more, 0.5 mol% or more, 1 mol% or more, 2 mol% or more, 3 mol% or more, 4 mol% or more, 5 mol% or more, 6 mol% or more, 7 mol% or more, 8 mol% or more, 9 mol% or more, 10 mol% or more, 11 mol% or more, 12 mol% or more, 13 mol% or more, 14 mol% or more, 15 mol% or more, 16 mol% or more, 17 mol% or more, 18 mol% or more, 19 mol% or more, 20 mol% or more, 21 mol% or more, 22 mol% or more, 23 mol% or more, 24 mol% or more, 25 mol% or more, 26 mol% or more, 27 mol% or more, 28 mol% or more, or 29 mol% or more).
  • atmospherics e.
  • the atmospherics content of the gas can range from any of the minimum values described above to any of the maximum values described above.
  • the gas can comprise from 0 mol% to 30 mol% atmospherics (e.g., from 0 to 15 mol%, from 15 to 30 mol%, from 0 to 10 mol%, from 10 to 20 mol%, from 20 to 30 mol%, from 0.1 to 25 mol%, from 0.1 to 20 mol%, from 0. 1 to 5 mol%, from 0.1 to 1 mol%, from 0 to 25 mol%, from 0 to 20 mol%, from 0 to 5 mol%, or from 0 to 1 mol%).
  • the gas comprises 20 mol% or less atmospherics.
  • the gas comprises 10 mol% or less atmospherics. In some examples, the gas comprises 5 mol% or less atmospherics. In some examples, the gas comprises 1 mol% or less atmospherics. In some examples, the gas can be substantially free of atmospherics.
  • the atmospherics content of the gas can be determined by any suitable method, such as those known in the art. For example, the atmospherics content of the gas can be determined using gas chromatography (GC) (e.g., GC-TCD, GC-FID, GC-MS, GC-ICP-MS, GC-TOF-MS, etc.).
  • GC gas chromatography
  • the gas has: a total chloride content of 40,000 ppmv or less; a total a metalloids content of 500 ppmv or less; an oxygenates content of 4000 ppmv or less; or a combination thereof. In some examples, the gas has: a total chloride content of 40,000 ppmv or less; a total bromide content of 2000 ppmv or less; a metalloids content of 500 ppmv or less; an oxygenates content of 4000 ppmv or less; or a combination thereof.
  • the gas has: a total chloride content of 40,000 ppmv or less; a metalloids content of 500 ppmv or less; a total sulfur content of 5000 ppmv or less; an oxygenates content of 4000 ppmv or less; or a combination thereof.
  • the gas has: a total chloride content of 40,000 ppmv or less; a total bromide content of 2000 ppmv or less; a metalloids content of 500 ppmv or less; a total sulfur content of 5000 ppmv or less; an oxygenates content of 4000 ppmv or less; or a combination thereof.
  • the gas has: a total chloride content of 40,000 ppmv or less; a total bromide content of 2000 ppmv or less; a metalloids content of 500 ppmv or less; a total sulfur content of 5000 ppmv or less; an oxygenates content of 4000 ppmv or less; an atmospheric gas content of 30 mol% or less; or a combination thereof.
  • the gas has: a total chloride content of 40,000 ppmv or less; a metalloids content of 500 ppmv or less; and an oxygenates content of 4000 ppmv or less.
  • the gas has: a total chloride content of 40,000 ppmv or less; a total bromide content of 2000 ppmv or less; a metalloids content of 500 ppmv or less; and an oxygenates content of 4000 ppmv or less.
  • the gas has: a total chloride content of 40,000 ppmv or less; a metalloids content of 500 ppmv or less; a total sulfur content of 5000 ppmv or less; and an oxygenates content of 4000 ppmv or less.
  • the gas has: a total chloride content of 40,000 ppmv or less; a total bromide content of 2000 ppmv or less; a metalloids content of 500 ppmv or less; a total sulfur content of 5000 ppmv or less; and an oxygenates content of 4000 ppmv or less.
  • the gas has: a total chloride content of 40,000 ppmv or less; a total bromide content of 2000 ppmv or less; a metalloids content of 500 ppmv or less; a total sulfur content of 5000 ppmv or less; an oxygenates content of 4000 ppmv or less; and an atmospheric gas content of 30 mol% or less.
  • the gas has: a total chloride content of 20,000 ppmv or less; a metalloids content of 150 ppmv or less; an oxygenates content of 2000 ppmv or less; or a combination thereof. In some examples, the gas has: a total chloride content of 20,000 ppmv or less; a total bromide content of 1000 ppmv or less; a metalloids content of 150 ppmv or less; an oxygenates content of 2000 ppmv or less; or a combination thereof.
  • the gas has: a total chloride content of 20,000 ppmv or less; a metalloids content of 150 ppmv or less; a total sulfur content of 2500 ppmv or less; an oxygenates content of 2000 ppmv or less; or a combination thereof.
  • the gas has: a total chloride content of 20,000 ppmv or less; a total bromide content of 1000 ppmv or less; a metalloids content of 150 ppmv or less; a total sulfur content of 2500 ppmv or less; an oxygenates content of 2000 ppmv or less; or a combination thereof.
  • the gas has: a total chloride content of 20,000 ppmv or less; a total bromide content of 1000 ppmv or less; a metalloids content of 150 ppmv or less; a total sulfur content of 2500 ppmv or less; an oxygenates content of 2000 ppmv or less; an atmospheric gas content of 15 mol% or less; or a combination thereof.
  • the gas has: a total chloride content of 20,000 ppmv or less; a metalloids content of 150 ppmv or less; and an oxygenates content of 2000 ppmv or less.
  • the gas has: a total chloride content of 20,000 ppmv or less; a total bromide content of 1000 ppmv or less; a metalloids content of 150 ppmv or less; and an oxygenates content of 2000 ppmv or less.
  • the gas has: a total chloride content of 20,000 ppmv or less; a metalloids content of 150 ppmv or less; a total sulfur content of 2500 ppmv or less; and an oxygenates content of 2000 ppmv or less.
  • the gas has: a total chloride content of 20,000 ppmv or less; a total bromide content of 1000 ppmv or less; a metalloids content of 150 ppmv or less; a total sulfur content of 2500 ppmv or less; and an oxygenates content of 2000 ppmv or less.
  • the gas has: a total chloride content of 20,000 ppmv or less; a total bromide content of 1000 ppmv or less; a metalloids content of 150 ppmv or less; a total sulfur content of 2500 ppmv or less; an oxygenates content of 2000 ppmv or less; and an atmospheric gas content of 15 mol% or less.
  • the gas has: a total chloride content of 4,000 ppmv or less; a metalloids content of 250 ppmv or less; an oxygenates content of 3000 ppmv or less; or a combination thereof. In some examples, the gas has: a total chloride content of 4,000 ppmv or less; a total bromide content of 200 ppmv or less; a metalloids content of 250 ppmv or less; an oxygenates content of 3000 ppmv or less; or a combination thereof.
  • the gas has: a total chloride content of 4,000 ppmv or less; a total bromide content of 200 ppmv or less; a metalloids content of 250 ppmv or less; a total sulfur content of 2500 ppmv or less; an oxygenates content of 3000 ppmv or less; or a combination thereof.
  • the gas has: a total chloride content of 4,000 ppmv or less; a total bromide content of 200 ppmv or less; a metalloids content of 250 ppmv or less; a total sulfur content of 2500 ppmv or less; and an oxygenates content of 3000 ppmv or less.
  • the gas has: a total chloride content of 400 ppmv or less; a metalloids content of 25 ppmv or less; an oxygenates content of 2500 ppmv or less; or a combination thereof. In some examples, the gas has: a total chloride content of 400 ppmv or less; a total bromide content of 100 ppmv or less; a metalloids content of 25 ppmv or less; an oxygenates content of 2500 ppmv or less; or a combination thereof.
  • the gas has: a total chloride content of 400 ppmv or less; a total bromide content of 100 ppmv or less; a metalloids content of 25 ppmv or less; a total sulfur content of 2000 ppmv or less; an oxygenates content of 2500 ppmv or less; or a combination thereof.
  • the gas has: a total chloride content of 400 ppmv or less; a total bromide content of 100 ppmv or less; a metalloids content of 25 ppmv or less; a total sulfur content of 2000 ppmv or less; and an oxygenates content of 2500 ppmv or less.
  • the gas has: a total chloride content of 40 ppmv or less; a metalloids content of 2.5 ppmv or less; an oxygenates content of 2000 ppmv or less; or a combination thereof. In some examples, the gas has: a total chloride content of 40 ppmv or less; a total bromide content of 10 ppmv or less; a metalloids content of 2.5 ppmv or less; an oxygenates content of 2000 ppmv or less; or a combination thereof.
  • the gas has: a total chloride content of 40 ppmv or less; a total bromide content of 10 ppmv or less; a metalloids content of 2.5 ppmv or less; a total sulfur content of 200 ppmv or less; an oxygenates content of 2000 ppmv or less; or a combination thereof.
  • the gas has: a total chloride content of 40 ppmv or less; a total bromide content of 10 ppmv or less; a metalloids content of 2.5 ppmv or less; a total sulfur content of 200 ppmv or less; and an oxygenates content of 2000 ppmv or less.
  • the gas has: a total chloride content of 20 ppmv or less; a metalloids content of 1 ppmv or less; an oxygenates content of 1800 ppmv or less; or a combination thereof. In some examples, the gas has: a total chloride content of 20 ppmv or less; a total bromide content of 1 ppmv or less; a metalloids content of 1 ppmv or less; an oxygenates content of 1800 ppmv or less; or a combination thereof.
  • the gas has: a total chloride content of 20 ppmv or less; a total bromide content of 1 ppmv or less; a metalloids content of 1 ppmv or less; a total sulfur content of 20 ppmv or less; an oxygenates content of 1800 ppmv or less; or a combination thereof.
  • the gas has: a total chloride content of 20 ppmv or less; a total bromide content of 1 ppmv or less; a metalloids content of 1 ppmv or less; a total sulfur content of 20 ppmv or less; and an oxygenates content of 1800 ppmv or less.
  • the gas is a raw pyrolysis product, meaning the gas is produced by a method that substantially excludes any hydrotreatment or further refining steps after pyrolysis. In some examples, the gas is produced by pyrolysis and further includes hydrotreatment or further refining steps after pyrolysis.
  • compositions e.g., gases
  • compositions disclosed herein are systems and methods for making hydrocarbon based compositions derived from pyrolysis of a feedstock comprising post-consumer and/or postindustrial plastics, such as any of the compositions described herein above.
  • the compositions disclosed herein can comprise a gas.
  • compositions described herein e.g., any of the gases described herein
  • the method comprises pyrolysis of a feedstock comprising post-consumer and/or post-industrial plastics.
  • the methods comprise thermal depolymerization of the feedstock.
  • Recycling of plastics via pyrolysis is a technology that generates products with a broad range of quality dependent upon a variety of factors, including the feedstock and manufacturing process. Pyrolysis depolymerizes plastics into products comprised of building block molecules. Contaminants are introduced during plastic formulation and manufacturing processes during the first life of plastic, optionally in conjunction with the source and collection method of the plastics.
  • plastic to liquids conversion can accept, for example, polyethylene, polypropylene, and/or polystyrene plastics that are neither suitable nor desirable for conventional (mechanical) plastic recycling.
  • the plastic is thermally converted (e.g., thermally depolymerized) to hydrocarbon products.
  • the hydrocarbon products can, for example, be used in the production of new plastics through conventional hydrocarbon cracking units.
  • the hydrocarbon products can, for example, also be used as an alternative for naphtha, fuel, etc.
  • the systems and methods herein can also produce char/coke and combustible gases, e.g. as products or byproducts.
  • Plastics that are typically received would have otherwise been destined for disposal at a landfill or waste to energy plant because of their physical form and/or make-up prevents them from being effectively recycled by current conventional (mechanical) recycling means.
  • Most film plastics fall into this category, as do others that have intermixed types of plastic resins or simply have contaminants (such as paper labels, organic food residue, functional additives, colorants, etc.) that make conventional (mechanical) recycling uneconomical.
  • the systems and/or methods described herein can, for example, operate on an industrial scale.
  • the systems and/or methods can produce the hydrocarbon product (e.g., gas) at an industrial scale.
  • the hydrocarbon product e.g., gas
  • the systems and/or methods described herein can process 5 metric tons or more of plastic feedstock per day (e.g., 5.5 metric tons or more, 6 metric tons or more,
  • the systems and methods described herein can process 1000 metric tons or less of plastic feedstock per day (e.g., 900 metric tons or less, 800 metric tons or less, 700 metric tons or less, 600 metric tons or less, 500 metric tons or less, 450 metric tons or less, 400 metric tons or less, 350 metric tons or less, 300 metric tons or less, 250 metric tons or less, 225 metric tons or less, 200 metric tons or less, 175 metric tons or less, 150 metric tons or less, 125 metric tons or less, 100 metric tons or less, 90 metric tons or less, 80 metric tons or less, 70 metric tons or less, 60 metric tons or less, 50 metric tons or less, 45 metric tons or less, 40 metric tons or less, 35 metric tons or less, 30 metric tons or less, 25 metric tons or less, 20 metric tons or less, 15 metric tons or less, 14 metric tons or less, 13 metric tons or less, 12 metric tons or less, 11
  • the amount of plastic feedstock processed by the systems and/or methods herein can range from any of the minimum values described above to any of the maximum values described above.
  • the systems and/or methods described herein can process from 5 to 1000 metric tons of plastic feedstock per day (e.g., from 5 to 500 metric tons, from 500 to 1000 metric tons, from 5 to 200 metric tons, from 200 to 400 metric tons, from 400 to 600 metric tons, from 600 to 800 metric tons, from 800 to 1000 metric tons, from 5 to 800 metric tons, from 5 to 600 metric tons, from 5 to 400 metric tons, from 5 to 100 metric tons, from 5 to 50 metric tons, from 5 to 25 metric tons, from 10 to 1000 metric tons, from 25 to 1000 metric tons, from 50 to 1000 metric tons, from 100 to 1000 metric tons, from 200 to 1000 metric tons, from 400 to 1000 metric tons, from 600 to 1000 metric tons, from 10 to 900 metric tons, from 15 to 800 metric tons, from 25 to 750 metric tons, or
  • the systems and/or methods described herein can produce 1,000 pounds (lbs.) of pyrolysis product (e.g., gas) or more in an amount of time (e.g., 1500 pounds or more; 2000 pounds or more; 2500 pounds or more; 3000 pounds or more; 3500 pounds or more; 4000 pounds or more; 4500 pounds or more; 5000 pounds or more; 6000 pounds or more; 7000 pounds or more; 8000 pounds or more; 9000 pounds or more; 10,000 pounds or more; 11,000 pounds or more; 12,000 pounds or more; 13,000 pounds or more; 14,000 pounds or more; 15,000 pounds or more; 20,000 pounds or more; 25,000 pounds or more; 30,000 pounds or more; 35,000 pounds or more; 40,000 pounds or more; 45,000 pounds or more; 50,000 pounds or more; 60,000 pounds or more; 70,000 pounds or more; 80,000 pounds or more; 90,000 pounds or more; 100,000 pounds or more; 125,000 pounds or more; 150,000 pounds or more; 175,000 pounds or more; 200,000 pounds or more; 225,000 pounds or more;
  • the systems and/or methods described herein can produce 200,000,000 pounds of pyrolysis product (e.g., gas) or more in an amount of time (e.g., 175,000,000 pounds or less; 150,000,000 pounds or less; 125,000,000 pounds or less; 100,000,000 pounds or less; 90,000,000 pounds or less; 80,000,000 pounds or less; 70,000,000 pounds or less; 60,000,000 pounds or less; 50,000,000 pounds or less; 45,000,000 pounds or less; 40,000,000 pounds or less; 35,000,000 pounds or less; 30,000,000 pounds or less; 25,000,000 pounds or less; 20,000,000 pounds or less; 15,000,000 pounds or less; 10,000,000 pounds or less; 9,000,000 pounds or less; 8,000,000 pounds or less; 7,000,000 pounds or less; 6,000,000 pounds or less; 5,000,000 pounds or less; 4,500,000 pounds or less; 4,000,000 pounds or less; 3,500,000 pounds or less; 3,000,000 pounds or less; 2,500,000 pounds or less; 2,250,000 pounds or less; 2,000,000 pounds or less; 1,750,000 pounds or less; 1,500,000 pounds or less; 1,250,000 pounds or less; 1,000,000 pounds or less; 900,000 pounds or less
  • the amount of pyrolysis product produced in the amount of time by the systems and/or methods described herein can range from any of the minimum values described above to any of the maximum values described above.
  • the systems and/or methods described herein can produce from 1,000 to 200,000,000 pounds of pyrolysis product (e.g., gas) or more in an amount of time (e.g., from 1,000 to 500,000 pounds; from 500,000 to 200,000,000 pounds; from 1,000 to 10,000 pounds; from 10,000 to 100,000 pounds; from 100,000 to 1,000,000 pounds; from 1,000,000 to 10,000,000, from 10,000,000 to 200,000,000 pounds; from 1,000 to 150,000,000 pounds; from 1,000 to 100,000,000 pounds; from 1,000 to 50,000,000 pounds; from 1,000 to 10,000,000 pounds; from 1,000 to 5,000,000 pounds; from 1,000 to 1,000,000 pounds; from 1,000 to 50,000 pounds; from 1,000 to 10,000 pounds; from 1,000 to 5,000 pounds; from 2,500 to 200,000,000 pounds; from 5,000 to 200,000,000 pounds; from 10,000 to 200,000,000 pounds; from 100,000 to 200,000,000 pounds; from 1,000,000 to 200,000,000 pounds; from 5,000,000 to 200,000,000 pounds;
  • the amount of time in which the pyrolysis product (e.g., gas) is produced by the systems and/or methods can, for example, be 5 days or more (e.g., 6 days or more, 7 days or more, 8 days or more, 9 days or more, 10 days or more, 11 days or more, 12 days or more, 13 days or more, 14 days or more, 15 days or more, 16 days or more, 17 days or more, 18 days or more, 19 days or more, 20 days or more, 21 days or more, 22 days or more, 23 days or more, 24 days or more, 25 days or more, 26 days or more, 27 days or more, 28 days or more, 29 days or more, 30 days or more, 35 days or more, 40 days or more, 45 days or more, 50 days or more, 60 days or more, 70 days or more, or 80 days or more).
  • 5 days or more e.g., 6 days or more, 7 days or more, 8 days or more, 9 days or more, 10 days or more, 11 days or more, 12 days or more, 13
  • the amount of time in which the pyrolysis product is produced by the systems and/or methods can be 90 days or less (e.g., 80 days or less, 70 days or less, 60 days or less, 50 days or less, 45 days or less, 40 days or less, 35 days or less, 30 days or less, 29 days or less, 28 days or less, 27 days or less, 26 days or less, 25 days or less, 24 days or less, 23 days or less, 22 days or less, 21 days or less, 20 days or less, 19 days or less, 18 days or less, 17 days or less, 16 days or less, 15 days or less, 14 days or less, 13 days or less, 12 days or less, 1 1 days or less, 10 days or less, 9 days or less, 8 days or less, or 7 days or less).
  • 90 days or less e.g., 80 days or less, 70 days or less, 60 days or less, 50 days or less, 45 days or less, 40 days or less, 35 days or less, 30 days or less, 29 days or less, 28 days or less, 27 days
  • the amount of time in which the pyrolysis product is produced by the systems and/or methods can range from any of the minimum values described above to any of the maximum values described above.
  • the amount of time in which the pyrolysis product is produced by the systems and/or methods can be from 5 to 90 days (e.g., from 4 to 45 days, from 45 to 90 days, from 5 to 30 days, from 30 to 60 days, from 60 to 90 days, from 5 to 80 days, from 5 to 70 days, from 5 to 60 days, from 5 to 50 days, from 5 to 40 days, from 5 to 21 days, from 5 to 14 days, from 5 to 10 days, from 7 to 90 days, from 10 to 90 days, from 14 to 90 days, from 21 to 90 days, from 30 to 90 days, from 40 to 90 days, from 50 to 90 days, from 70 to 90 days, from 7 to 80 days, or from 10 to 60 days).
  • 5 to 90 days e.g., from 4 to 45 days, from 45 to 90 days, from 5 to 30 days, from 30 to 60 days, from 60 to
  • the systems and/or methods described herein can produce from 1,000 to 200,000,000 pounds of pyrolysis product (e.g., gas) per 5 to 90 days. In some examples, the systems and/or methods described herein can process from 5 to 1000 metric tons per day of plastic feedstock and produce from 1,000 to 200,000,000 pounds of pyrolysis product (e.g., gas) per 5 to 90 days.
  • pyrolysis product e.g., gas
  • the systems and/or methods described herein can produce from 1,000 to 200,000,000 pounds of pyrolysis product (e.g., gas) per 5 to 90 days, per line. In some examples, the systems and/or methods described herein can process from 5 to 1000 metric tons per day of plastic feedstock and produce from 1 ,000 to 200,000,000 pounds of pyrolysis product (e.g., gas) per 5 to 90 days, per line.
  • pyrolysis product e.g., gas
  • Figure 1 - Figure 5 are block flow diagrams of example systems and methods described herein.
  • the systems and methods can, for example, include intake of plastic feedstock, sorting and/or reducing the size of the plastic feedstock, followed by pyrolysis and/or removal of contaminants to produce the hydrocarbon product, which can optionally be recycled for further pyrolysis and/or which can optionally be post-treated.
  • Figure 1 depicts an example system SI 00a for pyrolyzing plastic feedstock comprising post-consumer and/or post-industrial plastics.
  • the system S 100a comprises a plastic feedstock infeed apparatus S 102, a size reduction and/or sorting apparatus S104, a pyrolysis and/or contaminant removal apparatus S108, an optional recycling apparatus SI 09, and one or more optional post- treatment and/or contaminant removal apparatuses SI 14a, SI 14b.
  • the plastic feedstock infeed apparatus S 102 is configured for receiving plastic feedstock (e.g., plastic feedstock deposited into the plastic feedstock infeed apparatus S102).
  • the plastic feedstock received by the plastic feedstock infeed apparatus S I 02 can include any of the feedstocks described in the “Feedstock” section herein (e.g., post-consumer and/or post-industrial plastics).
  • the plastic feedstock infeed apparatus S102 can comprise an infeed conveyer, for example, as described in the “Infeed” section herein. As depicted in Figure 1, the plastic feedstock can be fed into the system SlOOa via the plastic feedstock infeed apparatus S102.
  • the plastic infeed apparatus S102 directs the plastic feedstock to the size reduction and/or sorting apparatus S104 (e.g., via a conveyor).
  • the size reduction and/or sorting apparatus S104 is configured for reducing the size of the plastic feedstock and/or sorting the plastic feedstock from contaminants.
  • contaminants S106 are removed from the plastic feedstock.
  • the size reduction and/or sorting apparatus SI 04 may not remove contaminants.
  • the size reduction and/or sorting apparatus SI 04 can comprise any of the sorting apparatuses or devices described in the “Sorting” section herein and/or any of the size reduction apparatuses or devices described in the “Size Reduction” section herein, either alone or in combination.
  • the size reduction and/or sorting apparatus SI 04 then directs the plastic feedstock into a pyrolysis and/or contaminant removal apparatus SI 08 as shown in Figure 1.
  • the pyrolysis and/or contaminant removal apparatus SI 08 is generally configured for pyrolyzing the plastic feedstock to generate a product SI 12 (e.g., hydrocarbon vapor).
  • the pyrolysis and/or contaminant removal apparatus S108 can be configured for removing vent gas and/or contaminants SI 10.
  • the pyrolysis and/or contaminant removal apparatus SI 08 can comprise one or more of the pyrolysis and/or contaminant removal apparatuses or devices described in the “Melting, Removal of Contaminants, and/or Pyrolysis,” “Extruders,” and “Pyrolysis Reactors” sections herein.
  • the product SI 12 shown in Figure 1 can comprise any of the compositions described in the “Compositions” section herein.
  • the product SI 12 can comprise a condensable portion that is condensable at ambient pressure (e.g., wax and/or oil) and/or a non-condensable portion that is not condensable at ambient pressure (e.g., gas).
  • the condensable portion or a portion thereof can be recycled back into the pyrolysis and/or contaminant removal apparatus S108, for example via the optional recycling apparatus S109, for example to be further pyrolyzed into a non-condensable product (e.g., gas).
  • the product S 112 can be directly generated by the pyrolysis and/or contaminant removal apparatus SI 08.
  • the product SI 12 can be generated by the optional post-treatment and/or contaminant removal apparatus SI 14a (e.g., configured for performing post-treatment or contaminant removal following the pyrolysis and/or contaminant removal apparatus S108).
  • the product SI 12 can be directly generated by the pyrolysis and/or contaminant removal apparatus S 108 and also be further processed by an optional post-treatment and/or contaminant removal apparatus SI 14b.
  • the product SI 12 can be generated by the optional post-treatment and/or contaminant removal apparatus SI 14a after the pyrolysis and/or contaminant removal apparatus S108 and also be further processed by the optional post-treatment and/or contaminant removal apparatus S 114b.
  • the optional post-treatment and/or contaminant removal apparatuses SI 14a, SI 14b can include any of the post- treatment apparatuses or devices described in the “Post-Treatment” section herein and/or any of the contaminant removal apparatuses and devices described in the “Melting, Removal of Contaminants, and/or Pyrolysis” section herein.
  • Figure 2 depicts another example system SI 00b for pyro lyzing plastic feedstock comprising post-consumer and/or post-industrial plastics (like numbers refer to like elements previously described with respect to the system SI 00a of Figure 1).
  • the system SlOOb comprises the plastic feedstock infeed apparatus S102, the size reduction and/or sorting apparatus SI 04, a melting and/or contaminant removal apparatus S107, the pyrolysis and/or contaminant removal apparatus S108, an optional recycling apparatus SI 09, and one or more optional post-treatment and/or contaminant removal apparatuses SI 14a, SI 14b.
  • the size reduction and/or sorting apparatus S 104 directs the plastic feedstock SI 02 into the melting and/or contaminant removal apparatus S 107.
  • the melting and/or contaminant removal apparatus S107 is configured for melting the plastic feedstock and removing vent gas and/or contaminants (shown as element SI 10 in Figure 2).
  • melting and/or contaminant removal apparatus SI 07 may not remove vent gas and/or contaminants.
  • the melting and/or contaminant removal apparatus SI 07 can comprise one or more of the pyrolysis and/or contaminant removal apparatuses or devices described in the “Melting, Removal of Contaminants, and/or Pyrolysis” and “Extruders” sections herein.
  • the melting and/or contaminant removal apparatus SI 07 is configured for directing the molten (or semi-molten) plastic feedstock into the pyrolysis and/or contaminant removal apparatus S108.
  • the pyrolysis and/or contaminant removal apparatus S108 is generally configured for pyrolyzing the plastic feedstock and producing a product SI 12 (which can be optionally subjected to: recycling for further pyrolysis by the optional recycling apparatus S109; and/or post-treatment or contaminant removal by the one or more optional post-treatment and/or contaminant removal apparatuses SI 14a, SI 14b).
  • Figure 3 depicts another example system SI 00c for pyrolyzing plastic feedstock comprising post-consumer and/or post-industrial plastics (like numbers refer to like elements previously described with respect to the systems SlOOa, SI 00b of Figure 1 and Figure 2).
  • the system SI 00c comprises a plastic feedstock infeed apparatus S 102, a size reduction and/or sorting apparatus S 104, a melting and/or contaminant removal apparatus S107, a pyrolysis and/or contaminant removal apparatus S108, an optional recycling apparatus S 109, a condenser S 116, and a storage apparatus S 118.
  • Optional posttreatment and/or contaminant removal apparatuses are not shown, however, it is understood that they can also be included (e.g., as in the system S 100b of Figure 2).
  • the product S 112 is directed from the pyrolysis and/or contaminant removal apparatus S108 to the condenser SI 16.
  • the condenser SI 16 is configured for condensing at least a portion of the product SI 12. The condensed product produced by the condenser SI 16 is then collected and stored in a storage apparatus SI 18.
  • the condenser SI 16 can comprise any of the condensers described in the “Vaporized Product Recovery” section herein.
  • the storage apparatus SI 18 can comprise any of the storage apparatuses described in the “Product Storage” section herein.
  • the system SlOOc can use other apparatuses besides condensers for product recovery (e.g., any of the other product recovery apparatuses described in the “Vaporized Product Recovery” section herein).
  • the system SI 00c can include only one condenser or other product recovery apparatus.
  • the system SI 00c can include more than two condensers or other product recovery apparatuses.
  • the system SlOOc can include only one storage apparatus.
  • the system SlOOc can include more than two storage apparatuses.
  • the system SlOOc can use other apparatuses (e.g., any of the other product recovery apparatuses described in the “Vaporized Product Recovery” section herein).
  • Figure 4 depicts another example system SlOOd for pyrolyzing plastic feedstock comprising post-consumer and/or post-industrial plastics (like numbers refer to like elements previously described with respect to the systems SlOOa, SlOOb, and SlOOc of Figure 1- Figure 3).
  • the system SlOOd comprises a plastic feedstock infeed apparatus S 102, a size reduction and/or sorting apparatus S 104, an extruder apparatus S017a, a pyrolysis reactor S108a, an optional recycling apparatus S109, a condenser SI 16, and a storage apparatus SI 18.
  • Optional post- treatment and/or contaminant removal apparatuses are not shown, however, it is understood that they can also be included (e.g., as in the system SlOOb of Figure 2).
  • the size reduction and/or sorting apparatus SI 04 directs the plastic feedstock SI 02 into the extruder apparatus SI 07a.
  • the extruder apparatus S107a is configured for melting the plastic feedstock and removing vent gas and/or contaminants (shown as element S 110a in Figure 4). In other examples, the extruder apparatus S107a may not remove vent gas and/or contaminants.
  • the extruder apparatus S107a can comprise one or more of the extruder apparatuses or devices described in the “Extruders” section herein (e.g., one or more of the extruders 100-800 shown and described with respect to Figure 6- Figure 16).
  • the extruder apparatus S107a depicted in Figure 4 can comprise one or more (e.g., a plurality of) extruder apparatuses (e.g., arranged in parallel or in series) for melting the plastic feedstock S102.
  • the extruder S107a can be a single extruder.
  • the extruder S107a can comprise multiple extruders (e.g., multiple extruders having the same configuration or multiple extruders having different configurations).
  • the extruder apparatus SI 07a is configured for directing the molten (or semi-molten) plastic feedstock into the pyrolysis reactor S 108a.
  • the pyrolysis reactor SI 08a is generally configured for pyrolyzing the plastic feedstock received from the extruder S107a and producing a product SI 12 (e.g., hydrocarbon vapor).
  • the product SI 12 can be recycled back to the pyrolysis reactor S108a by the optional recycling apparatus S 109 for further pyrolysis of the product.
  • the product SI 12 can be subjected to post- treatment or contaminant removal by the one or more optional post-treatment and/or contaminant removal apparatuses SI 14a, SI 14b (not shown in Figure 4).
  • the pyrolysis reactor S108a can comprise one or more of the pyrolysis reactor apparatuses or devices described in the “Pyrolysis Reactors” section herein (e.g., one or more of the pyrolysis reactors 1000-8000 shown and described with respect to Figure 17- Figure 44).
  • the pyrolysis reactor SI 08a depicted in Figure 4 can comprise one or more (e.g., a plurality of) pyrolysis reactors configured for receiving molten or semi-molten plastic feedstock from the one or more extruder(s) SI 07a and pyrolyzing the plastic feedstock S102 to produce the product SI 12.
  • the pyrolysis reactor S108a can be a single pyrolysis reactor.
  • the pyrolysis reactor SI 08a can comprise multiple pyrolysis reactors (e.g., multiple pyrolysis reactors having the same configuration or multiple pyrolysis reactors having different configurations).
  • the extruder S107a and the pyrolysis reactor S108a can remove substantially the same quantity of vent gas and/or contaminants SI 10a or SI 10b, respectively. In other examples, the extruder S107a and the pyrolysis reactor S108a can remove different quantities of vent gas and/or contaminants SI 10a or SI 10b, respectively. In some examples, the vent gas and/or contaminants SI 10a can have substantially the same composition as the contaminants SI 10b. In other examples, the vent gas and/or contaminants can have different compositions.
  • the extruder S 107a can be selected to remove a different type of vent gas and/or contaminant than the pyrolysis reactor S108a.
  • the pyrolysis reactor SI 08a can, additionally or alternatively, be selected to remove a different type of contaminant than the extruder SI 07a.
  • Figure 5 depicts another example system SlOOe for pyrolyzing plastic feedstock comprising post-consumer and/or post-industrial plastics (like numbers refer to like elements previously described with respect to the systems SlOOa, SlOOb, SlOOe, and SlOOd of Figure 1- Figure 4).
  • the system SlOOe comprises a plastic feedstock infeed apparatus S102, a first size reduction and/or sorting apparatus S104a, a trommel S 104b, a second size reduction and/or sorting apparatus S 104c, a dryer S120, an extruder S017a, a pyrolysis reactor S108a, an optional recycling apparatus S109, a condenser SI 16, and a storage apparatus SI 18.
  • Optional post-treatment and/or contaminant removal apparatuses are not shown, however, it is understood that they can also be included (e.g., as in the system SI 00b of Figure 2).
  • the plastic feedstock S102 enters a first size reduction and/or sorting apparatus S104a, which removes a first group of contaminants S106a.
  • the plastic feedstock S 102 is then directed from the first size reduction and/or sorting apparatus SI 04a to a trommel SI 04b, which removes a second group of contaminants SI 06b.
  • the plastic feedstock SI 02 exiting the trommel SI 04b is then directed to a third size reduction and/or sorting apparatus S104c, which removes a third group of contaminants S106c.
  • any of the first size reduction and/or sorting apparatus S104a, the trommel SI 04b, and the third size reduction and/or sorting apparatus SI 04c may not remove contaminants.
  • each of the first size reduction and/or sorting apparatus SI 04a and the third size reduction and/or sorting apparatus S104c can include any of the sorting apparatuses described in the “Sorting” section below and/or any of the size reduction apparatuses described in the “Size Reduction” section below.
  • the first size reduction and/or sorting apparatus SI 04a can be the same as the third size reduction and/or sorting apparatus SI 04c. In other examples, the first size reduction and/or sorting apparatus SI 04a can be different than the third size reduction and/or sorting apparatus S104c.
  • each of the first size reduction and/or sorting apparatus S104a, the trommel SI 04b, and the third size reduction and/or sorting apparatus 104c can remove substantially the same quantity of contaminants S106a, S106b, or S 106c, respectively. In other examples, each of the first size reduction and/or sorting apparatus S104a, the trommel S104b, and the third size reduction and/or sorting apparatus SI 04c can remove different quantities of contaminants S 106a, S 106b, or S106c, respectively.
  • each of the first group of contaminants SI 06a, the second group of contaminants S106b, and the third group of contaminants S106c can have substantially the same composition. In other examples, each of the first group of contaminants SI 06a, the second group of contaminants SI 06b, and the third group of contaminants SI 06c can have different compositions.
  • the first size reduction and/or sorting apparatus SI 04a can be selected to remove a different type of contaminant than the trommel SI 04b and/or the third size reduction and/or sorting apparatus S104c.
  • the third size reduction and/or sorting apparatus S104c can, additionally or alternatively, be selected to remove a different type of contaminant than the trommel SI 04b and/or the first size reduction and/or sorting apparatus S 104a.
  • the plastic feedstock S102 exiting the second size reduction and/or sorting apparatus S104c is directed to a dryer S120.
  • the dryer S120 is configured to remove moisture and/or contaminants S122 from the plastic feedstock SI 02.
  • the dryer SI 20 can include any of the dryers described in the “Drying Component” section below.
  • any of the systems SlOOa, SlOOb, SlOOc, SlOOd, or SlOOe can include a storage bunker to store plastic feedstock S102 before and/or after the size reduction and/or sorting apparatus S104.
  • the storage bunker can include any of the storage bunkers described in the “Storage Bunker” section below.
  • any of the systems SlOOa, SlOOb, SlOOc, SlOOd, or SlOOe can include a metals detection and removal apparatus before and/or after the size reduction and/or sorting apparatus S 104.
  • the metals detection and removal apparatus can include any of the metals detection and removal apparatuses described in the “Metals Detection and Removal” section below.
  • the plastic feedstock SI 02 and/or the product SI 12 can be transported by one or more conveyors in any of the systems S lOOa, S lOOb, S lOOc, SlOOd, and/or SlOOe.
  • the one or more conveyors can include any of the conveyors described in the “Conveyors” section below.
  • any of the systems SlOOa, SlOOb, SlOOc, SlOOd, or SlOOe can include one or more heat tracing components.
  • the one or more heat tracing components can include any of the heat tracing components described in the “Heat Tracing” section below.
  • the feedstock comprises post-consumer and/or post-industrial plastics.
  • Post-industrial or Pre-consumer plastics include materials derived from waste streams during a plastic manufacturing process.
  • Post-consumer plastics include materials generated by households or by commercial, industrial, and/or institutional facilities in their roles as end-users of the product which can no longer be used for its intended purpose. This includes returns of material from the distribution chain.
  • the feedstock comprises 50% or more by weight post-consumer and/or post-industrial plastics (e.g., 51% or more, 52% or more, 53% or more, 54% or more, 55% or more, 56% or more, 57% or more, 58% or more, 59% or more, 60% or more, 61% or more, 62% or more, 63% or more, 64% or more, 65% or more, 66% or more, 67% or more, 68% or more, 69% or more, 70% or more, 71% or more, 72% or more, 73% or more, 74% or more, 75% or more, 76% or more, 77% or more, 78% or more, 79% or more, 80% or more, 81% or more, 82% or more, 83% or more, 84% or more, 85% or more, 86% or more, 87% or more, 88% or more, 89% or more, 90% or more, 91% or more, 92% or more, 93% or more, 94% or more, 95% or more, 9
  • the feedstock comprises 100% or less by weight post-consumer and/or post-industrial plastics (e.g., 99% or less, 98% or less, 97% or less, 96% or less, 95% or less, 94% or less, 93% or less, 92% or less, 91% or less, 90% or less, 89% or less, 88% or less, 87% or less, 86% or less, 85% or less, 84% or less, 83% or less, 82% or less, 81% or less, 80% or less, 79% or less, 78% or less, 77% or less, 76% or less, 75% or less, 74% or less, 73% or less, 72% or less, 71% or less, 70% or less, 69% or less, 68% or less, 67% or less, 66% or less, 65% or less, 64% or less, 63% or less, 62% or less, 61% or less, 60% or less, 59% or less, 58% or less, 57% or less, 56% or less, 55% or less, 5
  • the percent by weight of the feedstock that is post-consumer and/or post-industrial plastics can range from any of the minimum values described above to any of the maximum values described above.
  • the feedstock can comprise from 50% to 100% by weight post-consumer and/or post-industrial plastics (e.g., from 50% to 75%, from 75% to 100%, from 50% to 60%, from 60% to 70%, from 70% to 80%, from 80% to 90%, from 90 to 100%, from 50 to 99%, from 50 to 95%, from 50 to 90%, from 50% to 80%, from 50% to 70%, from 55% to 100%, from 60% to 100%, from 70% to 100%, from 75 to 100%, from 80 to 100%, from 95 to 100%, from 55% to 99%, from 70% to 99%, or from 75 to 95%).
  • Plastic feedstock can be provided in any suitable form, such as, for example, loose film, baled film, rigids, thermoforms, sheets, foams, non-wovens, strips, pellets, powder, purge patties, densified, shredded, etc.
  • the feedstock comprises films, such as single and/or multi-layered films.
  • the plastic feedstock can be packaged, e.g. in bales, boxes, drums, etc.
  • the feedstock can, for example, comprise polyethylene (e.g., LDPE, LLDPE, VLDPE, MDPE, HDPE, UHMWPE, PEX, etc.), polypropylene, polystyrene, or a combination thereof.
  • the feedstock includes plastics with a plastic type classification # 2, 4, 5, 6, or a combination thereof.
  • a majority of the plastic that is processed by the systems and methods described herein comprises low-density or linear-low density polyethylene (LDPE - #4) and high-density polyethylene (HDPE - #2), in particular film plastic, and the systems and methods described herein are optimized to effectively process these materials.
  • LDPE - #4 low-density or linear-low density polyethylene
  • HDPE - #2 high-density polyethylene
  • Polyethylene and polypropylene polymers are used in single use plastics and get discarded after its use.
  • Polyethylene is used widely in various consumer and industrial products. Polyethylene is the most common plastic, over 100 million tons of polyethylene resins are produced annually. Its primary use is in packaging (plastic bags, plastic films, geomembranes, containers including bottles, etc.).
  • Polyethylene is produced in a variety of forms (e.g., ultra-high molecular weight polyethylene (UHMWPE), high-density polyethylene (HDPE), medium density polyethylene (MDPE), linear low-density polyethylene (LLDPE), low- density polyethylene (LDPE), very low density polyethylene (VLDPE), crosslinked polyethylene (PEX)) with the same chemical formula (CzH ⁇ n but different molecular structure.
  • UHMWPE ultra-high molecular weight polyethylene
  • HDPE high-density polyethylene
  • MDPE medium density polyethylene
  • LLDPE linear low-density polyethylene
  • LDPE low- density polyethylene
  • VLDPE very low density polyethylene
  • PEX crosslinked polyethylene
  • HDPE has a low degree of branching with short side chains
  • LDPE has a very high degree of branching with long side chains.
  • LLDPE is a substantially linear polymer with significant numbers of short branches, commonly made by copolymerization of ethylene with short-chain al
  • the feedstock can, for example, comprise polyethylene, polypropylene, polystyrene, or a combination thereof in an amount of 90% or more by weight (e.g., 91% or more, 92% or more, 93% or more, 94% or more, 95% or more, 96% or more, 97% or more, 98% or more, or 99% or more).
  • the feedstock comprises polyethylene, polypropylene, polystyrene, or a combination thereof in an amount of 100% or less by weight (e.g., 99% or less, 98% or less, 97% or less, 96% or less, 95% or less, 94% or less, 93% or less, 92% or less, or 91% or less).
  • the amount of polyethylene, polypropylene, polystyrene, or a combination thereof in the feedstock can range from any of the minimum values described above to any of the maximum values described above.
  • the feedstock can comprise polyethylene, polypropylene, polystyrene, or a combination thereof in an amount of from 90% to 100% by weight (e.g., from 90% to 95%, from 95% to 100%, from 90% to 92%, from 92% to 94%, from 94% to 96%, from 96% to 98%, from 98% to 100%, from 90% to 98%, from 90% to 96%, from 90% to 94%, from 92% to 100%, from 94% to 100%, from 96% to 100%, from 91% to 99%, from 92% to 98%, or from 93% to 97%).
  • the feedstock comprises moisture (e.g., water) in an amount of 20% or less by weight (e.g., 19.5% or less, 19% or less, 18.5% or less, 18% or less, 17.5% or less, 17% or less, 16.5% or less, 16% or less, 15.5% or less, 15% or less, 14.5% or less, 14% or less, 13.5% or less, 13% or less, 12.5% or less, 12% or less, 11.5% or less, 11% or less, 10.5% or less, 10% or less, 9.5% or less, 9% or less, 8.5% or less, 8% or less, 7.5% or less, 7% or less, 6.5% or less, 6% or less, 5.5% or less, 5% or less, 6% or less, 5.5% or less, 5% or less, 6% or less, 5.5% or less, 5% or less, 6% or less, 5.5% or less, 5% or less, 4.5% or less, 4% or less, 3.5% or less, 3% or less, 2.5% or less, 2% or less, 1.5% or
  • the amount of moisture in the feedstock can range from any of the minimum values described above to any of the maximum values described above.
  • the feedstock can comprise moisture in an amount of from 0% to 20% by weight (e.g., from 0% to 10%, from 10% to 20%, from 0% to 5%, from 5% to 10%, from 5% to 15%, from 15% to 20%, from 0% to 2.5%, 2.5% to 5%, from 5% to 7.5%, from 7.5% to 10%, from 10% to 12.5%, from 12.5% to 15%, from 15% to 17.5%, from 17.5% to 20.%, from 0% to 19%, from 0% to 18%, from 0% to 17%, from 0% to 16%, from 0% to 15%, from 0% to 14%, from 0% to 13%, from 0% to 12%, from 0% to 11%, from 0% to 9%, from 0% to 8%, from 0% to 7%, from 0% to 6%, from 0% to 4%, from 0% to 3%, from 0% to 2%, from 0% to 1 %, from 1 % to 20%, from 2% to 20%, from 3% to 20%, from 4% to 0%
  • PVDC polyvinylidene chloride
  • PET polyethylene terephthalate
  • EVOH ethylene vinyl alcohol
  • PC polycarbonate
  • ABS acrylonitrile butadiene styrene
  • non-plastic components e.g., metal, glass, wood, cotton, paper, cardboard, dirt, inorganics, etc.
  • the feedstock comprises 10% or less by weight polyvinyl chloride (PVC), polyvinylidene chloride (PVDC), polyethylene terephthalate (PET), nylon, ethylene vinyl alcohol (EVOH), polycarbonate (PC), acrylonitrile butadiene styrene (ABS), rubber, thermosets, or a combination thereof (e.g., 9% or less, 8% or less, 7% or less, 6% or less, 5% or less, 4.5% or less, 4% or less, 3.5% or less, 3% or less, 2.5% or less, 2% or less, 1.75% or less, 1.5% or less, 1.25% or less, 1% or less, 0.9% or less, 0.8% or less, 0.7% or less, 0.6% or less, 0.5% or less, 0.4% or less, 0.3% or less, 0.2% or less, or 0.1% or less).
  • PVC polyvinyl chloride
  • PVDC polyvinylidene chloride
  • PET polyethylene terephthalate
  • the feedstock comprises 0% or more by weight polyvinyl chloride (PVC), polyvinylidene chloride (PVDC), polyethylene terephthalate (PET), nylon, ethylene vinyl alcohol (EVOH), polycarbonate (PC), acrylonitrile butadiene styrene (ABS), rubber, thermosets, or a combination thereof (e.g., 0.1% or more, 0.2% or more, 0.3% or more, 0.4% or more, 0.5% or more, 0.6% or more, 0.7% or more, 0.8% or more, 0.9% or more, 1% or more, 1.25% or more, 1.5% or more, 1.75% or more, 2% or more, 2.5% or more, 3% or more, 3.5% or more, 4% or more, 5% or more, 6% or more, 7% or more, 8% or more, or 9% or more).
  • PVDC polyvinyl chloride
  • PVDC polyvinylidene chloride
  • PET polyethylene terephthalate
  • EVOH ethylene vinyl
  • the amount of polyvinyl chloride (PVC), polyvinylidene chloride (PVDC), polyethylene terephthalate (PET), nylon, ethylene vinyl alcohol (EVOH), polycarbonate (PC), acrylonitrile butadiene styrene (ABS), rubber, thermosets, or a combination thereof in the feedstock can range from any of the minimum values described above to any of the maximum values described above.
  • the feedstock can comprise from 0% to 10% by weight polyvinyl chloride (PVC), polyvinylidene chloride (PVDC), polyethylene terephthalate (PET), nylon, ethylene vinyl alcohol (EVOH), polycarbonate (PC), acrylonitrile butadiene styrene (ABS), rubber, thermosets, or a combination thereof (e.g., from 0% to 5%, from 5% to 10%, from 0% to 2.5%, from 2.5% to 5%, from 5% to 7.5%, from 7.5% to 10%, from 0% to 1%, from 1% to 2%, from 2% to 3%, from 3% to 4%, from 4% to 5%, from 5% to 6%, from 6% to 7%, from 7% to 8%, from 8% to 9%, from 9% to 10%, from 0% to 9%, from 0% to 8%, from 0% to 7%, from 0% to 6%, from 0% to 4.5%, from 0% to 4%, from 0% to
  • the feedstock can, for example, comprise 15% by weight or less non-plastic materials, such as metal, glass, wood, cotton, paper, cardboard, dirt, inorganics, etc., or a combination thereof (e.g., 14.5% or less, 14% or less, 13.5% or less, 13% or less, 12.5% or less, 12% or less, 11.5% or less, 11% or less, 10.5% or less, 10% or less, 9.5% or less, 9% or less, 8.5% or less, 8% or less, 7.5% or less, 7% or less, 6.5% or less, 6% or less, 5.5% or less, 5% or less, 4.5% or less, 4% or less, 3.5% or less, 3% or less, 2.5% or less, 2% or less, 1.5% or less, 1% or less, or 0.5% or less).
  • non-plastic materials such as metal, glass, wood, cotton, paper, cardboard, dirt, inorganics, etc., or a combination thereof (e.g., 14.5% or less, 14% or less, 13.5% or less
  • the feedstock comprises 0% or more by weight non-plastic materials (e.g., 0.5% or more, 1% or more, 1.5% or more, 2% or more, 2.5% or more, 3% or more, 3.5% or more, 4% or more, 4.5% or more, 5% or more, 5.5% or more, 6% or more, 6.5% or more, 7% or more, 7.5% or more, 8% or more, 8.5% or more, 9% or more, 9.5% or more, 10% or more, 10.5% or more, 11% or more, 11.5% or more, 12% or more, 12.5% or more, 13% or more, 13.5% or more, or 14% or more).
  • non-plastic materials e.g., 0.5% or more, 1% or more, 1.5% or more, 2% or more, 2.5% or more, 3% or more, 3.5% or more, 4% or more, 4.5% or more, 5% or more, 5.5% or more, 6% or more, 6.5% or more, 7% or more, 7.5% or more, 8% or more, 8.5%
  • the amount of non-plastic materials in the feedstock can range from any of the minimum values described above to any of the maximum values described above.
  • the feedstock can comprise non-plastic materials in an amount of from 0% to 15% by weight (e.g., from 0% to 7.5%, from 7.5% to 15%, from 0% to 5%, from 5% to 10%, from 10% to 15%, from 0% to 2.5%, 2.5% to 5%, from 5% to 7.5%, from 7.5% to 10%, from 10% to 12.5%, from 12.5% to 15%, from 0% to 14%, from 0% to 13%, from 0% to 12%, from 0% to 11%, from 0% to 10%, from 0% to 9%, from 0% to 8%, from 0% to 7%, from 0% to 6%, from 0% to 4%, from 0% to 3%, from 0% to 2%, from 1% to 15%, from 2% to 15%, from 3% to 15%, from 4% to 15%, from 5% to 15%, from 6% to 15%, from 7% to 15%, from
  • the feedstock can include plastic having an average initial size of 0.025 inches or more (longest dimension) (e.g., 0.05 inches or more, 0.075 inches or more, 0.1 inches or more, 0.25 inches or more, 0.5 inches or more, 0.75 1 inch or more, 1.5 inches or more, 2 inches or more, 3 inches or more, 4 inches or more, 5 inches or more, 6 inches or more, 7 inches or more, 8 inches or more, 9 inches or more, 10 inches or more, 11 inches or more, 12 inches or more, 13 inches or more, 14 inches or more, 15 inches or more, 16 inches or more, 17 inches or more, 18 inches or more, 20 inches or more, 22 inches or more, 24 inches or more, 26 inches or more, 28 inches or more, 30 inches or more, 32 inches or more, or 34 inches or more, 36 inches or more, 42 inches or more, 48 inches or more, 54 inches or more, 60 inches or more).
  • longest dimension e.g., 0.05 inches or more, 0.075 inches or more, 0.1 inches or more, 0.
  • the feedstock can include plastic having an average initial size of 60 inches or less (longest dimension) (e.g., 54 inches or less, 48 inches or less, 42 inches or less, 36 inches or less, 34 inches or less, 32 inches or less, 30 inches or less, 28 inches or less, 26 inches or less, 24 inches or less, 22 inches or less, 20 inches or less, 18 inches or less, 17 inches or less, 16 inches or less, 15 inches or less, 14 inches or less, 13 inches or less, 12 inches or less, 11 inches or less, 10 inches or less, 9 inches or less, 8 inches or less, 7 inches or less, 6 inches or less, 5 inches or less, 4 inches or less, 3 inches or less, 2 inches or less, 1 inch or less, 0.5 inches or less, or 0.25 inches or less).
  • longest dimension e.g., 54 inches or less, 48 inches or less, 42 inches or less, 36 inches or less, 34 inches or less, 32 inches or less, 30 inches or less, 28 inches or less, 26 inches or less, 24 inches or less, 22 inches or
  • the average longest dimension of the plastic in the feedstock can range from any of the minimum values described above to any of the maximum values described above.
  • the feedstock can include plastic having an average initial size of from 0.025 inches to 60 inches (longest dimension) (e.g., from 0.025 to 30 inches, from 30 to 60 inches, from 0.025 to 12 inches, from 12 to 24 inches, from 24 to 36 inches, from 36 to 48 inches, from 48 to 60 inches, from 0.025 to 50 inches, from 0.025 to 40 inches, from 0.025 to 30 inches, from 0.025 to 24 inches, from 0.025 to 18 inches, from 0.025 to 16 inches, from 0.025 to 14 inches, from 0.025 to 10 inches, from 0.025 to 8 inches, from 0.025 to 4 inches, from 0.025 to 2 inches, from 0.025 inches to 1 inch, from 0.25 to 60 inches, from 1 to 60 inches, from 2 to 60 inches, from 4 to 60 inches, from 6 to 60 inches, from 8 to 60 inches, from 10 to 60 inches, from 12 to 60 inches
  • the feedstock can initially be manually, visually, and/or automatically (e.g., by an automated system/component) checked to ensure it contains the correct material and does not contain an inordinate amount of obvious contamination.
  • the feedstock is inspected for large contaminant items, such as metal, glass, PVC, paper, wood, PET plastics, and cardboard, which are removed when identified.
  • the feedstock can further be assessed, e.g. for chemical and/or physical properties. This can include, for example, assessing at least a representative sample portion of each feedstock via infrared analysis (e.g., portable infrared analyzer), gas chromatography- mass spectrometry (GC-MS), a bench-scale pyrolysis test, ASTM testing for specific contaminants and physical properties, melt-index test, ash test, or a combination thereof.
  • infrared analysis e.g., portable infrared analyzer
  • GC-MS gas chromatography- mass spectrometry
  • ASTM testing for specific contaminants and physical properties e.g., melt-index test, ash test, or a combination thereof.
  • Feedstock that fails to meet the initial inspection criteria is not further processed by the systems or methods described herein.
  • the acceptable feedstock can be stored for future use (e.g., in a stockpile, a hopper, etc.) and/or loaded into the system for processing.
  • the feedstock can be loaded into the system via an infeed conveyor.
  • the rate at which the infeed conveyor provides feedstock to the system can, for example, be 500 pounds per hour (Ib./hr.) or more (e.g., 550 Ib./hr. or more; 600 Ib./hr. or more; 650 Ib./hr. or more; 700 Ib./hr. or more; 750 Ib./hr. or more; 800 Ib./hr. or more; 850 Ib./hr. or more; 900 Ib./hr. or more; 950 Ib./hr. or more; 1000 Ib./hr.
  • Ib./hr. or more 2000 Ib./hr. or more; 2250 Ib./hr. or more; 2500 Ib./hr. or more; 2750 Ib./hr. or more; 3000 Ib./hr. or more; 3250 Ib./hr. or more; 3500 Ib./hr. or more; 3750 Ib./hr. or more; 4000
  • Ib./hr. or more 4250 Ib./hr. or more; 4500 Ib./hr. or more; 4750 Ib./hr. or more; 5000 Ib./hr. or more; 5500 Ib./hr. or more; 6000 Ib./hr. or more; 6500 Ib./hr. or more; 7000 Ib./hr. or more; 7500
  • Ib./hr. or more 8000 Ib./hr. or more; 8500 Ib./hr. or more; 9000 Ib./hr. or more; 9500 Ib./hr. or more; 10,000 Ib./hr. or more; 11,000 Ib./hr. or more; 12,000 Ib./hr. or more; 13,000 Ib./hr. or more; 14,000 Ib./hr. or more; 15,000 Ib./hr. or more; 16,000 Ib./hr. or more; 17,000 Ib./hr. or more; 18,000 Ib./hr. or more; or 19,000 lb ./hr. or more).
  • the rate at which the infeed conveyor provides feedstock to the system can be 20,000 Ib./hr. or less (e.g., 19,000 Ib./hr. or less; 18,000 Ib./hr. or less; 17,000 Ib./hr. or less; 16,000 Ib./hr. or less; 15,000 Ib./hr. or less; 14,000 Ib./hr. or less; 13,000 Ib./hr. or less; 12,000 Ib./hr. or less; 11,000 Ib./hr. or less; 10,000 Ib./hr. or less; 9500 Ib./hr. or less; 9000 Ib./hr.
  • the rate at which the infeed conveyor provides feedstock to the system can range from any of the minimum values described above to any of the maximum values described above.
  • the rate at which the infeed conveyor provides feedstock to the system can be from 500 pounds per hour (Ib./hr.) to 20,000 Ib./hr.
  • feedstock loaded into the system can undergo additional sorting.
  • the plastic feedstock can be deposited onto a conveyor and/or further processed to remove contaminants.
  • This can, for example, include visual inspection and manual removal, automated inspection and removal, positioning one or more magnets to magnetically remove ferrous contaminants (e.g., various components such as nuts, bolts, screws, small pieces of wire, etc. comprising ferrous metals and/or alloys), washing and/or drying, size based separation (e.g., screening, sifting, etc.), air jets, sink float, etc.
  • the feedstock can be transported to a trommel, such as a screen trommel.
  • the screen trommel can, for example, be used to remove fine dust, particles, and other contaminants from the incoming feedstock stream, for example before and/or after it has passed through a shredder.
  • the trommel can receive feedstock and trommel rotation can agitate incoming feedstock and promote removal of granular materials (e.g., sand, pigment, binder, food particulates, dirt, etc.) in the feedstock through the trommel screen.
  • the remaining oversized material from the trommel can be deposited, for example, onto a conveyor for further inspection and/or sorting.
  • visual inspection and manual sorting and/or automated inspection and sorting is used to remove contaminants from the plastic feedstock, e.g., before and/or after passing through the trommel and/or shredder.
  • Contaminants to be removed can, for example, include undesirable plastic (such as PET, PVC, nylon, and thermosets) as well as other materials that can damage downstream equipment or degrade the quality of the finished products such as strapping, paper, cardboard, rope, batteries, beverage bottles still containing liquid, glass, wood, metal, electronics, and a wide range of other non-plastic materials.
  • feedstock loaded into the system can undergo one or more size reductions.
  • the size reduction can be accomplished by any suitable means, such as those known in the art.
  • the feedstock can be shredded, pelletized, densified, or a combination thereof.
  • the system can include one or more size reduction components, such as a chipper, granulator, grinder, hammermill, shredder (e.g., a shear shredder), pelletizer, densifier, agglomerator, or a combination thereof.
  • the feedstock can be shredded, for example using one or more shredders.
  • Each shredder can comprise any suitable type of shredder, such as those known in the art.
  • the system can include one or more shear shredders.
  • the shredder can perform a size reduction on incoming plastic, for example to a range of 0.25 to 36 inches (longest dimension).
  • the shredder can reduce the average initial size of the incoming plastic to 0.25 inches or more (longest dimension) (e.g., 0.5 inches or more, 1 inch or more, 1.5 inches or more, 2 inches or more, 3 inches or more, 4 inches or more, 5 inches or more, 6 inches or more, 7 inches or more, 8 inches or more, 9 inches or more, 10 inches or more, 11 inches or more, 12 inches or more, 13 inches or more, 14 inches or more, 15 inches or more, 16 inches or more, 17 inches or more, 18 inches or more, 20 inches or more, 22 inches or more, 24 inches or more, 26 inches or more, 28 inches or more, 30 inches or more, 32 inches or more, or 34 inches or more).
  • the shredder can reduce the average initial size of the incoming plastic to 36 inches or less (longest dimension) (e.g., 34 inches or less, 32 inches or less, 30 inches or less, 28 inches or less, 26 inches or less, 24 inches or less, 22 inches or less, 20 inches or less, 18 inches or less, 17 inches or less, 16 inches or less, 15 inches or less, 14 inches or less, 13 inches or less, 12 inches or less, 11 inches or less, 10 inches or less, 9 inches or less, 8 inches or less, 7 inches or less, 6 inches or less, 5 inches or less, 4 inches or less, 3 inches or less, 2 inches or less, or 1 inch or less).
  • longest dimension e.g., 34 inches or less, 32 inches or less, 30 inches or less, 28 inches or less, 26 inches or less, 24 inches or less, 22 inches or less, 20 inches or less, 18 inches or less, 17 inches or less, 16 inches or less, 15 inches or less, 14 inches or less, 13 inches or less, 12 inches or less, 11 inches or less, 10
  • the average longest dimension of the plastic processed by the shredder can range from any of the minimum values described above to any of the maximum values described above.
  • the shredder can reduce the average initial size of the incoming plastic to from 0.25 inches to 36 inches (longest dimension) (e.g., from 0.25 to 18 inches, from 18 to 36 inches, from 0.25 to 6 inches, from 6 to 12 inches, from 12 to 18 inches, from 18 to 24 inches, from 24 to 30 inches, from 30 to 36 inches, from 0.25 to 30 inches, from 0.25 to 24 inches, from 0.25 to 18 inches, from 0.25 to 16 inches, from 0.25 to 14 inches, from 0.25 to 12 inches, from 0.25 to 10 inches, from 0.25 to 8 inches, from 0.25 to 4 inches, from 0.25 to 2 inches, from 0.25 inches to 1 inch, from 1 to 36 inches, from 2 to 36 inches, from 4 to 36 inches, from 6 to 36 inches, from 8 to 36 inches, from 10 to 36 inches, from 12 to 36 inches, from 14 to 36 inches, from 16 to 36 inches, from 18 to 36
  • Plastic feedstock that passes through the shredder can then be stored in a hopper and/or transported for further processing.
  • the shredded feedstock can go through a second size reduction process using any suitable size reduction technique.
  • systems and methods can further include washing and/or drying the feedstock.
  • the systems and methods can further comprise drying the feedstock, for example to remove at least a portion of the moisture or other liquids comprising a contaminant within the feedstock.
  • the feedstock can be deposited onto a conveyor which passes the feedstock through a dryer before depositing the feedstock in a storage bunker and/or transporting the feedstock to a further system component for further processing.
  • the dryer can comprise any suitable equipment, such as a rotary dryer. Heated air can be directed through the dryer across the feedstock to remove moisture from the feedstock. The surface area exposed can allow the heated air flow to remove moisture or free water that can be present in the feedstock.
  • the moist air along with small, entrained particles from the dryer can be exhausted using any suitable means.
  • the required air can be heated by any suitable means, such as electrically heated. The maximum air temperature will be below the softening point of any of the plastics. Using an effective drying solution upstream of the extruders and/or reactors can reduce the problems of vent flow at downstream extrusion equipment and water intrusion to the reactors.
  • the system can further include a storage bunker, for example to store feedstock before undergoing melting, removal of contaminants, pyrolysis, or a combination thereof.
  • the system includes a storage bunker that receives the feedstock from the infeed conveyor, the shredder (when present), the dryer (when present), the trommel (when present), etc. or a combination thereof.
  • the storage bunker can, for example, have the capacity to store enough feedstock to provide an uninterrupted supply of plastic to the downstream components (e.g., extruder(s)) for a period of time (e.g., up to two hours), for example if any of the upstream equipment has to be shut down briefly for maintenance or repair.
  • the downstream components e.g., extruder(s)
  • a period of time e.g., up to two hours
  • Feedstock levels inside the storage bunker can be monitored, for example using one or more cameras or other feedback mechanisms.
  • feedstock loaded into the system can undergo additional metals detection and removal.
  • the plastic feedstock can be deposited onto a conveyor and/or further processed to metal contaminants. This can, for example, include visual inspection and manual removal, automated inspection and removal, positioning one or more magnets to magnetically remove ferrous contaminants (e.g., various components such as nuts, bolts, screws, small pieces of wire, etc. comprising ferrous metals and/or alloys), washing and/or drying, size based separation (e.g., screening, sifting, etc.), air jets, sink float, etc.
  • ferrous contaminants e.g., various components such as nuts, bolts, screws, small pieces of wire, etc. comprising ferrous metals and/or alloys
  • size based separation e.g., screening, sifting, etc.
  • the system can include magnets positioned before, after, or as part of each of the one or more conveyors that transport the feedstock between each system location/component. The strength of the magnets can be selected based on the location in the system and/or the throughput of feedstock processed.
  • the system can further include a metal detection and rejection system to eliminate further metal contaminants, such as non-ferrous metals (e.g., copper, brass, bronze, stainless steel, aluminum and other non-ferrous alloys).
  • non-ferrous metals e.g., copper, brass, bronze, stainless steel, aluminum and other non-ferrous alloys.
  • Non-ferrous metals can be present in a variety of forms, such as, for example, nuts, bolts, screws, washers, batteries, machine parts, tools, etc.
  • the additional metal detection system can be included in the system, for example, on the conveyors feeding the storage bunkers. This additional metal detection system can detect non-ferrous metals and then trigger a quick-acting diverter gate (or another similar device) that moves this metal off the conveyor and into a collection bin (or the conveyor can be stopped entirely to allow operators to manually remove the detected metal). While aluminum is the primary target of this system, copper, stainless steel, and brass can also be detected and rejected.
  • each of the conveyors can comprise any suitable type of conveyor.
  • conveyors include, but are not limited to, belt conveyors, roller conveyors, slat conveyors, apron conveyors, ball transfer conveyors, magnetic conveyors, bucket conveyors, chute conveyors, chain conveyors, pneumatic conveyors, vacuum conveyors, screw conveyors, vibrating conveyors, wheel conveyors, sandwich conveyors, and combinations thereof.
  • each of the conveyors can comprise a screw conveyor, a belt conveyor, or a combination thereof.
  • the system can include a plurality of belt conveyors.
  • the belt conveyors can, for example, be designed with side walls.
  • the belt conveyors can include any type of belt conveyor, such as standard flat belts, cleated belts, semi-trough belts, compound belts (e.g., hockey stick configurations), or a combination thereof.
  • any of the conveyors can be selected in view of a variety of factors.
  • the dimensions and/or speed of the conveyor can be selected to regulate the flow of materials at a desired rate.
  • the systems can include one or more components (e.g., energy transfer apparatuses) for melting the feedstock, volatilizing various contaminants in the feedstock, pyrolyzing the feedstock, or a combination thereof.
  • components e.g., energy transfer apparatuses
  • the systems and methods can comprise pyrolyzing the feedstock, wherein the pyrolysis reactor and method includes a component or step for removal of volatile contaminants.
  • the pyrolysis can be accomplished using any suitable pyrolysis reactor, such as, for example, an auger pyrolysis reactor, a screw pyrolysis reactor, a rotary kiln pyrolysis reactor, a drum pyrolysis reactor, a tubular pyrolysis reactor, a fluidized bed reactor, a spouted bed reactor, a molten salt reactor, a molten material reactor, a fixed-bed reactor, a continuously stirred reactor, a Heinz Retort Pyrolysis reactor, a vortex pyrolysis reactor, a batch pyrolysis reactor, a semi-batch pyrolysis reactor, or a combination thereof.
  • the systems and methods can comprise heating and/or melting the feedstock before introducing the melted feedstock into a pyrolysis reactor, wherein the feedstock is heated and/or melted at a temperature sufficient to volatilize a contaminant and the systems and methods can further include removing said volatilized contaminants.
  • Any suitable component for heating and/or melting can be used, such as those known in the art.
  • the systems and methods can include one or more extruders, wherein the feedstock is heated and/or melted within the extruder and optionally wherein the extruder includes one or more vents for removing volatile contaminants from the heated and/or melted feedstock.
  • one or more energy transfer apparatuses can be implemented and configured for receiving the plastic feedstock, applying energy to the plastic feedstock, and pyrolyzing the plastic feedstock at industrial scale.
  • the one or more energy transfer apparatuses can comprise one or more extruders and/or one or more pyrolysis reactors.
  • the one or more extruders can be configured for receiving the plastic feedstock, transferring energy to the plastic feedstock to melt the plastic feedstock to produce at least semi-molten feedstock, and directing the at least semi-molten feedstock to at least one of the one or more pyrolysis reactors.
  • the one or more pyrolysis reactors are configured for receiving the plastic feedstock (e.g., in a molten or semi-molten state from the one or more extruders) and pyrolyzing the plastic feedstock at industrial scale.
  • the one or more pyrolysis reactors can comprise a reactor vessel defining an internal volume configured for receiving and pyrolyzing the plastic feedstock at an industrial scale, and one or more heaters configured for heating the feedstock in the reactor vessel’s internal volume to a temperature between 200°C and l,000°C.
  • the pyrolysis systems can include one or more extruders (e.g., one or more extruders configured for heating plastic feedstock and converting the plastic feedstock into a molten or semi-molten state that is directed into one or more pyrolysis reactors).
  • the plastic feedstock being fed into the extruder has a bulk density.
  • the bulk density refers to the mass of the plastic feedstock divided by its volume prior to the plastic feedstock being directed into an extruder or pyrolysis reactor (e.g., the bulk density of the uncompressed plastic feedstock in the extruder hopper prior to being forced into the extruder barrel). Bulk density can, for example, be determined using ASTM DI 895 B.
  • the plastic feedstock can comprise low bulk density recycled plastic feedstock.
  • the low bulk density recycled plastic feedstock can be provided in the form of recycled plastic film feedstock (e.g., shredded recycled plastic film feedstock that has been subjected to one or more sorting, size reduction, and/or drying operations and that has a bulk density less than recycled plastic feedstock provided in pellet form).
  • the low bulk density recycled plastic feedstock can be fed into an extruder from a hopper (e.g., such that the low bulk density recycled plastic feedstock exits the hopper and a pneumatic or hydraulic ram or other compression apparatus then compresses the low bulk density feedstock as it enters the extruder barrel, as shown and described with respect to Figure 6- Figure 16).
  • the feedstock can then be output from the extruder in molten or semi-molten form and directed into a pyrolysis reactor according to various implementations described herein.
  • the low bulk density recycled plastic feedstock can have a bulk density of 500 kg/m 3 or less (e.g., 450 kg/m 3 or less, 400 kg/m 3 or less, 350 kg/m 3 or less, 300 kg/m 3 or less, 275 kg/m 3 or less, 250 kg/m 3 or less, 225 kg/m 3 or less, 200 kg/m 3 or less, 175 kg/m 3 or less, 150 kg/m 3 or less, 140 kg/m 3 or less, 130 kg/m 3 or less, 120 kg/m 3 or less, 110 kg/m 3 or less, 100 kg/m 3 or less, 95 kg/m 3 or less, 90 kg/m 3 or less, 85 kg/m 3 or less, 80 kg/m 3 or less, 75 kg/m 3 or less, 70 kg/m 3 or less, 65 kg/m 3 or less, 60 kg/m 3 or less, 55 kg/m 3 or less, 50 kg/m 3 or less, 45 kg/m 3 or less, 40 kg/m 3 or less, 35 kg/
  • the bulk density of the low bulk density recycled plastic feedstock can range from any of the minimum values described above to any of the maximum values described above.
  • the low bulk density plastic feedstock can have a bulk density of from 10 to 500 kg/m 3 (e.g., from 10 to 250 kg/m 3 , from 250 to 500 kg/m 3 , from 10 to 100 kg/m 3 , from 100 to 200 kg/m 3 , from 200 to 300 kg/m 3 , from 300 to 400 kg/m 3 , from 400 to 500 kg/m 3 , from 10 to 450 kg/m 3 , from 10 to 400 kg/m 3 , from 10 to 350 kg/m 3 , from 10 to 300 kg/m 3 , from 10 to 250 kg/m 3 , from 10 to 200 kg/m 3 , from 10 to 150 kg/m 3 , from 10 to 100 kg/m 3 , from 10 to 50 kg/m 3 , from 20 to 500 kg/m 3 , from 30 to 500 kg/m 3 , from 40 to 500 kg/m 3 , from 50
  • the low bulk density recycled plastic feedstock can have a bulk density of from 10 to 250 kg/m 3 . In some examples, the low bulk density recycled plastic feedstock can have a bulk density of from 10 to 100 kg/m 3 . In some examples, the low bulk density recycled plastic feedstock can have a bulk density of from 20 to 100 kg/m 3 . In some examples, the low bulk density recycled plastic feedstock can have a bulk density of from 30 to 100 kg/m 3 . In some examples, the low bulk density recycled plastic feedstock can have a bulk density of from 20 to 250 kg/m 3 . In some examples, the low bulk density recycled plastic feedstock can have a bulk density of from 30 to 250 kg/m 3 .
  • the recycled plastic feedstock being fed into the extruder can have an average melt flow index (MFI).
  • the plastic feedstock can comprise a plurality of different plastic materials, each with its own MFI, such that the average MFI of the plastic feedstock comprises a weighted average of the MFI of the different plastic materials.
  • average melt flow index refers to the weighted average (e.g., weighted average by volume or mass) of the MFI of the plastic materials comprising the recycled plastic feedstock prior to the feedstock being directed into an extruder or pyrolysis reactor (e.g., shredded recycled plastic film feedstock that has been subjected to one or more sorting, size reduction, and/or drying operations prior to being directed to an extruder).
  • the melt flow index of each of the different plastic materials and/or the average melt flow index of the plastic feedstock can be determined, for example, using ASTM DI 238 B.
  • the plastic feedstock can have an average melt flow index of 20 g/lOmin or less (e.g., 19 g/lOmin or less, 18 g/lOmin or less, 17 g/lOmin or less, 16 g/lOmin or less, 15 g/lOmin or less, 14 g/lOmin or less, 13 g/lOmin or less, 12 g/lOmin or less, 11 g/lOmin or less, 10 g/lOmin or less, 9.5 g/lOmin or less, 9 g/lOmin or less, 8.5 g/lOmin or less, 8 g/lOmin or less, 7.5 g/lOmin or less, 7 g/lOmin or less, 6.5 g/lOmin or less, 6 g/lOmin or less, 5.75 g/lOmin or less, 5.5 g/lOmin or less, 5.25 g/lOmin or less, 5 g/lOmin
  • the plastic feedstock can have an average melt flow index of 0.01 g/lOmin or more (e.g., 0.05 g/lOmin or more, 0.1 g/lOmin or more, 0.15 g/lOmin or more, 0.2 g/lOmin or more, 0.25 g/lOmin or more, 0.3 g/lOmin or more, 0.35 g/lOmin or more, 0.4 g/lOmin or more, 0.45 g/lOmin or more, 0.5 g/lOmin or more, 0.55 g/lOmin or more, 0.6 g/lOmin or more, 0.65 g/lOmin or more, 0.7 g/lOmin or more, 0.75 g/lOmin or more, 0.8 g/lOmin or more, 0.85 g/lOmin or more, 0.9 g/lOmin or more, 0.95 g/lOmin or more, 1 g/lOmin or more, 1.1 g
  • the average melt flow index of the plastic feedstock being fed into the extruder can range from any of the minimum values described above to any of the maximum values described above.
  • the plastic feedstock being fed into the extruder can have an average melt flow index of from 0.01 g/lOmin to 20 g/lOmin (e.g., from 0.05 g/lOmin to 20 g/lOmin, from 0.05 g/lOmin to 19 g/lOmin, from 0.05 g/lOmin to 18 g/lOmin, from 0.05 g/lOmin to 17 g/lOmin, from 0.05 g/lOmin to 16 g/lOmin, from 0.05 g/lOmin to 15 g/lOmin, from 0.05 g/lOmin to 14 g/lOmin, from 0.05 g/lOmin to 13 g/lOmin, from 0.05 g/lOmin to 12 g/lOmin, from 0.05 g/lOmin to 11
  • the recycled plastic feedstock can have a distribution of melt flow indexes (MFI distribution).
  • the plastic feedstock can comprise a plurality of different plastic materials, each with its own MFI.
  • the MFI distribution of the plastic feedstock refers to the distribution of MFIs in the recycled plastic feedstock spanning from the lowest-MFI plastic material within the recycled plastic feedstock to the highest-MFI plastic material within the recycled plastic feedstock.
  • the recycled plastic feedstock can comprise a first plastic material having a first melt flow index and a second plastic material having a second melt flow index, wherein the first melt flow index is different than the second melt flow index.
  • the first melt flow index is lower than the second melt flow index.
  • the first melt flow index is the lowest melt flow index of any of the plastic materials within the plastic feedstock.
  • the second melt flow index is the highest melt flow index of any of the plastic materials within the plastic feedstock.
  • the distribution of melt flow indexes can be from the first melt flow index to the second melt flow index.
  • the recycled plastic feedstock can have a distribution of melt flow indexes of from 0.05 g/lOmin to 20 g/lOmin (e.g., from 0.05 g/lOmin to 19 g/lOmin, from 0.05 g/lOmin to 18 g/lOmin, from 0.05 g/lOmin to 17 g/lOmin, from 0.05 g/lOmin to 16 g/lOmin, from 0.05 g/lOmin to 15 g/lOmin, from 0.05 g/lOmin to 14 g/lOmin, from 0.05 g/lOmin to 13 g/lOmin, from 0.05 g/lOmin to 12 g/lOmin, from 0.05 g/lOmin to 11 g/lOmin, from 0.05 g/lOmin to 10 g/lOmin, from 0.1 g/lOmin to 10 g/lOmin, from 0.1 g/lOmin to 9.5 9.5
  • the recycled plastic feedstock being fed into the extruder can have an average glass transition temperature (T g ).
  • the plastic feedstock can comprise a plurality of different plastic materials, each with its own T g , such that the average T g of the plastic feedstock comprises a weighted average of the T g of the different plastic materials.
  • average glass transition temperature refers to the weighted average (e.g., weighted average by volume or mass) of the T g of the plastic materials comprising the recycled plastic feedstock prior to the feedstock being directed into an extruder or pyrolysis reactor (e.g., shredded recycled plastic film feedstock that has been subjected to one or more sorting, size reduction, and/or drying operations prior to being directed to an extruder).
  • the glass transition temperature of each of the different plastic materials and/or the average glass transition temperature of the plastic feedstock can be determined, for example, using ASTM D3418.
  • the recycled plastic feedstock can have an average glass transition temperature (T g ) of 100°C or more (e.g., 105°C or more, 110°C or more, 115°C or more, 120°C or more, 125°C or more, 130°C or more, 135°C or more, 140°C or more, 145°C or more, 150°C or more, 155°C or more, 160°C or more, 165°C or more, 170°C or more, 175°C or more, 180°C or more, 185 °C or more, 190°C or more, 195 °C or more, 200°C or more).
  • T g average glass transition temperature
  • the recycled plastic feedstock can have an average glass transition temperature (T g ) of 200°C or less (e.g., 195°C or less, 190°C or less, 185°C or less, 180°C or less, 175°C or less, 170°C or less, 165°C or less, 160°C or less, 155°C or less, 150°C or less, 145°C or less, 140°C or less, 135°C or less, 130°C or less, 125°C or less, 120°C or less, 115°C or less, 110°C or less, 105°C or less, 100°C or less).
  • T g average glass transition temperature
  • the recycled plastic feedstock can have an average glass transition temperature (T g ) ranging from any of the minimum values described above to any of the maximum values described above.
  • the recycled plastic feedstock can have an average glass transition temperature (T g ) of from 100°C to 200°C (e.g., from 105°C to 195°C, from 105°C to 190°C, from 105°C to 185°C, from 105°C to 180°C, from 105°C to 175°C, from 110°C to 175°C, from 110°C to 170°C, from 110°C to 165°C, from 110°C to 160°C, from 110°C to 155°C, from 110°C to 150°C, from 115°C to 150°C, from 120°C to 150°C, from 125°C to 150°C).
  • the recycled plastic feedstock can have a distribution of glass transition temperatures (T g distribution).
  • the plastic feedstock can comprise a plurality of different plastic materials, each with its own T g .
  • the T g distribution of the plastic feedstock refers to the distribution of glass transition temperatures in the recycled plastic feedstock spanning from the lowest- T g plastic material within the recycled plastic feedstock to the highest-T g plastic material within the recycled plastic feedstock.
  • the recycled plastic feedstock can comprise a first plastic material having a first T g and a second plastic material having a second T g , wherein the first T g is different than the second T g .
  • the first T g is lower than the second T g .
  • the first T g is the lowest T g of any of the plastic materials within the plastic feedstock.
  • the second T g is the highest T g of any of the plastic materials within the plastic feedstock.
  • the distribution of glass transition temperatures can be from the first T g to the second T g .
  • the recycled plastic feedstock can have a distribution of glass transition temperatures (T g distribution) of from 100°C to 200°C (e.g., from 105°C to 195 °C, from 105°C to 190°C, from 105°C to 185°C, from 105°C to 180°C, from 105°C to 175°C, from 110°C to 175°C, from 110°C to 170°C, from 110°C to 165°C, from 110°C to 160°C, from 110°C to 155°C, from 110°C to 150°C, from 115°C to 150°C, from 120°C to 150°C, from 125°C to 150°C).
  • T g distribution glass transition temperatures
  • plastic feedstock e.g., optionally shredded plastic feedstock, such as the low bulk density plastic feedstock described herein
  • one or more extruders e.g., two or more
  • the extruders can be any suitable type of extruder.
  • the extruders can, for example, be designed to heat the plastic feedstock and convert the plastic feedstock into a semi-molten state that is moved to the reactors.
  • the pyrolysis systems described herein include two or more extruders, and the two or more extruders can be in operation simultaneously.
  • one or more extruders can be configured to pyrolyze the plastic feedstock and thereby function as a pyrolysis reactor.
  • the system includes a plurality of extruders and each extruder is configured to process a portion of normal throughput, for example so as to allow feedstock flow to and operation of the reactors to continue when one of the extruders is taken out of service for repair or maintenance.
  • the system can include three extruders, with two extruders being in operation simultaneously and the third extruder being a redundancy, for example the third extruder can be operated while one of the other extruders is taken out of service for repair or maintenance.
  • Each extruder can, for example, use an internal pneumatically operated ram to increase the density of the plastic in order to achieve the desired throughput rate.
  • the ram can also move the plastic from the extruder inlet into the extruder’s screw mechanism.
  • the plastic feedstock fed into the extruder can be fed using a screw or auger device that is capable of both moving feedstock into the extruder and compressing it in the same.
  • the extruder barrel can include one or more openings (e.g. one or more vents or ports) at one or more positions along the length of the extruder barrel.
  • each extruder barrel can include a plurality of vents (e.g., two or more vents) along the length of the extruder barrel.
  • the vent(s) can allow vapors and/or gases produced from the plastic feedstock during the heating process to escape from the extruder. Moisture in the feedstock is converted to steam at the high temperatures created in the extruder and this steam typically exits at one or more vents.
  • gaseous material such as volatile inks from plastic labels, various lipids and fats from food contamination on the plastic, and decomposed PVC and PET polymers can also exit at one or more vents along with gas made up of entrained fine particulates.
  • This system allows removal of significant amounts of chlorides and other undesirable elements that otherwise would end up in the reactor and potentially affect the quality of the pyrolysis products (e.g., gas) and/or corrode the processing equipment.
  • each extruder comprises two or more vents (e.g., wherein the extruder includes at least a first vent and a second vent).
  • the first vent of the extruder comprises an ambient pressure vent.
  • the second vent of the extruder comprises a vacuum vent, for example where a vacuum is applied through the vent to pull gases and/or contaminants out of the semi-molten feedstock.
  • a vent feeding device can be used at one or more of the extruder vents to prevent expulsion of melted feedstock from that vent.
  • the vent feeder can force any feedstock that is flowing or being expelled from the vent back into the barrel where it is then carried forward down the extruder.
  • This feeder can be equipped with a vent section that can allow steam and other volatiles to pass by the feeder.
  • the barrel of the extruder can be heated, for example by one or more externally mounted heaters.
  • the barrel of the extruder can be heated by a plurality of externally mounted heaters.
  • the heaters can be any suitable type of heater, such as resistive electric heaters and/or inductive heaters. Additional heating can, for example, be provided by friction as the feedstock is forced through the internal geometry of the extruder barrel by the screw.
  • Multiple zones along the length of the extruder can, in some examples, be independently heated and cooled using barrel heaters and/or cooling fans to achieve a pre-set temperature profile that varies depending on the type of material being fed into the extruder.
  • the barrel of the extruder can be heated such that the feedstock within the extruder has a temperature of 20°C or more at the first of the one or more vents (e.g., 25 °C or more, 50°C or more, 75°C or more, 100°C or more, 125°C or more, 150°C or more, 175°C or more, 200°C or more, 225°C or more, 250°C or more, 275°C or more, 280°C or more, 285°C or more, 290°C or more, 295 °C or more, 300°C or more, 305°C or more, 3I0°C or more, 315°C or more, 320°C or more, 325 °C or more, 350°C or more, 375 °C or more, 400°C or more, or 425 °C or more).
  • a temperature of 20°C or more at the first of the one or more vents e.g., 25 °C or more, 50°
  • the barrel of the extruder can be heated such that the feedstock within the extruder has a temperature of 450°C or less at the first of the one or more vents (e.g., 425°C or less, 400°C or less, 375°C or less, 35O°C or less, 325°C or less, 320°C or less, 315°C or less, 310°C or less, 305 °C or less, 300°C or less, 295°C or less, 290°C or less, 285°C or less, 285°C or less, 280°C or less, 275°C or less, 250°C or less, 225°C or less, 200°C or less, 175°C or less, 150°C or less, 125°C or less, 100°C or less, 75°C or less, or 50°C or less).
  • a temperature of 450°C or less at the first of the one or more vents e.g., 425°C or less, 400°C
  • the temperature of the feedstock within the extruder at the first vent can range from any of the minimum values described above to any of the maximum values described above.
  • the barrel of the extruder can be heated such that the feedstock within the extruder has a temperature of from 20°C to 450°C at the first of the one or more vents (e.g., from 20°C to 225°C, from 225°C to 450°C, from 20°C to 125°C, from 125°C to 225°C, from 225°C to 325°C, from 325°C to 450°C, from 20°C to 400°C, from 20°C to 350°C, from 20°C to 300°C, from 20°C to 250°C, from 20°C to 200°C, from 20°C to 250°C, from 20°C to 100°C, from 20°C to 50°C, from 50°C to 450°C, from 100°C to 450°C, from 150°C to 450°C, from 200
  • each extruder includes a screw with multiple zones, such as a pumping section, a compression section, a decompression section, a mixing section, or a combination thereof.
  • each extruder screw includes a decompression section at or before the first vent, for example to promote expulsion of entrained air, moisture, and/or other gases (e.g., volatiles) from the feedstock at the first vent.
  • the residence time of the feedstock within each extruder can be selected in view of a variety of factors.
  • the residence time of the feedstock within each extruder can be selected in view of the speed at which the extruder is run (which in turn can be selected based on the throughput rate of the reactor(s) that the extruder is feeding), the identity of the plastics within the feedstock, the melt flow characteristics of the plastic, or a combination thereof.
  • the residence time of the feedstock within each extruder can be selected in view of the speed at which the extruder is run (which in turn can be selected based on the throughput rate of the reactor(s) that the extruder is feeding), the identity of the plastics within the feedstock, or a combination thereof
  • the residence time of the feedstock within the extruder can be 30 seconds or more (e.g., 1 minute or more, 1.5 minutes or more, 2 minutes or more, 2.5 minutes or more, 3 minutes or more, 3.5 minutes or more, 4 minutes or more, 5 minutes or more, 5.5 minutes or more, 6 minutes or more, 6.5 minutes or more, 7 minutes or more, 7.5 minutes or more, 8 minutes or more, 8.5 minutes or more, or 9 minutes or more).
  • the residence time of the feedstock within the extruder can be 10 minutes or less (e.g., 9.5 minutes or less, 9 minutes or less, 8.5 minutes or less, 8 minutes or less, 7.5 minutes or less, 7 minutes or less, 6.5 minutes or less, 6 minutes or less, 5.5 minutes or less, 5 minutes or less, 4.5 minutes or less, 4 minutes or less, 3.5 minutes or less, 3 minutes or less, 2.5 minutes or less, 2 minutes or less, 1.5 minutes or less, or 1 minute or less).
  • the residence time of the feedstock within the extruder can range from any of the minimum values described above to any of the maximum values described above.
  • the residence time of the feedstock within the extruder can be from 30 seconds to 10 minutes (e.g., from 30 seconds to 5 minutes, from 5 minutes to 10 minutes, from 30 seconds to 2.5 minutes, from 2.5 to 5 minutes, from 5 to 7.5 minutes, from 7.5 minutes to 10 minutes, from 30 seconds to 9 minutes, from 30 seconds to 8 minutes, from 30 seconds to 7 minutes, from 30 seconds to 6 minutes, from 30 seconds to 4 minutes, from 30 seconds to 3 minutes, from 30 seconds to 2 minutes, from 1 minute to 10 minutes, from 2 to 10 minutes, from 3 to 10 minutes, from 4 to 10 minutes, from 6 to 10 minutes, from 7 to 10 minutes, from 8 to 10 minutes, from 1 minute to 9 minutes, or from 1.5 minutes to 5 minutes).
  • 30 seconds to 10 minutes e.g., from 30 seconds to 5 minutes, from 5 minutes to 10 minutes, from 30 seconds to 2.5 minutes, from 2.5 to 5 minutes, from 5 to 7.5 minutes, from 7.5 minutes to 10 minutes, from 30 seconds to 9 minutes, from 30 seconds to 8 minutes, from 30 seconds to 7 minutes, from 30 seconds
  • Feedstock material subsequently enters the extruder screw’s pumping section where it is propelled out of the extruder and into the pyrolysis reactor, for example via a heated transfer pipe.
  • a rupture disk can be provided for emergency pressure relief to prevent down-stream damage to piping and equipment.
  • Figure 6 provides a perspective view of an example implementation of an extruder 100 configured for heating plastic feedstock (e.g., loose film, baled film, rigids, thermoforms, sheets, foams, non-wovens, strips, pellets, powder, purge patties, densified, shredded, and other postconsumer and/or post-industrial plastics) and converting the feedstock into a molten or semimolten state.
  • plastic feedstock e.g., loose film, baled film, rigids, thermoforms, sheets, foams, non-wovens, strips, pellets, powder, purge patties, densified, shredded, and other postconsumer and/or post-industrial plastics
  • the molten or semi-molten state output by the extruder 100 can be directed to a pyrolysis reactor for pyrolysis of the plastic feedstock (e.g., various implementations of the pyrolysis reactors discussed herein).
  • an extruder 100 can be configured to heat or otherwise process the plastic feedstock to the point where the plastic is a fully molten liquid and the polymers “depolymerize” (e.g., fully or partially depolymerize), functioning as a pyrolysis reactor (e.g., a plug flow reactor).
  • Figure 7 shows a cross-sectional view of the extruder 100 shown in Figure 6. Certain elements depicted in Figure 6 are also depicted in Figure 7 and, accordingly, reference to either figure can be regarded as a reference to both figures.
  • the extruder 100 includes a motor 102 (e.g., three-phase AC motor) configured to drive a screw 142 within an extruder barrel 110.
  • the motor 102 is coupled to a reducer assembly 104 and cooling system 106.
  • the cooling system 106 is configured to maintain desired temperatures within the reducer assembly and or motor.
  • the extruder screw 142 is coupled to a drive shaft via a seal assembly 108, allowing the motor 302 to drive rotation of the extruder screw 142.
  • Plastic feedstock is directed into the extruder barrel 110 via a hopper 120, which is configured to receive plastic feedstock (e.g., loose film, baled film, rigids, thermoforms, sheets, foams, non-wovens, strips, pellets, powder, purge patties, densified, shredded, and other postconsumer and/or post-industrial plastics).
  • a pneumatic ram 122 is configured to increase the density of the plastic feedstock in order to assist in achieving a desired throughput rate within the extruder 100.
  • the extruder 100 includes a single extruder screw 142 housed within a heated barrel 110.
  • the barrel 110 can be encased by heating elements 144 configured for heating various zones along the length of the extruder barrel 110.
  • the heating elements 144 can comprise electric heaters.
  • the heating elements 144 can comprise forced-air, gas, indirect, or direct heating arrangements.
  • the extruder 100 can include multiple heating elements 144 positioned throughout the length of the extruder 100 configured to heat the extruder barrel 1 10.
  • the extruder 300 includes between two and fifteen electric heaters defining between two and fifteen heating zones along the length of the barrel 110.
  • the heaters e.g., electric heaters
  • the heaters can be controlled to obtain a desired temperature gradient along the length of the extruder barrel 110, such that the temperature of the feedstock within the extruder barrel 110 reaches desired temperatures. Additional heating is provided by friction as the plastic is forced through the internal geometry of the extruder barrel by the screw. In other implementations, two extruder screws can be used within the barrel 1 10.
  • the extruder screw 142 within the barrel 110 is provided with multiple zones (e.g., a pumping section, a compression section, and a decompression section).
  • a pumping section the molten (or semi-molten) feedstock material is propelled out of the extruder (e.g., via a barrel outlet 140 shown in Figure 6) and into the pyrolysis reactor (e.g., via a heated transfer pipe).
  • Figure 8 provides a perspective view of another example implementation of an extruder 200 configured for heating plastic feedstock (e.g., loose film, baled film, rigids, thermoforms, sheets, foams, non-wovens, strips, pellets, powder, purge patties, densified, shredded, and other post-consumer and/or post-industrial plastics) and converting the feedstock into a molten or semi-molten state.
  • plastic feedstock e.g., loose film, baled film, rigids, thermoforms, sheets, foams, non-wovens, strips, pellets, powder, purge patties, densified, shredded, and other post-consumer and/or post-industrial plastics
  • plastic feedstock e.g., loose film, baled film, rigids, thermoforms, sheets, foams, non-wovens, strips, pellets, powder, purge patties, densified, shredded, and other post-consumer and/or post-industrial plastics
  • Figure 9 shows a cross-
  • the extruder 200 is configured as a twin screw extruder. As shown in Figure 8 and Figure 9, a pair of extruder screws 242, 243 are provided in the extruder’s barrel 210. In various implementations, the screws are configured for 242, 243 are configured for driving the feedstock material through the barrel 210 as the feedstock material is heated.
  • Figure 10 provides a perspective view of another example implementation of an extruder 300 configured for heating plastic feedstock (e.g., loose film, baled film, rigids, thermoforms, sheets, foams, non-wovens, strips, pellets, powder, purge patties, densified, shredded, and other post-consumer and/or post-industrial plastics) and converting the feedstock into a molten or semi-molten state.
  • plastic feedstock e.g., loose film, baled film, rigids, thermoforms, sheets, foams, non-wovens, strips, pellets, powder, purge patties, densified, shredded, and other post-consumer and/or post-industrial plastics
  • Elements shared with the extruder 100 are given common references (e.g., the extruder 100’s barrel is labeled 110 while the extruder 300’s barrel is labeled 310).
  • the extruder 300 includes one or more gas powered heating elements 346.
  • the gas-powered heating elements 346 are configured for heating the extruder’s barrel 310 in order to thereby heat the feedstock material being translated through the barrel 310.
  • the extruder 300 is depicted with a single screw 342, in other implementations, the extruder 300 can be provided with twin screws. Additionally, various implementations can include a combination of gas and electric heating elements for heating the barrel 310.
  • Figure 11 provides a perspective view of another example implementation of an extruder 400 configured for heating plastic feedstock (e.g., loose film, baled film, rigids, thermoforms, sheets, foams, non-wovens, strips, pellets, powder, purge patties, densified, shredded, and other post-consumer and/or post-industrial plastics) and converting the feedstock into a molten or semi-molten state.
  • plastic feedstock e.g., loose film, baled film, rigids, thermoforms, sheets, foams, non-wovens, strips, pellets, powder, purge patties, densified, shredded, and other post-consumer and/or post-industrial plastics
  • plastic feedstock e.g., loose film, baled film, rigids, thermoforms, sheets, foams, non-wovens, strips, pellets, powder, purge patties, densified, shredded, and other post-consumer and/or post-industrial plastics
  • the extruder 400 includes one or more oil-based heating elements 346.
  • the oil-based heating elements 445 can define a series of conduits or channels around the barrel 410, through which heated oil (or another suitable liquid) can be pumped. In this way, the oil-based heating elements 445 are configured for heating the extruder’s barrel 410 in order to thereby heat the feedstock material being translated through the barrel 410.
  • the heated oil can be heated by electric or gas-powered heating elements associated with the oil-based heating elements 445.
  • the oil-based heating elements 346 can comprise one or more molten salt heating elements.
  • the extruder 400 is depicted with a single screw 442, in other implementations, the extruder 400 can be provided with twin screws. Additionally, various implementations can include a combination of oil, gas, and electric heating elements for heating the barrel 410.
  • vent 532 As shown in Figure 12, electric heaters 544 are positioned around the extruder’s barrel 510.
  • a vent 532 is configured to allow vapors and/or gases produced from the plastic feedstock during the heating process to escape from the extruder 500. In this way, the vent 532 can allow for removal of residual vapor and contaminants that can have a negative impact on the pyrolysis product quality.
  • the vent 532 is an ambient pressure vent. In other implementations, the vent 532 is under vacuum.
  • extruder 500 is depicted with a single screw 542, in other implementations, the extruder 500 can be provided with twin screws. Additionally, various implementations can include a combination of oil, gas, and electric heating elements for heating the barrel 510.
  • Figure 13 provides a perspective view of another example implementation of an extruder 600 configured for heating plastic feedstock (e.g., loose film, baled film, rigids, thermoforms, sheets, foams, non-wovens, strips, pellets, powder, purge patties, densified, shredded, and other post-consumer and/or post-industrial plastics) and converting the feedstock into a molten or semi-molten state.
  • plastic feedstock e.g., loose film, baled film, rigids, thermoforms, sheets, foams, non-wovens, strips, pellets, powder, purge patties, densified, shredded, and other post-consumer and/or post-industrial plastics
  • plastic feedstock e.g., loose film, baled film, rigids, thermoforms, sheets, foams, non-wovens, strips, pellets, powder, purge patties, densified, shredded, and other post-consumer and/or post-industrial plastics
  • vents 632, 634 are provided along the extruder’s barrel 610.
  • the vents 632, 634 are configured to allow vapors and/or gases produced from the plastic feedstock during the heating process to escape from the extruder 600. In this way, the vents 632, 634 can allow for removal of residual vapor and contaminants that can have a negative impact on the pyrolysis product quality.
  • both vents 632, 634 are ambient pressure vents.
  • both vents 632, 634 are under vacuum.
  • the first vent 632 is an ambient pressure vent while the second vent 634 is under vacuum.
  • extruder 600 is depicted with a single screw 642, in other implementations, the extruder 600 can be provided with twin screws. Additionally, various implementations can include a combination of oil, gas, and electric heating elements for heating the barrel 610.
  • the single screw 642 of the extruder 600 can comprise a dual vent extruder screw configured for melting low bulk density recycled plastic feedstock and/or recycled plastic feedstock having a wide MFI range.
  • the dual vent extruder screw is configured for receiving recycled plastic feedstock (e.g., low bulk density recycled plastic feedstock), melting recycled plastic feedstock into a molten or semi-molten form, and pumping the molten or semi-molten feedstock out of the extruder (e.g., so the molten or semi-molten feedstock can be directed into a pyrolysis reactor).
  • Figure 53 shows a schematic side view of an example dual vent extruder screw 8642 disposed within barrel 610 of the extruder 600. Additionally, a feed throat 8610 is disposed around a feed end of the dual vent extruder screw 8642 (e.g., for directing recycled plastic feedstock from the hopper 620 and pneumatic ram 622 on the screw 8642 and into the extruder barrel 610).
  • the dual vent extruder screw 8642 defines a plurality of screw sections (8001 -8005b) configured for processing recycled plastic feedstock (e.g., recycled plastic feedstock having low bulk density, a wide MFI distribution, and/or a wide glass transition temperature distribution).
  • the dual vent extruder screw 8642 includes a feed section 8001, a mixing section 8002, a first decompression section 8003a, a first degassing section 8004a (degassing sections are also referred to herein as compression sections), a first pumping section 8005a, a second decompression section 8003b, a second degassing 8004b, and a second pumping section 8005b.
  • the extruder 600 can also be provided with a plurality of temperature control zones for sensing and controlling the temperature of the feedstock as it is pumped through the various sections (8OOl-8OO5b) of the dual vent extruder screw 8642.
  • Figure 54 shows a schematic side view of the extruder 600 provided with a plurality of temperature control systems (8101-81 11 ) each defining a respective temperature control zone of the extruder barrel 610 (and/or feed throat 8610) and dual vent extruder screw 8642.
  • each of the temperature control systems (8101-8111) can be comprised of a heater (e.g., an electric heater, for example an electric inductive heater, surrounding a portion of the extruder barrel 610), a cooling fan (e.g., an electric cooling fan positioned adjacent to an exterior portion of the extruder barrel 610), a cooling jacket (e.g., a liquid cooled jacket surrounding a portion of the extruder barrel 610), a cooling lance (e.g., a liquid cooled passage disposed within a portion of the dual vent extruder screw 8642), one or more temperature sensors (e.g., a thermocouple or other temperature sensing device configured to measuring and transmitting the temperature of the plastic feedstock within the extruder barrel 610 or feed throat 8610), or combinations thereof.
  • the temperature control systems (8101-8111) and their respective sub-components can be individually controllable by the pyrolysis control system.
  • the dual vent extruder screw’s feed section 8001 is generally configured to receive solid recycled plastic feedstock, engage the recycled plastic feedstock, perform the first phase of the extruder’s heating and melting of the recycled plastic feedstock (e.g., via compression and heating), and pump the plastic feedstock into the extruder barrel 610 and to the mixing section 8002.
  • the feed section 8001 is positioned at a first end of the dual vent extruder screw 8642 and extends through the feed throat 8610 and a portion of the extruder barrel 610 at the first end of the extruder barrel 610.
  • the extruder 600 includes a hopper 620 configured for receiving solid recycled plastic feedstock (e.g., low density recycled plastic feedstock).
  • the recycled plastic feedstock in the hopper 620 is then directed under compression by the pneumatic ram 622 into the feed section 8001 of the dual vent extruder screw 8642 (e.g., the portion of extruder screw’s feed section 8001 that is positioned within the feed throat 8610).
  • the pneumatic ram 622 is configured to increase the density of the recycled plastic feedstock as it exits the hopper 620 and enters the screw’s feed section 8001 within the feed throat 8610, and to press the recycled plastic feedstock into the extruder screw’s feed section 8001.
  • a pneumatic ram 622 is shown, other compression apparatuses (e.g., a crammer having a helical screw) can be implemented to increase the density of the recycled plastic feedstock as it is directed into the feed section 8001.
  • the dual vent extruder screw’s feed section 8001 is configured for receiving low density recycled plastic feedstock under compression from the pneumatic ram 622.
  • the extruder screw’s feed section 8001 has root diameter, flight depth, flight volume, and channel width characteristics that provide sufficient space within extruder barrel for the screw’s the feed section 8001 to engage and process low density recycled plastic feedstock.
  • the screw’s feed section 8001 has a maximum root diameter that is less than the maximum root diameter in one or more of the downstream screw sections (8002-8005b) (e.g., the maximum root diameter of the feed section 8001 is less than the maximum root diameter of the mixing section 8002, the maximum root diameter of the feed section 8001 is less than the maximum root diameter of the first decompression section 8003a, the maximum root diameter of the feed section 8001 is less than the maximum root diameter of the first degassing section 8004a, the maximum root diameter of the feed section 8001 is less than the maximum root diameter of the first pumping section 8005 a, the maximum root diameter of the feed section 8001 is less than the maximum root diameter of the second decompression section 8003b, the maximum root diameter of the feed section 8001 is less than the maximum root diameter of the second degassing 8004b, and/or the maximum root diameter of the feed section 8001 is less than the maximum root diameter of the second pumping section 8005b).
  • the maximum root diameter of the feed section 8001 is less than the
  • the screw’s feed section 8001 has a maximum root diameter that is at least 15% smaller than the maximum root diameter of the mixing section 8002 (e.g., at least 20% smaller than the maximum root diameter of the mixing section 8002, at least 25% smaller than the maximum root diameter of the mixing section 8002, or at least 30% smaller than the maximum root diameter of the mixing section 8002).
  • the screw’s feed section 8001 has a maximum flight depth that is deeper than the maximum flight depths in one or more of the downstream screw sections (8002-8005b) (e.g., the flight depth of the feed section 8001 is greater than the flight depth of the mixing section 8002, the flight depth of the feed section 8001 is greater than the flight depth of the first decompression section 8003a, the flight depth of the feed section 8001 is greater than the flight depth of the first degassing section 8004a, the flight depth of the feed section 8001 is greater than the flight depth of the first pumping section 8005 a, the flight depth of the feed section 8001 is greater than the flight depth of the second decompression section 8003b, the flight depth of the feed section 8001 is greater than the flight depth of the second degassing 8004b, and/or the flight depth of the feed section 8001 is greater than the flight depth of the second pumping section 8005b).
  • the flight depth of the feed section 8001 is greater than the flight depth of the mixing section 8002
  • the screw’s feed section 8001 has a maximum flight depth that is at least 15% deeper than the maximum flight depth of the mixing section 8002 (e.g. at least 20% deeper than the maximum flight depth of the mixing section 8002, at least 25% deeper than the maximum flight depth of the mixing section 8002, or at least 30% deeper than the maximum flight depth of the mixing section 8002).
  • the screw’s feed section 8001 has a flight volume (e.g., the volumetric space between flights in a single revolution) that is greater than the flight volumes in one or more of the downstream screw sections (8002-8005b) (e.g., the flight volume of the feed section 8001 is greater than the flight volume of the mixing section 8002, the flight volume of the feed section 8001 is greater than the flight volume of the first decompression section 8003a, the flight volume of the feed section 8001 is greater than the flight volume of the first degassing section 8004a, the flight volume of the feed section 8001 is greater than the flight volume of the first pumping section 8005a, the flight volume of the feed section 8001 is greater than the flight volume of the second decompression section 8003b, the flight volume of the feed section 8001 is greater than the flight volume of the second degassing 8004b, and/or the flight volume of the feed section 8001 is greater than the flight volume of the second pumping section 8005b).
  • the flight volume of the feed section 8001 is greater than the
  • the screw’s feed section 8001 has a flight volume that is at least 15% greater than the flight volume of the mixing section 8002 (e.g., at least 20% greater than the flight volume of the mixing section 8002, at least 25% greater than the flight volume of the mixing section 8002, or at least 30% greater than the flight volume of the mixing section 8002).
  • the screw’s feed section 8001 has a maximum channel width that is greater than the maximum channel widths in each of the downstream screw sections (8002-8005b) (e.g., the maximum channel width of the feed section 8001 is greater than the maximum channel width of the mixing section 8002, the maximum channel width of the feed section 8001 is greater than the maximum channel width of the first decompression section 8003 a, the maximum channel width of the feed section 8001 is greater than the maximum channel width of the first degassing section 8004a, the maximum channel width of the feed section 8001 is greater than the maximum channel width of the first pumping section 8005a, the maximum channel width of the feed section 8001 is greater than the maximum channel width of the second decompression section 8003b, the maximum channel width of the feed section 8001 is greater than the maximum channel width of the second degassing 8004b, and the maximum channel width of the feed section 8001 is greater than the maximum channel width of the second pumping section 8005b).
  • the maximum channel width of the feed section 8001 is greater than the maximum channel width
  • the screw’s feed section 8001 has a maximum channel width that is at least 15% greater than the maximum channel width of the mixing section 8002 (e.g., at least 20% greater than the maximum channel width of the mixing section 8002, at least 25% greater than the maximum channel width of the mixing section 8002, or at least 30% greater than the maximum channel width of the mixing section 8002).
  • the extruder screw’s feed section 8001 is associated with at least one feed section temperature control system 8101 .
  • the feed section temperature control system 8101 comprises one or more temperature sensors configured to measuring and transmitting the temperature of the plastic feedstock within the feed section
  • the cooling jacket 652 can comprise a controllable liquid-cooled jacket surrounding (or partially surrounding) the portion of the feed throat 8610 (or extruder barrel 610) associated with the extruder screw’s feed section 8001.
  • the cooling lance 654 can comprise a controllable liquid-cooled passage extending through at least a portion of the extruder’s screw’s root within the feed section 8001. In some implementations, as shown in Figure 53 and Figure 54, the cooling lance 654 extends further into the screw’s mixing section
  • the cooling fan 656a can comprise a controllable electric fan positioned adjacent to the portion of the feed throat 8610 (or extruder barrel 610) associated with the extruder screw’s feed section 8001.
  • the feed section temperature control system 8101 can comprise the cooling jacket 652 and cooling lance 654 (and may not include a cooling fan).
  • the feed section temperature control system 8101 (including the cooling jacket 652, cooling lance 654, and cooling fan 656a) are controllable by pyrolysis control system (e.g., the pyrolysis control system 7500b shown and described with respect to Figure 46).
  • the feed section temperature control system 8101 can be programmed with a feed section temperature set point (e.g., stored by pyrolysis control system) and configured to automatically control the cooling jacket 652, cooling lance 654, and cooling fan 656a to maintain the average temperature of the feedstock in the extruder screw’s feed section 8001 at the feed section temperature set point.
  • the extruder screw’s feed section 8001 and feed section temperature control system 8101 are configured for heating the recycled plastic feedstock received from the pneumatic ram 622 (e.g., due to shearing of the of the feedstock within the extruder barrel 610) and maintaining the average temperature of the feedstock in the feed section 8001 at less than 200°C (e.g., less than 190°C, less than 180°C, less than 170°C, less than 160°C, less than 155°C).
  • the extruder screw’s feed section 8001 and feed section temperature control system 8101 are configured for heating the recycled plastic feedstock received from the pneumatic ram 622 (e.g., due to shearing of the of the feedstock within the extruder barrel 610) and maintaining the average temperature of the feedstock in the feed section 8001 at the average glass transition temperature (T g ) of the feedstock or within the distribution of glass transition temperatures (T g distribution) of the feedstock.
  • the dual vent extruder screw’s mixing section 8002 is generally configured for receiving semi-molten recycled plastic feedstock from the feed section 8001, mixing and heating the feedstock, and pumping the feedstock downstream and into the first decompression section 8003 a.
  • the extruder screw’s mixing section 8002 is associated with one or more temperature controls systems.
  • the extruder screw’s mixing section 8002 is associated with a first mixing temperature control system 8102 and a second mixing temperature control system 8103.
  • the first and second mixing temperature control systems 8102, 8103 each comprise one or more temperature sensors configured to measuring and transmitting the temperature of the plastic feedstock within the mixing section 8002, an electric heater 644a, 644b and a cooling fan 656b, 656c.
  • the electric heaters 644a, 644b can each comprise an electrically powered, controllable heating element surrounding (or partially surrounding) a portion of the extruder barrel 610 associated with the extruder screw’s mixing section 8002.
  • the cooling fans 656b, 656c can each comprise a controllable electric fan positioned adjacent to the portion of the extruder barrel 610 associated with the extruder screw’s mixing section 8002.
  • the mixing section temperature control systems 8102, 8103 are controllable by pyrolysis control system (e.g., the pyrolysis control system 7500b shown and described with respect to Figure 46).
  • the mixing section temperature control systems 8102, 8103 can each be programmed with a mixing section temperature set point (e.g., stored by pyrolysis control system) and configured to automatically control the heaters 644a, 644b and cooling fans 656b, 656c to maintain the average temperature of the feedstock in the extruder screw’s mixing section 8002 at the mixing section temperature set point(s).
  • the extruder screw’s mixing section 8002 and mixing section temperature control systems 8102, 8103 are configured for maintaining the temperature of the recycled plastic feedstock (e.g., by heating and/or cooling the plastic feedstock) such that the average temperature of the feedstock in the mixing section 8002 is between 120°C and 245°C (e.g., between 130°C and 235°C, between 140°C and 215°C, between 150°C and 205°C, between 180°C and 215 °C, between 180°C and 205°C, between 180°C and 225°C).
  • 120°C and 245°C e.g., between 130°C and 235°C, between 140°C and 215°C, between 150°C and 205°C, between 180°C and 215 °C, between 180°C and 205°C, between 180°C and 225°C.
  • the dual vent extruder screw’s first decompression section 8003 a is generally configured for receiving semi-molten recycled plastic feedstock from the mixing section 8002, reducing the pressure on the feedstock relative to the mixing section 8002, and pumping the feedstock downstream into the first degassing section 8004a.
  • the first decompression section 8003a to configured to reduce the pressure on the feedstock (relative to the mixing section 8002) such that vapor in the semi-molten feedstock is allowed to separate from the feedstock.
  • flights provided on the dual vent extruder screw’s first decompression section 8003a are configured with scalloped outer edges.
  • flights provided on the dual vent extruder screw’s first decompression section 8003a are configured with cut-and-folded outer edges.
  • flights provided on the dual vent extruder screw’s first decompression section 8003a are configured with interior gaps (e.g., “ribbon flights”).
  • any of these modifications to the flights provided on the dual vent extruder screw’s first decompression section 8003a can provide passages for vapor to separate from the plastic feedstock within the extruder barrel 610.
  • the screw’s first decompression section 8003a has a maximum root diameter that is less than the maximum root diameter of the mixing section 8002.
  • the screw’s first decompression section 8003a has a maximum root diameter that is at least 15% smaller than the maximum root diameter of the mixing section 8002 (e.g., at least 20% smaller than the maximum root diameter of the mixing section 8002, at least 25% smaller than the maximum root diameter of the mixing section 8002, or at least 30% smaller than the maximum root diameter of the mixing section 8002).
  • the screw’s first decompression section 8003a has a flight depth that is greater than the maximum root diameter of the mixing section 8002.
  • the screw’s first decompression section 8003a has a maximum flight depth that is at least 15% deeper than the maximum flight depth of the mixing section 8002 (e.g., at least 20% deeper than the maximum flight depth of the mixing section 8002, at least 25% deeper than the maximum flight depth of the mixing section 8002, or at least 30% deeper than the maximum flight depth of the mixing section 8002).
  • the extruder screw’s first decompression section 8003a is associated with a first decompression temperature control system 8104.
  • the first decompression temperature control system 8104 comprises one or more temperature sensors configured to measuring and transmitting the temperature of the plastic feedstock within the first decompression section 8003a, an electric heater 644c and a cooling fan 656d.
  • the electric heater 644c can comprise an electrically powered, controllable heating element surrounding (or partially surrounding) a portion of the extruder barrel 610 associated with the extruder screw’s first decompression section 8003a.
  • the cooling fan 656d can comprise a controllable electric fan positioned adjacent to the portion of the extruder barrel 610 associated with the extruder screw’s first decompression section 8003a.
  • the first decompression temperature control system 8104 (including the heater 644c and cooling fan 656d) are controllable by the pyrolysis control system (e.g., the pyrolysis control system 7500b shown and described with respect to Figure 46).
  • the first decompression temperature control system 8104 can be programmed with a first decompression temperature set point (e.g., stored by the pyrolysis control system) and configured to automatically control the heater 644c and cooling fan 656d to maintain the average temperature of the feedstock in the extruder screw’s first decompression section 8003a at the first decompression temperature set point.
  • the extruder screw’s first decompression section 8003a and first decompression temperature control system 8104 are configured for maintaining the temperature of the recycled plastic feedstock (e.g., by heating and/or cooling the plastic feedstock) such that the average temperature of the feedstock in the first decompression section 8003a is between 220°C and 320°C (e.g., between 230°C and 320°C, between 240°C and 320°C, between 250°C and 320°C, between 260°C and 320°C, between 270°C and 320°C, between 280°C and 320°C, between 290°C and 310°C, between 295°C and 305°C, between 220°C and 280°C, between 230°C and 270°C, between 240°C and 260°C, between 245°C and 255°C).
  • 220°C and 320°C e.g., between 230°C and 320°C, between 240°C
  • the dual vent extruder screw’s first degassing section 8004a is generally configured for receiving semi-molten recycled plastic feedstock from the first decompression section 8003a, maintaining the pressure on the feedstock relative to the first decompression section 8003a, driving vapor out of the plastic feedstock via the first extruder vent 632, and pumping the feedstock downstream into the first pumping section 8005a.
  • the first degassing section 8004a is configured to maintain the pressure on the feedstock (relative to the first decompression section 8003a) such that vapor (e.g., steam) in the semi-molten feedstock is forced out of the extruder barrel 610.
  • the extruder’s first vent 632 is positioned on the extruder barrel 610 such vapor forced out of the plastic feedstock in the first degassing section 8004a can exit the extruder barrel 610 via the first vent 632.
  • flights provided on the dual vent extruder screw’s first degassing section 8004a are configured with scalloped outer edges (or cut-and-fold outer edges, or interior gaps), which provide passages for vapor to separate from the plastic feedstock and exit through the first vent 632.
  • the root diameter, flight depth, flight volume, and or channel width of the flights in the first degassing section 8004a can be the same as those in the first decompression section 8003a.
  • the extruder screw’s first degassing section 8004a is associated with a first degassing temperature control system 8105.
  • the first degassing temperature control system 8105 comprises one or more temperature sensors configured to measuring and transmitting the temperature of the plastic feedstock within the first degassing section 8004a, an electric heater 644d and a cooling fan 656e.
  • the electric heater 644d can comprise an electrically powered, controllable heating element surrounding (or partially surrounding) a portion of the extruder barrel 610 associated with the extruder screw’s first degassing section 8004a.
  • the cooling fan 656e can comprise a controllable electric fan positioned adjacent to the portion of the extruder barrel 610 associated with the extruder screw’s first degassing section 8004a.
  • the first degassing temperature control system 8105 (including the heater 644d and cooling fan 656e) are controllable by the pyrolysis control system (e.g., the pyrolysis control system 7500b shown and described with respect to Figure 46).
  • the first degassing temperature control system 8105 can be programmed with a first degassing temperature set point (e.g., stored by the pyrolysis control system) and configured to automatically control the heater 644d and cooling fan 656e to maintain the average temperature of the feedstock in the extruder screw’s first degassing section 8004a at the first degassing temperature set point.
  • the extruder screw’s first degassing section 8004a and first degassing temperature control system 8105 are configured for maintaining the temperature of the recycled plastic feedstock (e.g., by heating and/or cooling the plastic feedstock) such that the average temperature of the feedstock in the first degassing section 8004a is between 235 °C and 355°C (e.g., between 245°C and 345°C, between 255°C and 335°C, between 265°C and 325°C, between 275°C and 315°C, between 285°C and 305°C, between 295°C and 305 °C, between 235°C and 315°C, between 245°C and 305°C, between 255°C and 295°C, between 265°C and 285°C).
  • 235 °C and 355°C e.g., between 245°C and 345°C, between 255°C and 335°C, between 265°C and 325°
  • the dual vent extruder screw’s first pumping section 8005a is generally configured for receiving semi-molten recycled plastic feedstock from the first degassing section 8004a, mixing and heating the feedstock, and pumping the feedstock downstream and into the second decompression section 8003b.
  • the screw’s first pumping section 8005a has a maximum root diameter that is greater than the maximum root diameter of the first degassing section 8004a.
  • the screw’s first pumping section 8005a has a maximum root diameter that is at least 15% greater than the maximum root diameter of the first degassing section 8004a (e.g., at least 20% greater than the maximum root diameter of the first degassing section 8004a, at least 25% greater than the maximum root diameter of the first degassing section 8004a, or at least 30% greater than the maximum root diameter of the first degassing section 8004a).
  • the screw’s first pumping section 8005a has a flight depth that is less than (shallower than) the maximum flight depth of the first degassing section 8004a.
  • the screw’s first pumping section 8005a has a maximum flight depth that is at least 15% less than the maximum flight depth of the first degassing section 8004a (e.g., at least 20% less than the maximum flight depth of the first degassing section 8004a, at least 25% less than the maximum flight depth of the first degassing section 8004a, or at least 30% less than the maximum flight depth of the first degassing section 8004a).
  • the extruder screw’s first pumping section 8005a is associated with one or more temperature controls systems.
  • the extruder screw’s first pumping section 8005a is associated with a first pumping temperature control system 8106 and a second pumping temperature control system 8107.
  • the first and second pumping temperature control systems 8106, 8107 each comprise one or more temperature sensors configured to measuring and transmitting the temperature of the plastic feedstock within the first pumping section 8005 a, an electric heater 644e, 644f and a cooling fan 656f, 656g.
  • the electric heaters 644e, 644f can each comprise an electrically powered, controllable heating element surrounding (or partially surrounding) a portion of the extruder barrel 610 associated with the extruder screw’s first pumping section 8005a.
  • the cooling fans 656f, 656g can each comprise a controllable electric fan positioned adjacent to the portion of the extruder barrel 610 associated with the extruder screw’s first pumping section 8005a.
  • the first pumping section temperature control systems 8106, 8107 are controllable by pyrolysis control system (e.g., the pyrolysis control system 7500b shown and described with respect to Figure 46).
  • the first pumping section temperature control systems 8106, 8107 can each be programmed with first pumping section temperature set point(s) (e.g., stored by pyrolysis control system) and configured to automatically control the heaters 644e, 644f and cooling fans 656f, 656g to maintain the average temperature of the feedstock in the extruder screw’s first pumping section 8005a at the first pumping section temperature set point(s).
  • the extruder screw’s first pumping section 8005a and first pumping section temperature control systems 8106, 8107 are configured for maintaining the temperature of the recycled plastic feedstock (e.g., by heating and/or cooling the plastic feedstock) such that the average temperature of the feedstock in the first pumping section 8005a is between 250°C and 360°C (e.g., between 270°C and 340°C, between 280°C and 330°C, between 290°C and 320°C).
  • the dual vent extruder screw’s second decompression section 8003b is generally configured for receiving semi-molten recycled plastic feedstock from the first pumping section 8005 a, reducing the pressure on the feedstock relative to the first pumping section 8005a, and pumping the feedstock downstream into the second degassing section 8004b.
  • the second decompression section 8003b to configured to reduce the pressure on the feedstock (relative to the first pumping section 8005a) such that vapor remaining in the semi-molten feedstock (e.g., vapor in the form of steam, dyes, plastic modifiers, or other undesirable contaminants) is allowed to separate from the feedstock.
  • flights provided on the dual vent extruder screw’s second decompression section 8003b are configured with scalloped outer edges, which provide passages for vapor to separate from the plastic feedstock within the extruder barrel 610.
  • the screw’s second decompression section 8003b has a maximum root diameter that is less than the maximum root diameter of the first pumping section 8005a.
  • the screw’s second decompression section 8003b has a maximum root diameter that is at least 15% smaller than the maximum root diameter of the first pumping section 8005a (e.g., at least 20% smaller than the maximum root diameter of the first pumping section 8005a, at least 25% smaller than the maximum root diameter of the first pumping section 8005a, or at least 30% smaller than the maximum root diameter of the first pumping section 8005a).
  • the screw’s second decompression section 8003b has a flight depth that is greater than the maximum flight depth of the first pumping section 8005a.
  • the screw’s second decompression section 8003b has a maximum flight depth that is at least 15% deeper than the maximum flight depth of the first pumping section 8005a (e.g., at least 20% deeper than the maximum flight depth of the first pumping section 8005a, at least 25% deeper than the maximum flight depth of the first pumping section 8005a, or at least 30% deeper than the maximum flight depth of the first pumping section 8005a).
  • the extruder screw’s second decompression section 8003b is associated with a second decompression temperature control system 8108.
  • the second decompression temperature control system 8108 comprises one or more temperature sensors configured to measuring and transmitting the temperature of the plastic feedstock within the second decompression section 8003b, an electric heater 644g, and a cooling fan 656h.
  • the electric heater 644g can comprise an electrically powered, controllable heating element surrounding (or partially surrounding) a portion of the extruder barrel 610 associated with the extruder screw’s second decompression section 8003b.
  • the cooling fan 656h can comprise a controllable electric fan positioned adjacent to the portion of the extruder barrel 610 associated with the extruder screw’s second decompression section 8003b.
  • the second decompression temperature control system 8108 (including the heater 644g and cooling fan 656h) are controllable by the pyrolysis control system (e.g., the pyrolysis control system 7500b shown and described with respect to Figure 46).
  • the second decompression temperature control system 8108 can be programmed with a second decompression temperature set point (e.g., stored by the pyrolysis control system) and configured to automatically control the heater 644g and cooling fan 656h to maintain the average temperature of the feedstock in the extruder screw’s second decompression section 8003b at the second decompression temperature set point.
  • the extruder screw’s second decompression section 8003b and second decompression temperature control system 8108 are configured for maintaining the temperature of the recycled plastic feedstock (e.g., by heating and/or cooling the plastic feedstock) such that the average temperature of the feedstock in the second decompression section 8003b is between 265 °C and 365 °C (e.g., between 285 °C and 345 °C, between 295 °C and 335°C, between 305°C and 325°C).
  • the dual vent extruder screw’s second degassing section 8004b is generally configured for receiving semi-molten recycled plastic feedstock from the second decompression section 8003b, maintaining the pressure on the feedstock relative to the second decompression section 8003b, driving vapor out of the plastic feedstock via the second extruder vent 634, and pumping the feedstock downstream into the second pumping section 8005b.
  • the second degassing section 8004b is configured to maintain the pressure on the feedstock (relative to the second decompression section 8003b) such that vapor (e.g., vapor in the form of steam, dyes, plastic modifiers, or other undesirable contaminants) in the semi-molten feedstock is forced out of the extruder barrel 610.
  • the extruder’s second vent 634 is positioned on the extruder barrel 610 such vapor forced out of the plastic feedstock in the second degassing section 8004b can exit the extruder barrel 610 via the second vent 634.
  • flights provided on the dual vent extruder screw’s second degassing section 8004b are configured with scalloped outer edges, which provide passages for vapor to separate from the plastic feedstock and exit through the second vent 634.
  • the root diameter, flight depth, flight volume, and or channel width of the flights in the second degassing section 8004b can be the same as those in the second decompression section 8003b.
  • the extruder screw’s second degassing section 8004b is associated with a second degassing temperature control system 8109.
  • the second degassing temperature control system 8109 comprises one or more temperature sensors configured to measuring and transmitting the temperature of the plastic feedstock within the second degassing section 8004b, an electric heater 644h, and a cooling fan 656i.
  • the electric heater 644h can comprise an electrically powered, controllable heating element surrounding (or partially surrounding) a portion of the extruder barrel 610 associated with the extruder screw’s second degassing section 8004b.
  • the cooling fan 656i can comprise a controllable electric fan positioned adjacent to the portion of the extruder barrel 610 associated with the extruder screw’s second degassing section 8004b.
  • the second degassing temperature control system 8109 (including the heater 644h and cooling fan 656i) are controllable by the pyrolysis control system (e.g., the pyrolysis control system 7500b shown and described with respect to Figure 46).
  • the second degassing temperature control system 8109 can be programmed with a second degassing temperature set point (e.g., stored by the pyrolysis control system) and configured to automatically control the heater 644h and cooling fan 656i to maintain the average temperature of the feedstock in the extruder screw’s second degassing section 8004b at the second degassing temperature set point.
  • the extruder screw’s second degassing section 8004b and second degassing temperature control system 8109 are configured for maintaining the temperature of the recycled plastic feedstock (e.g., by heating and/or cooling the plastic feedstock) such that the average temperature of the feedstock in the second degassing section 8004b is between 270°C and 370°C (e.g., between 290°C and 350°C, between 300°C and 340°C, between 310°C and 330°C).
  • the dual vent extruder screw’s second pumping section 8005b is generally configured for receiving semi-molten recycled plastic feedstock from the second degassing section 8004b, mixing and heating the feedstock, and pumping the out of the extruder.
  • the second pumping section 8005b is configured for pumping molten or semi-molten feedstock out of the extruder 600 (e.g., via a barrel outlet 640) and into the pyrolysis reactor (e.g., via a heated transfer pipe).
  • the screw’s second pumping section 8005b has a maximum root diameter that is greater than the maximum root diameter of the second degassing section 8004b.
  • the screw’s second pumping section 8005b has a maximum root diameter that is at least 15% greater than the maximum root diameter of the second degassing section 8004b (e.g., at least 20% greater than the maximum root diameter of the second degassing section 8004b, at least 25% greater than the maximum root diameter of the second degassing section 8004b, or at least 30% greater than the maximum root diameter of the second degassing section 8004b).
  • the screw’s second pumping section 8005b has a flight depth that is less than (shallower than) the maximum flight depth of the second degassing section 8004b.
  • the screw’s second pumping section 8005b has a maximum flight depth that is at least 15% less than the maximum flight depth of the second degassing section 8004b (e.g., at least 20% less than the maximum flight depth of the first degassing section 8004b, at least 25% less than the maximum flight depth of the first degassing section 8004b, or at least 30% less than the maximum flight depth of the first degassing section 8004b).
  • the extruder screw’s second pumping section 8005b is associated with one or more temperature controls systems.
  • the extruder screw’s second pumping section 8005b is associated with a first pumping temperature control system 8110 and a second pumping temperature control system 8111.
  • the first and second pumping temperature control systems 8110, 8111 each comprise one or more temperature sensors configured to measuring and transmitting the temperature of the plastic feedstock within the second pumping section 8005b, an electric heater 644i, 644j and a cooling fan 656j, 656k.
  • the electric heaters 644i, 644j can each comprise an electrically powered, controllable heating element surrounding (or partially surrounding) a portion of the extruder barrel 610 associated with the extruder screw’s second pumping section 8005b.
  • the cooling fans 656j, 656k can each comprise a controllable electric fan positioned adjacent to the portion of the extruder barrel 610 associated with the extruder screw’s second pumping section 8005b.
  • the second pumping section temperature control systems 8110, 8111 are controllable by pyrolysis control system (e.g., the pyrolysis control system 7500b shown and described with respect to Figure 46).
  • the second pumping section temperature control systems 8110, 8111 can each be programmed with second pumping section temperature set point(s) (e.g., stored by pyrolysis control system) and configured to automatically control the heaters 644i, 644j and cooling fans 656j, 656k to maintain the average temperature of the feedstock in the extruder screw’s second pumping section 8005b at the second pumping section temperature set point(s).
  • the extruder screw’s second pumping section 8005b and second pumping section temperature control systems 81 10, 811 1 are configured for maintaining the temperature of the recycled plastic feedstock (e.g., by heating and/or cooling the plastic feedstock) such that the average temperature of the feedstock in the second pumping section 8005b is between 270°C and 370°C (e.g., between 290°C and 350°C, between 300°C and 340°C, between 310°C and 330°C).
  • the extruder 600 is configured such that no additives are added to the plastic feedstock as it moves through the extruder barrel 610 (from the feed section 8001 through the second pumping section 8005b).
  • the temperature control systems (8101-8111) and their respective sub-components can be individually controllable by the pyrolysis control system.
  • Figure 46 shows a schematic diagram of a pyrolysis control system 7500b configured for controlling both a pyrolysis reactor (e.g., the pyrolysis reactor 5000 of Fig. 47) and an extruder configured for transferring molten or semi-molten feedstock into the pyrolysis reactor (e.g., the extruder 600 of Figure 13 or the extruder 800 of Figure 15) according to another example implementation.
  • Figure 14 provides a perspective view of another example implementation of an extruder 700 configured for heating plastic feedstock (e.g., loose film, baled film, rigids, thermoforms, sheets, foams, non-wovens, strips, pellets, powder, purge patties, densified, shredded, and other post-consumer and/or post-industrial plastics) and converting the feedstock into a molten or semi-molten state.
  • plastic feedstock e.g., loose film, baled film, rigids, thermoforms, sheets, foams, non-wovens, strips, pellets, powder, purge patties, densified, shredded, and other post-consumer and/or post-industrial plastics
  • plastic feedstock e.g., loose film, baled film, rigids, thermoforms, sheets, foams, non-wovens, strips, pellets, powder, purge patties, densified, shredded, and other post-consumer and/or post-industrial plastics
  • vents 732, 734, 736, 738 are provided along the extruder’s barrel 710.
  • the vents 732, 734, 736, 738 are configured to allow vapors and/or gases produced from the plastic feedstock during the heating process to escape from the extruder 700.
  • the vents 732, 734, 736, 738 can allow for removal of residual vapor and contaminants that can have a negative impact on the pyrolysis product quality.
  • the vents 732, 734, 736, 738 are ambient pressure vents.
  • the vents 732, 734, 736, 738 are under vacuum.
  • one or more of the vents 732, 734, 736, 738 are ambient pressure vents while one or more of the vents 732, 734, 736, 738 are under vacuum.
  • extruder 700 is depicted with a single screw 742, in other implementations, the extruder 700 can be provided with twin screws. Additionally, various implementations can include a combination of oil, gas, and electric heating elements for heating the barrel 710.
  • Figure 15 provides a perspective view of another example implementation of an extruder 800 configured for heating plastic feedstock (e.g., loose film, baled film, rigids, thermoforms, sheets, foams, non-wovens, strips, pellets, powder, purge patties, densified, shredded, and other post-consumer and/or post-industrial plastics) and converting the feedstock into a molten or semi-molten state.
  • plastic feedstock e.g., loose film, baled film, rigids, thermoforms, sheets, foams, non-wovens, strips, pellets, powder, purge patties, densified, shredded, and other post-consumer and/or post-industrial plastics
  • plastic feedstock e.g., loose film, baled film, rigids, thermoforms, sheets, foams, non-wovens, strips, pellets, powder, purge patties, densified, shredded, and other post-consumer and/or post-industrial plastics
  • vents 832, 834 are provided along the extruder’s barrel 810.
  • the vents 832, 834 are configured to allow vapors and/or gases produced from the plastic feedstock during the heating process to escape from the extruder 800. In this way, the vents 832, 834 can allow for removal of residual vapor and contaminants that can have a negative impact on the pyrolysis product quality.
  • both vents 832, 834 are ambient pressure vents.
  • both vents 832, 834 are under vacuum.
  • the first vent 832 is an ambient pressure vent while the second vent 834 is under vacuum.
  • extruder 800 is depicted with a single screw 842, in other implementations, the extruder 800 can be provided with twin screws. Additionally, various implementations can include a combination of oil, gas, and electric heating elements for heating the barrel 810.
  • the single screw 842 of the extruder 800 can comprise a dual vent extruder screw configured for melting low bulk density recycled plastic feedstock and/or recycled plastic feedstock having a wide MFI range.
  • the dual vent extruder screw is configured for receiving recycled plastic feedstock (e.g., low bulk density recycled plastic feedstock), melting recycled plastic feedstock into a molten or semi-molten form, and pumping the molten or semi-molten feedstock out of the extruder (e.g., so the molten or semi-molten feedstock can be directed into a pyrolysis reactor).
  • the extruder 800 is configured such that no additives are added to the plastic feedstock as it moves through the extruder.
  • a vent feeding device 900 is used at the first vent 832 to prevent expulsion of melted plastic from the vent 832.
  • Figure 16 shows a vent feeding device 900 according to one implementation.
  • the vent feeding device 900 is elevated on a stand 902 with wheels 940 and configured to be selectively engaged with the vent 832 via a vent inlet interface 922.
  • the vent feeding device 900 further includes a motor 904 that is coupled to a gearbox 906 and configured for driving single or twin screw elements (not shown) positioned within a vent inlet 920.
  • the vent feeder 900 also includes a vapor outlet 930 (e.g., a vent) that will allow vapor and contaminants to pass by the screw(s) (e.g., into a scrubber system).
  • a vapor outlet 930 e.g., a vent
  • the vent feeding device 900 serves to prevent the occurrence of vent flow from the extruder (e.g., preventing molten feedstock from being expelled from the extruder vent 832).
  • the hydrocarbons that make up the feedstock plastic polymers include chains and rings of hydrocarbon molecules linked together to form the solid materials with some additives to the structures to adjust properties such as plasticity, stabilization against ultraviolet light degradation, and extrusion slip.
  • Gas production is accomplished by heating the incoming stream of plastic (e.g., raw feedstock, melted feedstock, semi-molten feedstock from the extruders, etc.) in an oxygen-free environment to the point where the plastic is a fully molten liquid and the polymers “depolymerize” (e.g., fully or partially depolymerize).
  • plastic e.g., raw feedstock, melted feedstock, semi-molten feedstock from the extruders, etc.
  • the polymers “depolymerize” e.g., fully or partially depolymerize.
  • the hydrocarbon plastic chains and groups of rings are split apart by the heating process into smaller segments until they are small and light enough to exit the reactor as a gas or vapor.
  • the systems and methods can include one or more pyrolysis reactors (e.g., two or more, or three or more) for pyrolyzing the feedstock.
  • the pyrolysis can be accomplished using any suitable pyrolysis reactor, such as, for example, an auger pyrolysis reactor, a screw pyrolysis reactor, a rotary kiln pyrolysis reactor, a drum pyrolysis reactor, a tubular pyrolysis reactor, a fluidized bed reactor, a spouted bed reactor, a molten salt reactor, a molten metal reactor, a fixed-bed reactor, a continuously stirred reactor, a Heinz Retort Pyrolysis reactor, a vortex pyrolysis reactor, a batch pyrolysis reactor, a semi-batch pyrolysis reactor, or a combination thereof.
  • the system and methods can include one or more batch pyrolysis reactors, semi-batch pyrolysis reactors, a continuously stirred reactor, or a combination thereof.
  • the reactors can have any suitable orientation, such as horizonal or vertical. In some examples, the reactors are vertical reactors.
  • Each reactor can receive feedstock from one or more upstream components (e.g., storage bunker, extruder, etc.).
  • upstream components e.g., storage bunker, extruder, etc.
  • the system includes one or more reactors (e.g., two or more, or three or more) configured to receive the semi-molten feedstock from the extruder(s).
  • the system can include a plurality of reactors. Each reactor can, for example, process the output of one or more extruders.
  • the volume of each reactor can be selected, for example, in view of the throughput of the system.
  • the volume of each reactor can independently be 1 cubic foot (ft 3 ) or more (e.g., 2 ft 3 or more, 3 ft 3 or more, 4 ft 3 or more, 5 ft 3 or more, 10 ft 3 or more, 15 ft 3 or more, 20 ft 3 or more, 25 ft 3 or more, 30 ft 3 or more, 35 ft 3 or more, 40 ft 3 or more, 45 ft 3 or more, 50 ft 3 or more, 60 ft 3 or more, 70 ft 3 or more, 80 ft 3 or more, 90 ft 3 or more, 100 ft 3 or more, 125 ft 3 or more, 150 ft 3 or more, 175 ft 3 or more, 200 ft 3 or more, 225 ft 3 or more, 250 ft 3 or more, 300 ft 3 or more, 350 ft 3 or more, 400 ft 3 or more, 450 ft 3 or
  • the volume of each reactor can independently be 3000 ft 3 or less (e.g., 2900 ft 3 or less, 2800 ft 3 or less, 2700 ft 3 or less, 2600 ft 3 or less, 2500 ft 3 or less, 2400 ft 3 or less,
  • 1700 ft 3 or less 1600 ft 3 or less, 1500 ft 3 or less, 1400 ft 3 or less, 1300 ft 3 or less, 1200 ft 3 or less,
  • the volume of each reactor can independently range from any of the minimum values described above to any of the maximum values described above.
  • the volume of each reactor can independently be from 1 ft 3 to 3000 ft 3 (e.g., from 1 to 1500 ft 3 , from 1500 to 3000 ft 3 , from 1 to 750 ft 3 , from 750 to 1500 ft 3 , from 1500 to 2250 ft 3 , from 2250 to 3000 ft 3 , from 1 to 500 ft 3 , from 500 to 1000 ft 3 , from 1000 to 1500 ft 3 , from 1500 to 2000 ft 3 , from 2000 to 2500 ft 3 , from 2500 to 3000 ft 3 , from 1 to 2800 ft 3 , from 1 to 2600 ft 3 , from 1 to 2400 ft 3 , from 1 to 2200 ft 3 , from 1 to 2000 ft 3 , from 1 to 1800 ft 3 , from 1 to 1600 ft
  • the volume of each reactor can independently be 100 gallons or more (e.g., 250 gallons or more; 500 gallons or more; 750 gallons or more; 1000 gallons or more;
  • the volume of each reactor can independently be 20,000 gallons or less (e.g., 19,000 gallons or less; 18,000 gallons or less; 17,000 gallons or less; 16,000 gallons or less; 15,000 gallons or less; 14,000 gallons or less; 13,000 gallons or less; 12,000 gallons or less; 11,000 gallons or less; 10,000 gallons or less; 9500 gallons or less; 9000 gallons or less; 8500 gallons or less; 8000 gallons or less; 7500 gallons or less; 7000 gallons or less; 6500 gallons or less; 6000 gallons or less; 5500 gallons or less; 5000 gallons or less; 4500 gallons or less; 4000 gallons or less; 3500 gallons or less; 3000 gallons or less; 2500 gallons or less; 2000 gallons or less; 1500 gallons or less; 1000 gallons or less; 750 gallons or less; 500 gallons or
  • the volume of each reactor can independently range from any of the minimum values described above to any of the maximum values described above.
  • the volume of each reactor can independently be from 100 gallons to 20,000 gallons (e.g., from 100 to 1000 gallons; from 1000 to 10,000 gallons; from 10,000 to 20,000 gallons; from 100 to 500 gallons; from 500 to 1000 gallons; from 1000 to 5000 gallons; from 5000 to 10,000 gallons; from 10,000 to 15,000 gallons; from 15,000 to 20,000 gallons; from 100 to 18,000 gallons; from 100 to 16,000 gallons; from 100 to 14,000 gallons; from 100 to 12,000 gallons; from 100 to 10,000 gallons; from 100 to 9000 gallons; from 100 to 8000 gallons; from 100 to 8000 gallons; from 100 to 7000 gallons; from 100 to 6000 gallons; from 100 to 5000 gallons; from 100 to 2000 gallons;
  • Each reactor is equipped with heaters, for example internal and/or external heaters.
  • the heaters can be any suitable type of heaters, such as electric, microwave, and/or gas heaters.
  • the heaters provide the heat needed to raise temperatures inside the reactor to a point where the pyrolysis process takes place.
  • the heaters can also provide the heat needed to maintain temperatures inside the reactor at a point where the pyrolysis process takes place.
  • a plurality of heaters can be arrayed on the reactor’s exterior and/or within its interior.
  • the heaters are gas heaters (e.g., gas powered heaters), which can be fed from commercial gas fuel and/or recycled hydrocarbon gases recovered from the reactor products (e.g., propane, butane, and/or pentane).
  • the heaters are electric heaters (e.g., electrically powered heaters, resistive heaters, inductive heaters, etc.).
  • the electric heaters can be powered by a generator, which in turn can be gas powered and which can be fed from commercial gas fuel and/or recycled hydrocarbon gases recovered from the reactor products (e.g., propane, butane, and/or pentane).
  • the reactors are equipped with a plurality of internal electric heaters, e.g. a plurality of electric heaters positioned within the reactor (e.g., 2 or more, 3 or more, 4 or more, 5 or more, 6 or more 7 or more, 8 or more, 9 or more, 10 or more, 11 or more, 12 or more, 13 or more, 14 or more, 15 or more, 20 or more, 25 or more, 30 or more, 35 or more, 40 or more, 45 or more, 50 or more, 60 or more, 70 or more, 80 or more, 90 or more, 100 or more, 125 or more, 150 or more, 175 or more, or 200 or more).
  • a plurality of internal electric heaters e.g., 2 or more, 3 or more, 4 or more, 5 or more, 6 or more 7 or more, 8 or more, 9 or more, 10 or more, 11 or more, 12 or more, 13 or more, 14 or more, 15 or more, 20 or more, 25 or more, 30 or more, 35 or more, 40 or more,
  • the electric heaters can, for example, be oriented in any suitable direction (e.g., horizontally, vertically, angled) within each reactor inside dry wells.
  • the electric heater temperature can be controlled to provide a prescribed temperature and energy density and/or heat density to the dry well walls which in turn provide a controlled heat flux into the feedstock bath to drive the reactions and minimizing char formation.
  • the number of internal heaters can, for example, be selected based on the size of the reactor and/or the size of the heaters.
  • Supplemental electric heaters on the outer surface of the reactors can also be provided that operate at the same temperatures and energy density and/or heat density as the internal heaters, as necessary.
  • the average heat density applied by each of the internal and/or external heaters can, for example, independently be 5 watts per square inch (W/in 2 ) or more (e.g., 6 W/in 2 or more, 7 W/in 2 or more, 8 W/in 2 or more, 9 W/in 2 or more, 10 W/in 2 or more, 11 W/in 2 or more, 12 W/in 2 or more, 13 W/in 2 or more, 14 W/in 2 or more, 15 W/in 2 or more, 16
  • W/in 2 or more 17 W/in 2 or more, 18 W/in 2 or more, 19 W/in 2 or more, 20 W/in 2 or more, 21
  • W/in 2 or more 22 W/in 2 or more, 23 W/in 2 or more, 24 W/in 2 or more, 25 W/in 2 or more, 26
  • W/in 2 or more 27 W/in 2 or more, 28 W/in 2 or more, 29 W/in 2 or more, 30 W/in 2 or more, 31
  • W/in 2 or more 32 W/in 2 or more, 33 W/in 2 or more, 34 W/in 2 or more, 35 W/in 2 or more, 36
  • W/in 2 or more 37 W/in 2 or more, 38 W/in 2 or more, 39 W/in 2 or more, 40 W/in 2 or more, 41 W/in 2 or more, 42 W/in 2 or more, 43 W/in 2 or more, 44 W/in 2 or more, 45 W/in 2 or more, 46 W/in 2 or more, 47 W/in 2 or more, 48 W/in 2 or more, 49 W/in 2 or more, 50 W/in 2 or more, 51 W/in 2 or more, 52 W/in 2 or more, 53 W/in 2 or more, or 54 W/in 2 or more).
  • the average heat density applied by each of the internal and/or external heaters can independently be 55 W/in 2 or less (e.g., 54 W/in 2 or less, 53 W/in 2 or less, 52 W/in 2 or less, 51 W/in 2 or less, 50 W/in 2 or less, 49 W/in 2 or less, 48 W/in 2 or less, 47 W/in 2 or less, 46 W/in 2 or less, 45 W/in 2 or less, 44 W/in 2 or less, 43 W/in 2 or less, 42 W/in 2 or less, 41 W/in 2 or less, 40 W/in 2 or less, 39 W/in 2 or less, 38 W/in 2 or less, 37 W/in 2 or less, 36 W/in 2 or less, 35 W/in 2 or less, 34 W/in 2 or less, 33 W/in 2 or less, 32 W/in 2 or less, 31 W/in 2 or less, 30 W/in 2 or less, 29 W/in 2 or less, 28 W/in 2 or less, 27 W/
  • the average heat density applied by each of the internal and/or external heaters can independently range from any of the minimum values described above to any of the maximum values described above.
  • the average heat density applied by each of the internal and/or external heaters can independently be from 5 to 55 W/in 2 (e.g., from 5 to 30 W/in 2 , from 30 to 55 W/in 2 , from 5 to 15 W/in 2 , from 15 to 25 W/in 2 , from 25 to 35 W/in 2 , from 35 to 45 W/in 2 , from 45 to 55 W/in 2 , from 5 to 50 W/in 2 , from 5 to 45 W/in 2 , from 5 to 40 W/in 2 , from 5 to 35 W/in 2 , from 5 to 30 W/in 2 , from 5 to 20 W/in 2 , from 5 to 25 W/in 2 , from 10 to 55 W/in 2 , from 15 to 55 W/in 2 , from 20 to 55 W/in 2 , from 25 to 55 W/in 2 , from 35 to
  • the combined energy density applied by the reactor’ s internal and/or external heater systems on a per hour basis can, for example, independently be 0.05 kilowatts per pound of pyrolyzed product produced within the reactor (kW/lb) or more (e.g., 0.05 kW/lb or more, 0.
  • the combined energy density applied by the reactor’s internal and/or external heater systems on a per hour basis can, for example, independently be 1.0 kW/lb or less (e.g., 0.95 kW/lb or less, 0.90 kW/lb or less, 0.85 kW/lb or less, 0.80 kW/lb or less, 0.75 kW/lb or less, 0.70 kW/lb or less, 0.65 kW/lb or less, 0.60 kW/lb or less, 0.55 kW/lb or less, 0.50 kW/lb or less, 0.45 kW/lb or less, 0.40 kW/lb or less, 0.35 kW/lb or less, 0.30 kW/lb or less, 0.25 kW/lb or less, 0.20 kW/lb or less, 0.15 kW/lb or less, 0.10 kW/lb or less).
  • 1.0 kW/lb or less e.g., 0.95 kW/lb or less, 0.90
  • the combined energy density applied by the reactor’s internal and/or external heater systems on a per hour basis can, for example, independently range from any of the minimum values described above to any of the maximum values described above.
  • the combined energy density applied by the reactor’s internal and/or external heater systems on a per hour basis can independently be from 0.05 to 1.0 kW/lb (e.g., from 0.05 to 0.5 kW/lb, from 0.5 to 1.0 kW/lb, from 0.05 to 0.25 kW/lb, from 0.25 to 0.50 kW/lb, from 0.50 to 0.75 kW/lb, from 0.75 to 1.0 kW/lb, from 0.05 to 0.15 kW/lb, from 0.15 to 0.30 kW/lb, from 0.30 to 0.45 kW/lb, from 0.45 to 0.60 kW/lb, from 0.60 to 0.75 kW/lb, from 0.75 to 0.90 kW/lb, from 0.90 to 1.0 kW/lb, from 0.05 to 0.9
  • the pyrolysis process can produce light hydrocarbon gases (e.g., propane, butane, and/or pentane) which, in some examples, can be separated from the product streams and used as an energy source, fuel, or chemical feedstock.
  • light hydrocarbon gases e.g., propane, butane, and/or pentane
  • Loose char can also be formed by any wood, cardboard, or paper materials that enter the system as part of the feedstock. Reactor temperature monitoring, accurate and precise individual heater control, and good heat transfer from the heaters into the liquid feedstock can, for example, be selected to control and limit the amount and/or rate of char formation.
  • the feedstock can, for example, be heated to a temperature of 200°C or more within the reactor (e.g., 225°C or more, 250°C or more, 275°C or more, 300°C or more, 325°C or more, 350°C or more, 375°C or more, 400°C or more, 425°C or more, 450°C or more, 475°C or more, 500°C or more, 550°C or more, 600°C or more, 650°C or more, 700°C or more, 750°C or more, 800°C or more, 850°C or more, or 900°C or more).
  • a temperature of 200°C or more within the reactor e.g., 225°C or more, 250°C or more, 275°C or more, 300°C or more, 325°C or more, 350°C or more, 375°C or more, 400°C or more, 425°C or more, 450°C or more, 475°C or more
  • the feedstock can be heated to a temperature of 1000°C or less within the reactor (e.g., 950°C or less, 900°C or less, 850°C or less, 800°C or less, 750°C or less, 700°C or less, 650°C or less, 600°C or less, 550°C or less, 500°C or less, 475°C or less, 450°C or less, 425°C or less, 400°C or less, 375°C or less, 350°C or less, 325 °C or less, 300°C or less, 275°C or less, or 250°C or less).
  • a temperature of 1000°C or less within the reactor e.g., 950°C or less, 900°C or less, 850°C or less, 800°C or less, 750°C or less, 700°C or less, 650°C or less, 600°C or less, 550°C or less, 500°C or less, 475°C or less, 450
  • the temperature to which the feedstock is heated within the reactor can range from any of the minimum values described above to any of the maximum values described above.
  • the feedstock can be heated to a temperature of from 200°C to 1000°C within the reactor (e.g., from 200°C to 600°C, from 600°C to 1000°C, from 200°C to 300°C, from 300°C to 400°C, from 400°C to 500°C, from 500°C to 600°C, from 600°C to 700°C, from 700°C to 800°C, 800°C to 900°C, 900°C to 1000°C, from 200°C to 900°C, from 200°C to 800°C, from 200°C to 700°C, from 200°C to 500°C, from 200°C to 400°C, from 300°C to 1000°C, from 400°C to 1000°C, from 500°C to 1000°C, , from 700°C to 1000°C, from 800°C to 1000°C, from 250°C to 950°C,
  • the feedstock can be heated to a temperature of from 375°C to 425°C, such as from 385°C to 415°C, within the reactor. In some examples, the feedstock can be heated to a temperature of from 600°C to 800°C within the reactor.
  • the feedstock can also, for example, be maintained at a temperature of 200°C or more within the reactor (e.g., 225 °C or more, 250°C or more, 275°C or more, 300°C or more, 325 °C or more, 350°C or more, 375°C or more, 400°C or more, 425°C or more, 450°C or more, 475°C or more, 500°C or more, 550°C or more, 600°C or more, 650°C or more, 700°C or more, 750°C or more, 800°C or more, 850°C or more, or 900°C or more).
  • a temperature of 200°C or more within the reactor e.g., 225 °C or more, 250°C or more, 275°C or more, 300°C or more, 325 °C or more, 350°C or more, 375°C or more, 400°C or more, 425°C or more, 450°C or more, 4
  • the feedstock can be maintained at a temperature of 1000°C or less within the reactor (e.g., 950°C or less, 900°C or less, 850°C or less, 800°C or less, 750°C or less, 700°C or less, 650°C or less, 600°C or less, 550°C or less, 500°C or less, 475°C or less, 450°C or less, 425°C or less, 400°C or less, 375°C or less, 350°C or less, 325°C or less, 300°C or less, 275°C or less, or 250°C or less).
  • a temperature of 1000°C or less within the reactor e.g., 950°C or less, 900°C or less, 850°C or less, 800°C or less, 750°C or less, 700°C or less, 650°C or less, 600°C or less, 550°C or less, 500°C or less, 475°C or less, 450°
  • the temperature at which the feedstock is maintained within the reactor can range from any of the minimum values described above to any of the maximum values described above.
  • the feedstock can be maintained at a temperature of from 200°C to 1000°C within the reactor (e.g., from 200°C to 600°C, from 600°C to 1000°C, from 200°C to 300°C, from 300°C to 400°C, from 400°C to 500°C, from 500°C to 600°C, from 600°C to 700°C, from 700°C to 800°C, 800°C to 900°C, 900°C to 1000°C, from 200°C to 900°C, from 200°C to 800°C, from 200°C to 700°C, from 200°C to 500°C, from 200°C to 400°C, from 300°C to 1000°C, from 400°C to 1000°C, from 500°C to 1000°C, , from 700°C to 1000°C, from 800°C to 1000°C, from 250°C to 950°C,
  • the feedstock can be maintained at a temperature of from 375°C to 425°C, such as from 385°C to 415°C, within the reactor. In some examples, the feedstock can be maintained at a temperature of from 600°C to 800°C within the reactor.
  • the feedstock can be maintained within a given tolerance of a target temperature (i.e., within an acceptable range of temperatures above or below the target temperature).
  • a target temperature i.e., within an acceptable range of temperatures above or below the target temperature.
  • the feedstock can be maintained within a given tolerance of a target temperature of from 200°C to l,000°C. Examples of suitable tolerances and control systems for maintaining temperature are described in further detail below.
  • the liquid and/or vapor phase feedstock inside a reactor can be agitated.
  • the pyrolysis reactor can comprise an auger pyrolysis reactor, a screw pyrolysis reactor, a rotary kiln pyrolysis reactor, a fluidized bed reactor, a continuously stirred reactor, or a combination thereof, wherein the reactor agitates the liquid and/or vapor phase feedstock.
  • the liquid and/or vapor phase feedstock inside a reactor can be kept in continuous motion using an agitator that circulates the liquid and/or vapor phase feedstock inside the reactor.
  • the liquid feedstock can be agitated in a manner that fosters heat transfer from the internal and/or external heaters to the liquid.
  • Liquid feedstock is a good insulator (i.e., has a low thermal conductivity) and the ability to get heat into it in a way that does not lead to charring but still provides enough heat to promote pyrolysis can be an important factor.
  • each reactor can include an agitator, for example a mixer or stirrer comprising one or more blades.
  • the agitator can be configured so that it can produce liquid flow velocities inside the reactor such that the bath acquires the necessary heat and also avoids long residence times at the heated surfaces.
  • the agitator can be configured such that the entire liquid bath is agitated, e.g. substantially none of the liquid bath is static.
  • the agitator can, for example, be operated at a speed of 20 RPM or more (e.g., 25 RPM or more, 30 RPM or more, 35 RPM or more, 40 RPM or more, 45 RPM or more, 50 RPM or more, 55 RPM or more, 60 RPM or more, 65 RPM or more, 70 RPM or more, 75 RPM or more, 80 RPM or more, 85 RPM or more, 90 RPM or more, 95 RPM or more, 100 RPM or more, 105 RPM or more, 110 RPM or more, 115 RPM or more, 120 RPM or more, 125 RPM or more, 130
  • RPM or more 135 RPM or more, 140 RPM or more, 145 RPM or more, 150 RPM or more, 155
  • RPM or more 160 RPM or more, 165 RPM or more, 170 RPM or more, 175 RPM or more, 180
  • the agitator can be operated at a speed of 200 RPM or less (e.g., 195 RPM or less, 190 RPM or less, 185 RPM or less, 180 RPM or less, 175 RPM or less, 170 RPM or less, 165 RPM or less, 160 RPM or less, 155 RPM or less, 150 RPM or less, 145 RPM or less, 140 RPM or less, 135 RPM or less, 130 RPM or less, 125 RPM or less, 120 RPM or less, 115 RPM or less, 110 RPM or less, 105 RPM or less, 100 RPM or less, 95 RPM or less, 90 RPM or less, 85 RPM or less, 80 RPM or less, 75 RPM or less, 70 RPM or less, 65 RPM or less, 60 RPM or less, 55 RPM or less, 50 RPM or less, 45 RPM or less, 40 RPM or less, 35 RPM or less (e.g., 195 RPM or less, 190 RPM or less, 185
  • the speed at which the agitator is operated can range from any of the minimum values described above to any of the maximum values described above.
  • the agitator can be operated at a speed of from 20 to 200 RPM (e.g., from 20 to 125 RPM, from 125 to 200 RPM, from 20 to 60 RPM, from 60 to 100 RPM, from 100 RPM to 140 RPM, from 140 to 200 RPM, from 20 to 180 RPM, from 20 to 160 RPM, from 20 to 140 RPM, from 20 to 120 RPM, from 20 to 100 RPM, from 20 to 80 RPM, from 20 to 40 RPM, from 40 to 200 RPM, from 60 to 200 RPM, from 80 to 200 RPM, from 100 to 200 RPM, from 120 to 200 RPM, from 140 to 200 RPM, from 160 to 200 RPM, from 25 to 195 RPM, from 30 to 190 RPM, from 50 to 175 RPM, from 75 to 150 RPM, or from 120 to 160 RPM).
  • 20 to 200 RPM e.g., from 20 to
  • the agitator can be configured to produce homogeneous or inhomogeneous fluid (e.g., liquid and/or vapor) flow inside the reactor.
  • the agitator is configured to produce average fluid flow velocities inside the reactor of greater than 0 meters per second (m/s) (e.g., 0.05 m/s or more, 0.1 m/s or more, 0.15 m/s or more, 0.2 m/s or more, 0.25 m/s or more, 0.3 m/s or more, 0.35 m/s or more, 0.4 m/s or more, 0.45 m/s or more, 0.5 m/s or more, 0.6 m/s or more, 0.7 m/s or more, 0.8 m/s or more, 0.9 m/s or more, 1 m/s or more, 1.25 m/s or more, 1.5 m/s or more, 1.75 m/s or more, 2 m/s or more, 2.25 m/s or more
  • the agitator is configured to produce average fluid flow velocities inside the reactor of 10 m/s or less (e.g., 9.5 m/s or less, 9 m/s or less, 8.5 m/s or less, 8 m/s or less, 7.5 m/s or less, 7 m/s or less, 6.5 m/s or less, 6 m/s or less, 5.5 m/s or less, 5 m/s or less, 4.5 m/s or less, 4 m/s or less, 3.5 m/s or less, 3 m/s or less, 2.75 m/s or less, 2.5 m/s or less, 2.25 m/s or less, 2 m/s or less, 1.75 m/s or less, 1.5 m/s or less, 1.25 m/s or less, 1 m/s or less, 0.9 m/s or less, 0.8 m/s or less, 0.7 m/s or less, 0.6 m/
  • the average fluid flow velocity inside the reactor produced by the agitator can range from any of the minimum values described above to any of the maximum values described above.
  • the agitator can be configured to produce average fluid flow velocities inside the reactor of from greater than 0 m/s to 10 m/s (e.g., from greater than 0 to 5 m/s, from 5 to 10 m/s, from greater than 0 to 2.5 m/s, from 2.5 to 5 m/s, from 5 to 7.5 m/s, from 7.5 to 10 m/s, from greater than 0 to 2 m/s, from 2 to 4 m/s, from 4 to 6 m/s, from 6 to 8 m/s, from 8 to 10 m/s, from greater than 0 to 9 m/s, from greater than 0 to 8 m/s, from greater than 0 to 7 m/s, from greater than 0 to 6 m/s, from greater than 0 to 4.5 m/s
  • Liquid level inside the reactors can be monitored using any suitable means, for example using one or more (e.g., a series of) thermocouples arranged along the internal reactor wall or through non-contact means, such as radar or ultrasonic sensors.
  • a plurality of thermocouples can be arranged vertically along the internal reactor wall.
  • the liquid bath is typically hotter than the vapor in the headspace above it. As the liquid bath level inside a reactor changes, the change can be seen by changing temperatures. Feedstock input and product output can be monitored and/or adjusted based on the observed variations in the liquid bath level.
  • the liquid volume in each reactor can, for example, comprise 40% or more of the volume of the reactor (e.g., 41% or more, 42% or more, 43% or more, 44% or more, 45% or more, 46% or more, 47% or more, 48% or more, 49% or more, 50% or more, 51% or more, 52% or more, 53% or more, 54% or more, 55% or more, 56% or more, 57% or more, 58% or more, 59% or more, 60% or more, 61% or more, 62% or more, 63% or more, 64% or more, 65% or more, 66% or more, 67% or more, 68% or more, 69% or more, 70% or more, 71% or more, 72% or more, 73% or more, 74% or more, 75% or more, 76% or more, 77% or more, 78% or more, 79% or more, 80% or more, 81% or more, 82% or more, 83% or more, 84% or more, 85% or more, 86% or more,
  • the liquid volume in the reactor can comprise 99% or less of the volume of the reactor (e.g., 98% or less, 97% or less, 96% or less, 95% or less, 94% or less, 93% or less, 92% or less, 91% or less, 90% or less, 89% or less, 88% or less, 87% or less, 86% or less, 85% or less, 84% or less, 83% or less, 82% or less, 81% or less, 80% or less, 79% or less, 78% or less, 77% or less, 76% or less, 75% or less, 74% or less, 73% or less, 72% or less, 71% or less, 70% or less, 69% or less, 68% or less, 67% or less, 66% or less, 65% or less, 64% or less, 63% or less, 62% or less, 61% or less, 60% or less, 59% or less, 58% or less, 57% or less, 56% or less, 55% or less, 54% or less, 53% or less, 53% or
  • the liquid volume in the reactor can comprise 80% or less of the volume of the reactor.
  • the liquid volume in the reactor can range from any of the minimum values described above to any of the maximum values described above.
  • the liquid volume in the reactor can comprise from 40% to 99% of the volume of the reactor (e.g., from 40% to 70%, from 70% to 99%, from 40% to 50%, from 50% to 60%, from 60% to 70%, from 70% to 80%, from 80% to 90%, from
  • the liquid volume of the reactor can comprise from 40% to 80% of the volume of the reactor (e.g., from 40% to 60%, from 60% to 80%, from 40% to 50%, from 50% to 60%, from 60% to 70%, from 70% to 80%, from 40% to 75%, from 40% to 70%, from 40% to 65%, from 40% to 55%, from 40% to 45%, from 45% to 80%, from 50% to 80%, from 55% to 80%, from 65% to 80%, from 75% to 680%, from 45% to 75%, or from 50% to 70%).
  • 40% to 80% of the volume of the reactor e.g., from 40% to 60%, from 60% to 80%, from 40% to 50%, from 50% to 60%, from 60% to 70%, from 70% to 80%, from 40% to 75%, from 40% to 70%, from 40% to 65%, from 40% to 55%, from 40% to 45%, from 45% to 80%, from 50% to 80%, from 55% to 80%, from 65% to 80%, from 75% to 680%, from 45% to 75%, or
  • the headspace volume in each reactor comprises 1% or more of the volume of the reactor (e.g., 2% or more, 3% or more, 4% or more, 5% or more, 6% or more, 7% or more, 8% or more, 9% or more, 10% or more, 11% or more, 12% or more, 13% or more, 14% or more, 15% or more, 16% or more, 17% or more, 18% or more, 19% or more, 20% or more, 21% or more, 22% or more, 23% or more, 24% or more, 25% or more, 26% or more, 27% or more, 28% or more, 29% or more, 30% or more, 31% or more, 32% or more, 33% or more, 34% or more, 35% or more, 36% or more, 37% or more, 38% or more, 39% or more, 40% or more, 41% or more, 42% or more, 43% or more, 44% or more, 45% or more, 46% or more, 47% or more, 48% or more,
  • the headspace volume in each reactor comprises 20% or more of the volume of the reactor. In some examples, the headspace volume in each reactor comprises 60% or less of the volume of the reactor (e.g., 59% or less, 58% or less, 57% or less, 56% or less, 55% or less, 54% or less, 53% or less, 52% or less, 51% or less, 50% or less, 49% or less, 48% or less, 47% or less, 46% or less, 45% or less, 44% or less, 43% or less, 42% or less, 41% or less, 40% or less, 39% or less, 38% or less, 37% or less, 36% or less, 35% or less, 34% or less, 33% or less, 32% or less, 31% or less, 30% or less, 29% or less, 28% or less, 27% or less, 26% or less, 25% or less, 24% or less, 23% or less, 22% or less, 21% or less, 20% or less, 19% or less, 18% or less, 1
  • the headspace volume in the reactor can range from any of the minimum values described above to any of the maximum values described above.
  • the headspace volume in the reactor can comprise from 1% to 60% of the reactor volume (e.g., from 1% to 30%, from 30% to 60%, from 1% to 20%, from 20% to 40%, from 40% to 60%, from 1% to 10%, from 10% to 20%, from 20% to 30%, from 30% to 40%, from 40% to 50%, from 50% to 60%, from 1% to 55%, from 1% to 50%, from 1% to 45%, from 1% to 35%, from 1% to 25%, from 1% to 15%, from 1% to 5%, from 5% to 60%, from 10% to 60%, from 15% to 60%, from 20% to 60%, from 25% to 60%, from 30% to 60%, from 35% to 60%, from 45% to 60%, from 55% to 60%, from 5% to 55%, or from 10% to 50%).
  • the headspace volume in the reactor can comprise from 20% to 60% of the reactor volume (e.g., from 20% to 40%, from 40% to 60%, from 20% to 30%, from 30% to 40%, from 40% to 50%, from 50% to 60%, from 20% to 55%, from 20% to 50%, from 20% to 45%, from 20% to 35%, from 20% to 25%, from 25% to 60%, from 30% to 60%, from 35% to 60%, from 45% to 60%, from 55% to 60%, from 25% to 55%, or from 30% to 50%).
  • 20% to 60% of the reactor volume e.g., from 20% to 40%, from 40% to 60%, from 20% to 30%, from 30% to 40%, from 40% to 50%, from 50% to 60%, from 20% to 55%, from 20% to 50%, from 20% to 45%, from 20% to 35%, from 20% to 25%, from 25% to 60%, from 30% to 60%, from 35% to 60%, from 45% to 60%, from 55% to 60%, from 25% to 55%, or from 30% to 50%).
  • Hydrocarbon vapor generated inside each reactor exits the reactor through a piping or ducting manifold connected to a product recovery system which is described below.
  • the reactor vapor pressure is monitored.
  • the type and quality of product output can be controlled to some degree by altering the pressure inside the reactor.
  • Each reactor is connected to a manifold, and vapor flow from each reactor is controlled by a valve designed to operate at the high vapor exit temperature or a down-stream blower/vacuum system, allowing the individual reactors to be maintained as needed between a slight positive pressure and a slight vacuum pressure, depending on reactor performance and the types of hydrocarbon products condensing in the downstream product recovery which operates under a slight vacuum as described below.
  • the piping manifold system also allows inert gases to be introduced when necessary to purge the reactor interior, or displace the liquid bath or vapor headspace in each reactor to another reactor without the use of pumps.
  • the pressure inside each reactor can, for example, be -7.25 psig or more (e.g., -7 psig or more, -6.5 psig or more, -6 psig or more, -5.5 psig or more, -5 psig or more, -4.5 psig or more, -4 psig or more, -3.5 psig or more, -3 psig or more, -2.5 psig or more, -2 psig or more, -1.5 psig or more, -1 psig or more, -0.5 psig or more, 0 psig or more, 0.5 psig or more, 1 psig or more, 1.5 psig or more, 2 psig or more, 2.5 psig or more, 3 psig or more, 3.5 psig or more, 4 psig or more, 4.5 psig or more, 5 psig or more, 5.5 psig or more, 6 psig or more, 6.5 psig or more, 7 psig or
  • the pressure inside the reactor can be 3500 psig or less (e.g., 3250 psig or less, 3000 psig or less, 2750 psig or less, 2500 psig or less, 2250 psig or less, 2000 psig or less, 1750 psig or less, 1500 psig or less, 1250 psig or less, 1000 psig or less, 900 psig or less, 800 psig or less, 700 psig or less, 600 psig or less, 500 psig or less, 450 psig or less, 400 psig or less, 350 psig or less, 300 psig or less, 250 psig or less, 225 psig or less, 200 psig or less, 175 psig or less, 150 psig or less, 125 psig or less, 100 psig or less, 90 psig or less, 80 psig or less, 70 psig or less, 60 psig or less, 50 psig or less, 45
  • the pressure within the reactor can range from any of the minimum values described above to any of the maximum values described above.
  • the pressure inside the reactor can be from -7.25 to 3500 psig (e.g., from -7.25 to 1750 psig, from 1750 to 3500 psig, from -7.25 to 0 psig, from 0 to 7.25 psig, from 7.25 to 14.5 psig, from 14.5 to 145 psig, from 145 to 1450 psig, from 1450 to 3500 psig, from -7.25 to 3000 psig, from -7.25 to 2500 psig, from -7.25 to 2000 psig, from -7.25 to 1500 psig, from -7.25 to 1000 psig, from -7.25 to 500 psig, from -7.25 to 100 psig, from -7.25 to 50 psig, from -7.25 to 25 psig, from -7.25 to 10 psig, from -7.25 to 5
  • the pressure inside the reactor can be from -7.25 to 14.5 psig. In some examples, the pressure inside the reactor can be from 14.5 psig to 3500 psig.
  • the residence time of the feedstock within the reactor (e.g., the time that it takes to pyrolyze) can vary based on a variety of factors. For example, the residence time of the feedstock within the reactor can vary based on the type of reactor, the composition of the feedstock, the temperature within the reactor, the pressure within the reactor, the agitation rate, the amount of char, or a combination thereof.
  • the residence time of a given polymer comprising the feedstock within the reactor can be 1 second or more (e.g., 2 seconds or more, 3 seconds or more, 4 seconds or more, 5 seconds or more, 10 seconds or more, 15 seconds or more, 20 seconds or more, 25 seconds or more, 30 seconds or more, 35 seconds or more, 40 seconds or more, 45 seconds or more, 50 seconds or more, 55 seconds or more, 1 minute or more, 2 minutes or more, 3 minutes or more, 4 minutes or more, 5 minutes or more, 10 minutes or more, 15 minutes or more, 20 minutes or more, 25 minutes or more, 30 minutes or more, 35 minutes or more, 40 minutes or more, 45 minutes or more, 50 minutes or more, 55 minutes or more, 1 hour or more, 1.5 hours or more, 2 hours or more, 2.5 hours or more, 3 hours or more, 3.5 hours or more, 4 hours or more, 4.5 hours or more, 5 hours or more, 5.5 hours or more, 6 hours or more, 7 hours or more, 8 hours or more, 9 hours or more, 10 hours or more,
  • the residence time of a given polymer comprising the feedstock within the reactor can be 24 hours or less (e.g., 22 hours or more, 20 hours or more, 18 hours or more, 16 hours or more, 14 hours or more, 12 hours or more, 10 hours or more, 9 hours or more, 8 hours or more, 7 hours or more, 6 hours or more, 5.5 hours or more, 5 hours or more, 4.5 hours or more, 4 hours or more, 3.5 hours or more, 3 hours or more, 2.5 hours or more, 2 hours or more, 1.5 hours or more, 1 hour or less, 55 minutes or less, 50 minutes or less, 45 minutes or less, 40 minutes or less, 35 minutes or less, 30 minutes or less, 25 minutes or less, 20 minutes or less, 15 minutes or less, 10 minutes or less, 5 minutes or less, 4 minutes or less, 3 minutes or less, 2 minutes or less, 1 minute or less, 55 seconds or less, 50 seconds or less, 45 seconds or less, 40 seconds or less, 35 seconds or less, 30 seconds or less, 25 seconds or less, 20 seconds or less, 15 minutes
  • the residence time of a given polymer comprising the feedstock within the reactor can range from any of the minimum values described above to any of the maximum values described above.
  • the residence time of a given polymer comprising the feedstock within the reactor can be from 1 second to 24 hours (e.g., from 1 second to 12 hours, from 12 hours to 24 hours, from 1 second to 1 minute, from 1 minute to 1 hour, from 1 hour to 24 hours, from 1 second to 1 hour, from 1 hour to 6 hours, from 6 hours to 12 hours, from 12 hours to 18 hours, to 24 hours, from 1 minute to 20 hours, from 1 second to 18 hours, from 1 second to 16 hours, from 1 second to 14 hours, from 1 second to 10 hours, from 1 second to 8 hours, from 1 second to 4 hours, from 1 second to 2 hours, from 1 second to 30 minutes, from 1 second to 15 minutes, from 1 second to 10 minutes, from 1 second to 5 minutes, from 1 minute to 24 hours, from 5 minutes to 24 hours, from 10 minutes to 24 hours, from 15 minutes to 24 hours, from
  • the reactor can be configured for producing an average of 0.30 lb. or more of pyrolyzed product per hour per gallon of the reactor’ s internal volume for a period of 24 hours or more (e.g., 0.31 lb. or more, 0.32 lb. or more, 0.33 lb. or more, 0.34 lb. or more, 0.35 lb. or more, 0.36 lb. or more, 0.37 lb. or more, 0.38 lb. or more, 0.39 lb. or more, 0.40 lb. or more, 0.41 lb. or more, 0.42 lb. or more, 0.43 lb. or more, 0.44 lb. or more, 0.45 lb.
  • 0.31 lb. or more 0.32 lb. or more, 0.33 lb. or more, 0.34 lb. or more, 0.35 lb. or more, 0.36 lb. or more, 0.37 lb. or more, 0.38 l
  • the reactor can be configured for producing an average of from 0.30 lb. to 0.75 lb. of pyrolyzed product per hour per gallon of the reactor’s internal volume for a period of 24 hours or more (e.g., from 0.31 lb. to 0.75 lb., from 0.32 lb. to 0.75 lb., from 0.33 lb.
  • the foregoing reactor throughput ranges can be achieved using the pyrolysis reactor 5000 shown and described with respect to Figure 29.
  • the foregoing reactor throughput ranges can be achieved using the pyrolysis system SlOOe of Figure 5, where the extruder S107a comprises the extruder 800 shown and described with respect to Figure 15 and the pyrolysis reactor SI 08a comprises the pyrolysis reactor 5000 shown and described with respect to Figure 29.
  • Inert material that enters the reactors can optionally be removed by any suitable processing component or step, such as sedimentation, decantation, filtration, sieving, etc.
  • the reactor can further include an additive, such as a catalyst, a diluent, an adsorbent, etc.
  • an additive such as a catalyst, a diluent, an adsorbent, etc.
  • the pyrolysis is substantially free of any added catalyst.
  • the pyrolysis includes a catalyst (e.g., Zeolites, metal catalysts, and the like).
  • a catalyst e.g., Zeolites, metal catalysts, and the like.
  • Figure 17 shows a side view of a rotary kiln pyrolysis reactor 1000 according to one implementation.
  • the rotary kiln pyrolysis reactor 1000 is generally configured for pyro lyzing feedstock.
  • the rotary kiln pyrolysis reactor 1000 is configured for receiving and pyrolyzing molten or semi-molten feedstock (e.g., received from an extruder).
  • the rotary kiln pyrolysis reactor 1000 is configured for receiving and pyrolyzing solid or semi-solid feedstock (e.g., loose film, baled film, rigids, thermoforms, sheets, foams, non-wovens, strips, pellets, powder, purge patties, densified, shredded, and other postconsumer and/or post-industrial plastics).
  • solid or semi-solid feedstock e.g., loose film, baled film, rigids, thermoforms, sheets, foams, non-wovens, strips, pellets, powder, purge patties, densified, shredded, and other postconsumer and/or post-industrial plastics.
  • the rotary kiln pyrolysis reactor 1000 can be used in the methods described herein for producing hydrocarbon-based compositions derived from pyrolysis of feedstock comprising post-consumer and/or post-industrial plastics, including gas.
  • Figure 18 provides a top view of the rotary kiln pyrolysis reactor 1000 shown in Figure
  • the rotary kiln pyrolysis reactor 1000 includes a reactor vessel within which plastic feedstock is deposited and pyrolyzed.
  • the reactor vessel comprises a reactor barrel 1004.
  • the reactor barrel 1004 is comprised of a cylindrical body 1012 having a first end 1006 and second end 1008.
  • the cylindrical body 1012 defines a horizontal longitudinal axis (e.g., parallel to the ground).
  • the cylindrical body 1012 defines a longitudinal axis that is angled (e.g., 10 degrees relative to the ground).
  • the interior of the cylindrical body 1012 defines the reactor vessel’s internal volume 1018.
  • the cylindrical body 1012 can be constructed from steel having a refractory lining (or other materials with suitable structural and thermal properties).
  • the rotary kiln pyrolysis reactor 1000 further includes a transfer assembly 1026 positioned at the reactor barrel’s second end 1008.
  • the transfer assembly 1026 includes a feedstock inlet 1020, a vapor outlet 1024, a sealing interface 1027, and a plurality of reactor sensors 1030.
  • the feedstock inlet 1020 defines an external opening and extends into the reactor barrel 1004.
  • the plastic feedstock e.g., semi-molten feedstock received from an extruder
  • the feedstock inlet’s external inlet opening is positioned outside of the reactor barrel 1004 and defines an aperture through which plastic feedstock can enter the feedstock inlet 1020.
  • the feedstock inlet 1020 which can comprise, for example, a pipe, extends into the internal volume 1018 and includes an outlet opening positioned within the reactor barrel’s internal volume 1018.
  • plastic feedstock e.g., semi-molten feedstock
  • the plastic feedstock will be directed through the feedstock inlet and deposited within the reactor vessel’s internal volume 1018 for processing.
  • the transfer assembly’s vapor outlet 1024 defines an internal opening (positioned within the reactor barrel’s internal volume 1018) and an external opening (positioned outside of the reactor barrel 1004).
  • the transfer assembly’s vapor outlet 1024 which can comprise, for example, a pipe, extends into the reactor barrel 1004 at the reactor barrel’s second end 1008 and enables vapor produced during pyrolysis of the feedstock within the reactor barrel 1004 to exit the reactor barrel 1004.
  • the rotary kiln pyrolysis reactor 1000 further comprises a drive motor 1016 and drive gear 1017 configured for rotating the reactor barrel 1004 about its longitudinal axis.
  • the reactor barrel 1004 is rotatably mounted on a plurality of roller supports 1023.
  • a plurality of rollers 1025 are positioned on the exterior wall of the reactor barrel’s cylindrical body 1012 and configured to enable the reactor barrel 1004 to rotate about its longitudinal axis.
  • the reactor barrel 1004 can be rotated via a chain drive (e.g., such that a chain links the drive motor 1016 to the drive gear 1017 positioned on the reactor barrel 1004).
  • reactor barrel 1004 are configured for continuously rotating such that the liquid plastic inside the reactor vessel is kept in continuous motion. In this way, the reactor barrel’s rotation provides sufficient movement of the liquid plastic to acquire heat for pyrolysis to occur.
  • the reactor barrel 1004 is continuously rotated during the pyrolysis process.
  • the transfer assembly 1026 includes a sealing interface 1027.
  • the sealing interface 1027 is configured to provide a seal between the reactor barrel’s second end 1008 and the transfer assembly 1026. In this way, the reactor barrel’s internal volume 1018 remains sealed and enclosed as the reactor barrel 1004 rotates about its longitudinal axis and the transfer assembly 1026 remains in a fixed position.
  • the rotary kiln pyrolysis reactor 1000 includes a heating device configured for heating the internal volume 1018 of the reactor barrel 1004.
  • the heating device comprises a burner assembly 1013 positioned at the reactor barrel’s first end 1006.
  • the burner assembly 1013 comprises a burner pipe 1015 and a kiln hood 1014.
  • the burner assembly 1013 is configured as a direct fired kiln system in which the burner pipe 1015 emits a flame that heats the reactor barrel’s 1004 internal volume 1018.
  • the burner pipe 1015 is oriented in a counter-current direction. In other implementations, the burner pipe 1015 can be oriented in a co-current direction.
  • the burner assembly 1013 can be configured as an indirect fired kiln system for heating the reactor barrel 1004.
  • the burner assembly 1013 is generally configured to provide the heat needed to raise temperatures inside the reactor barrel 1004 to a point where pyrolysis takes place.
  • the burner assembly 1013 can also be configured to provide the heat needed to maintain temperatures inside the reactor barrel 1004 at a point where the pyrolysis process takes place.
  • burner pipe 1015 can be controlled to provide a prescribed temperature and heat density (W/in 2 ) that results in a controlled heat flux into the liquid feedstock within the reactor barrel 1004.
  • W/in 2 temperature and heat density
  • the pyrolysis reaction within the reactor barrel 1004 can be controlled to provide a desired reaction temperature and energy density (kW/lb).
  • the rotary kiln pyrolysis reactor 1000 includes a vapor outlet 1024.
  • the reactor is configured to provide a conduit for hydrocarbon vapor exiting the reactor 1000 and thus extends upwardly from the transfer assembly 1026.
  • the vapor outlet 1024 can be connected (e.g., via additional piping or a ducting manifold) to a product recovery system.
  • the vapor outlet 1024 is configured to direct vapor exiting the reactor barrel 1004 following pyrolysis to a product collection system 1036 configured for product recovery (e.g., gas as described herein).
  • the product collection system 1036 can include, for example, a condenser, a reflux unit, and/or a catalyst bed.
  • the reactor’s transfer assembly 1026 includes a plurality of reactor sensors 1030.
  • the reactor sensors 1030 can be configured for measuring the dynamic properties of the liquid plastic within the reactor, output and dynamic properties of the heating system, as well as the dynamic properties of the reactor’s input (e.g., feedstock input) and output (e.g., vapor production) and a variety of other variables.
  • the reactor sensors 1030 can comprise thermocouples, pressure sensors, flow meters, and the like. In this way, feedstock input (e.g., from an extruder) and product output can be monitored and/or adjusted based on the observed variations in the liquid plastic within the reactor.
  • a plurality of rotary kiln pyrolysis reactors 1000 can also be provided for use in the production of pyrolysis products, such as gas.
  • pyrolysis products such as gas.
  • three rotary kiln pyrolysis reactors 1000 are used and can be operational in any combination with one another (e.g., such that all three pyrolysis reactors 1000 are processing feedstock simultaneously, or such that two of the pyrolysis reactors 1000 are processing feedstock while a third remains on standby in the event one of the other reactors requires service or maintenance).
  • Figure 19 shows a side view of a screw pyrolysis reactor 2000 according to one implementation.
  • the screw pyrolysis reactor 2000 is generally configured for pyrolyzing feedstock.
  • the screw pyrolysis reactor 2000 is configured for receiving and pyrolyzing semi-molten feedstock (e.g., received from an extruder).
  • the screw pyrolysis reactor 2000 is configured for receiving and pyrolyzing solid or semi-solid plastic feedstock (e.g., loose film, baled film, rigids, thermoforms, sheets, foams, non-wovens, strips, pellets, powder, purge patties, densified, shredded, and other postconsumer and/or post-industrial plastics).
  • the screw pyrolysis reactor 2000 can be used in the methods described herein for producing hydrocarbon-based compositions derived from pyrolysis of feedstock comprising post-consumer and/or post-industrial plastics, including gas.
  • Figure 20 provides a top view of the screw pyrolysis reactor 2000 shown in Figure 19. Certain elements depicted in Figure 19 are also depicted in Figure 20 and, accordingly, reference to either figure can be regarded as a reference to both figures.
  • the screw pyrolysis reactor 2000 includes a reactor vessel within which plastic feedstock is deposited and pyrolyzed.
  • the reactor vessel comprises a reactor barrel 2010.
  • the reactor barrel 2010 is comprised of a cylindrical body 2012 having a first end 2006 and second end 2008.
  • the cylindrical body 2012 defines a horizontal longitudinal axis (e.g., parallel to the ground).
  • the interior of the cylindrical body 2012 defines the reactor vessel’s internal volume 2018.
  • the cylindrical body 2012 can be constructed from steel (or other materials with suitable structural and thermal properties).
  • the screw pyrolysis reactor 2000 further includes a screw 2014 positioned within the reactor barrel’s internal volume 2018.
  • the screw 2014 is oriented horizontally and extends longitudinally through the reactor barrel’s internal volume 2018 (e.g., such that a longitudinal axis of the screw 2014 is parallel to the longitudinal axis of the rector barrel 2010.
  • the screw 2014 is configured to rotate (e.g., about its longitudinal axis) and transfer plastic feedstock laterally through the reactor barrel’s internal volume 2018.
  • the reactor barrel’s internal volume 2018 is heated to drive pyrolysis of the plastic feedstock as the screw 2014 transfers the feedstock through the reactor barrel 2010.
  • the screw pyrolysis reactor 2000 further comprises a drive motor and gear assembly 2016 configured for rotating the screw 2014 about its longitudinal axis.
  • the screw 2014 includes a helical protrusion that, when rotating, transfers the plastic feedstock through the reactor barrel 2010 (e.g., from the first end 2006 towards the second end 2008). Accordingly, by controlling the speed of the motor and gear assembly 2016, the rotational speed of the screw 2014 can be controlled to dictate the velocity of the plastic feedstock as it is transferred through the reactor barrel 2010.
  • Various implementations of the screw 2014 are configured for continuously rotating such that the liquid plastic inside the reactor barrel 2010 is kept in continuous motion. In this way, the screw’s rotation provides sufficient movement of the liquid plastic to acquire heat for pyrolysis to occur as it is transferred laterally through the reactor barrel 2010.
  • the reactor barrel 1004 is continuously rotated during the pyrolysis process.
  • the screw pyrolysis reactor 2000 further comprises a feedstock inlet 2020, a vapor outlet 2024, one or more ports 2025, one or more external heating elements 2034, a discharge manifold 2022, and a plurality of reactor sensors 2030.
  • the feedstock inlet 2020 defines an external opening and extends into the reactor barrel 2010.
  • the plastic feedstock e.g., semi-molten feedstock received from an extruder or solid feedstock
  • the feedstock inlet’s external inlet opening is positioned outside of the reactor barrel 2010 and defines an aperture through which plastic feedstock can enter the feedstock inlet 2020.
  • the feedstock inlet 2020 which can comprise, for example, a pipe, extends into the internal volume 2018 and includes an outlet opening positioned within the reactor barrel’s internal volume 2018.
  • plastic feedstock e.g., semi-molten feedstock or solid feedstock
  • the plastic feedstock will be directed through the feedstock inlet and deposited within the reactor vessel’s internal volume 2018 for processing.
  • the screw pyrolysis reactor 2000 includes a plurality of heating elements 2034 configured for heating the internal volume 2018 of the reactor barrel 2010.
  • the heating elements 2034 comprise electric heaters positioned externally around the reactor barrel 2010. When activated, the transfer of heat from the electric heaters 2034 through the reactor barrel’s cylindrical body 2012 thereby heats the internal volume 2018 of the reactor barrel 2010.
  • the heating elements 2034 are generally configured to provide the heat needed to raise temperatures inside the reactor barrel 2010 to a point where pyrolysis takes place.
  • the heating elements 2034 can also be configured to provide the heat needed to maintain temperatures inside the reactor barrel 2010 at a point where pyrolysis takes place.
  • the heating elements 2034 can be controlled to provide a prescribed temperature and heat density (W/in 2 ) that results in a controlled heat flux into the liquid feedstock within the reactor barrel 2010.
  • W/in 2 temperature and heat density
  • the pyrolysis reaction within the reactor barrel 2010 can be controlled to provide a desired reaction temperature and energy density (kW/lb).
  • the screw pyrolysis reactor 2000 can be configured for driving the pyrolysis process using only electricity (e.g., without using gas as a direct heat source).
  • the plurality of heating elements 2034 can comprise gas fired heaters positioned around the reactor barrel 2010.
  • the screw pyrolysis reactor 2000 can also include one or more heat inlets positioned around the reactor barrel 2010.
  • the heat inlets can be configured for receiving heated elements (e.g., heated ceramic balls) deposited into the reactor barrel’s internal volume 2018 for transferring heat directly to the liquid plastic feedstock within the reactor barrel 2010.
  • the heat inlets can be configured for receiving heated gas directed into (or around) the reactor barrel 2010 to heat the reactor barrel’s internal volume 2018.
  • the screw pyrolysis reactor 2000 further includes one or more vapor outlet ports 2025.
  • the ports 2025 can be positioned and configured to allow certain pre-pyrolysis vapors and/or gases produced from the plastic feedstock during the heating process to escape from the reactor barrel 2010.
  • the ports can be configured to allow air, steam, and other low melting point volatiles to exit the reactor barrel 2010.
  • the ports 2025 can be omitted from the screw pyrolysis reactor 2000.
  • the screw pyrolysis reactor 2000 further includes a discharge manifold 2022 positioned at the reactor barrel’s second end 2008.
  • the discharge manifold 2022 is configured to provide an outlet for material within the reactor barrel 2010.
  • the discharge manifold 2022 can be used to transfer or otherwise remove liquid plastic (or other material generated during the pyrolysis process) from the reactor barrel 2010.
  • various implementations of the discharge manifold 2022 can include a sealable discharge opening (e.g., a port which can be selectively opened or sealed and closed).
  • the screw pyrolysis reactor 2000 also includes a vapor outlet 2024.
  • the vapor outlet 2024 defines an internal opening (positioned within the reactor barrel’s internal volume 2018) and an external opening (positioned outside of the reactor barrel 2010).
  • the vapor outlet 2024 which can comprise, for example, a pipe, extends into the reactor barrel 2010 at the reactor barrel’s second end 2008 and enables vapor produced during pyrolysis of the plastic feedstock within the reactor barrel 2010 to exit the reactor barrel 2010.
  • the reactor’s vapor outlet 2024 is configured to provide a conduit for hydrocarbon vapor exiting the reactor 2000 and thus extends upwardly from the reactor barrel 2010.
  • the vapor outlet 2024 can be connected (e.g., via additional piping or a ducting manifold) to a product recovery system.
  • the vapor outlet 2024 is configured to direct vapor exiting the reactor barrel 2010 following pyrolysis to a product collection system 2036 (e.g., production of gas).
  • the product collection system 2036 can include, for example, a condenser, a reflux unit, and/or a catalyst bed.
  • the screw pyrolysis reactor 2000 further includes a plurality of reactor sensors 2030.
  • the reactor sensors 2030 can be configured for measuring dynamic properties of the liquid plastic within the reactor, as well as the dynamic properties of the reactor’s input (e.g., feedstock input) and output (e.g., vapor production).
  • the reactor sensors 2030 can comprise thermocouples, pressure sensors, flow meters, and the like. In this way, feedstock input (e.g., from the extruder 400) and product output can be monitored and/or adjusted based on the observed variations in the liquid plastic within the reactor.
  • a plurality of screw pyrolysis reactors 2000 can also be provided for use in the production of pyrolysis products, such as gas.
  • pyrolysis products such as gas.
  • three screw pyrolysis reactors 2000 are used and can be operational in any combination with one another (e.g., such that all three pyrolysis reactors 2000 are processing feedstock simultaneously, or such that two of the pyrolysis reactors 2000 are processing feedstock while a third remains on standby in the event one of the other reactors requires service or maintenance).
  • Figure 21 shows a side view of a fluidized bed pyrolysis reactor 3000 according to one implementation.
  • the fluidized bed pyrolysis reactor 3000 is generally configured for pyrolyzing feedstock.
  • the fluidized bed pyrolysis reactor 3000 is configured for receiving and pyrolyzing semi-molten feedstock (e.g., received from an extruder).
  • the fluidized bed pyrolysis reactor 3000 is configured for receiving and pyrolyzing solid or semi-solid plastic feedstock (e.g., loose film, baled film, rigids, thermoforms, sheets, foams, non-wovens, strips, pellets, powder, purge patties, densified, shredded, and other post-consumer and/or post-industrial plastics).
  • solid or semi-solid plastic feedstock e.g., loose film, baled film, rigids, thermoforms, sheets, foams, non-wovens, strips, pellets, powder, purge patties, densified, shredded, and other post-consumer
  • the fluidized bed pyrolysis reactor 3000 can be used in the methods described herein for producing hydrocarbon-based compositions derived from pyrolysis of feedstock comprising post-consumer and/or postindustrial plastics, including gas.
  • Figure 22 provides a top view of the fluidized bed pyrolysis reactor 3000 shown in Figure 21 . Certain elements depicted in Figure 21 are also depicted in Figure 22 and, accordingly, reference to either figure can be regarded as a reference to both figures.
  • the fluidized bed pyrolysis reactor 3000 includes a reactor vessel 3010 within which plastic feedstock is deposited and pyrolyzed.
  • the reactor vessel 3010 is comprised of a cylindrical body 3012, a first ellipsoidal head 3014 positioned at an upper end of the cylindrical body 3012 (herein the upper ellipsoidal head 3014), and a second ellipsoidal head 3016 positioned at a lower end of the cylindrical body 3012 (herein the lower ellipsoidal head 3016).
  • the cylindrical body 3012 and ellipsoidal heads 3014, 3016 define an internal volume 3018 of the reactor vessel 3010 (shown in Figure 21).
  • the cylindrical body 3012 and ellipsoidal heads 3014, 3016 can be constructed from stainless steel (or other materials with suitable structural and thermal properties).
  • the fluidized bed pyrolysis reactor 3000 further comprises a catalyst inlet 3020, pressurized feedstock inlet 3021, a discharge manifold 3022, a vapor outlet 3024, a distributor 3028, a plurality of reactor sensors 3030, one or more external heating elements 3034, and a product collection system 3036.
  • the pressurized feedstock inlet 3021 defines an external opening and extends into the reactor vessel 3010.
  • the plastic feedstock e.g., semi-molten feedstock received from an extruder
  • the feedstock inlet’s external inlet opening is positioned outside of the reactor vessel 3010 and defines an aperture through which plastic feedstock can enter the feedstock inlet 3021.
  • the feedstock inlet 3021 which can comprise, for example, a pipe, extends into the internal volume 3018 and includes an outlet opening positioned within the reactor vessel’s internal volume 3018.
  • plastic feedstock e.g., semi-molten feedstock
  • the plastic feedstock will be directed through the feedstock inlet and deposited within the reactor vessel’s internal volume 3018 for processing.
  • the pressurized feedstock inlet 3021 is configured to inject molten or semi-molten feedstock at pressure into the reactor vessel 3010.
  • the pressurized feedstock inlet’s outlet opening is positioned in a lower portion of the reactor vessel’s internal volume 3018 and below a distributor 3028.
  • the distributor 3028 comprises a porous plate defining a plurality of apertures through which liquid plastic can flow through. The pressure at which the plastic feedstock is injected into the reactor vessel 3010 forces the liquid plastic feedstock upwardly, through the apertures defined in the distributor 3028, and further into the reactor vessel’s internal volume 3018.
  • the distributor 3028 divides the liquid plastic into a plurality of streams, thereby exposing a greater surface area of the liquid plastic within the reactor vessel 3010. Furthermore, the distributor’s apertures are dimensioned such that the catalyst provided within the reactor vessel 3010 cannot pass through the distributor 3028.
  • the catalyst inlet 3020 is positioned at an upper portion of the reactor vessel 3010 and substantially above the distributor 3028. As shown in Figure 21, the catalyst inlet 3020 defines an external opening and extends into the reactor vessel 3010. In the illustrated implementation, a catalyst (e.g., Zeolites, metal catalysts, and the like) is deposited into the reactor vessel’s internal volume 3018 by way of the catalyst inlet 3020. In various implementations, the catalyst inlet’s opening is positioned outside of the reactor vessel 3010 and defines an aperture through which a catalyst material can enter the catalyst inlet 3020.
  • the feedstock inlet 3021 which can comprise, for example, a pipe, extends into the internal volume 3018 and includes an outlet opening positioned within the reactor vessel’s internal volume 3018. As will be appreciated from Figure 21, when a catalyst is directed through the catalyst inlet 3020 via its inlet opening, the catalyst will be directed through the catalyst inlet and deposited within the reactor vessel’s internal volume 3018.
  • the fluidized bed pyrolysis reactor 3000 is configured such that the liquid plastic feedstock is directed into the reactor vessel 3010 (via the feedstock inlet 3021 and through the distributor 3028) with a velocity that is sufficient to reach incipient fluidization.
  • the velocity of the plastic feedstock is sufficient to balance the weight of the catalyst or catalytic material being deposited into the reactor vessel 3010 via the catalyst inlet 3020 (e.g., such that the bath of liquid plastic and catalyst mix and swirl within the reactor vessel 3010).
  • the reactor vessel’s internal volume 3018 comprises a fluidized bed, which includes the catalyst and liquid plastic feedstock.
  • the catalyst can be selected to accelerate the rate of pyrolysis within the reactor vessel 3010 and/or lower the temperature at which pyrolysis occurs within the reactor vessel 3010.
  • the fluidized bed pyrolysis reactor 3000 includes a plurality of external heating elements 3034 configured for heating the internal volume 3018 of the reactor vessel 3010.
  • the external heating elements 3034 can comprise electric heaters positioned externally around the reactor vessel 3010. When activated, the transfer of heat from the electric heaters 3034 through the reactor vessel’s cylindrical body 3012 thereby heats the internal volume 3018 of the reactor vessel 3010.
  • the heating elements 3034 are generally configured to provide the heat needed to raise temperatures inside the reactor vessel 3010 to a point where pyrolysis takes place.
  • the heating elements 3034 can also be configured to provide the heat needed to maintain temperatures inside the reactor barrel 3010 at a point where pyrolysis takes place.
  • the heating elements 3034 can be controlled to provide a prescribed temperature and heat density (W/in 2 ) that results in a controlled heat flux into the liquid feedstock within the reactor vessel 3010.
  • W/in 2 temperature and heat density
  • the pyrolysis reaction within the reactor vessel 3010 can be controlled to provide a desired reaction temperature and energy density (kW/lb).
  • the fluidized bed pyrolysis reactor 3000 can be configured for driving the pyrolysis process using only electricity (e.g., without using gas as a direct heat source).
  • the external heating elements 3034 can comprise gas powered heaters positioned around the reactor vessel 3010.
  • one or more heat inlets can be positioned around the reactor vessel 3010.
  • the heat inlets can be configured for receiving heated elements (e.g., heated ceramic balls) deposited into the reactor vessel’s internal volume 3018 for transferring heat directly to the liquid plastic feedstock within the reactor vessel 3010.
  • the heat inlets can be configured for receiving heated gas directed around or within the reactor vessel 3010 to heat the reactor vessel’s internal volume 3018.
  • the fluidized bed pyrolysis reactor 3000 further includes a discharge manifold 3022.
  • the discharge manifold 3022 is configured to provide an outlet for material within the reactor vessel 3010.
  • the discharge manifold 3022 can be used to transfer or otherwise remove liquid plastic (or other material generated during the pyrolysis process) from the reactor vessel 3010.
  • various implementations of the discharge manifold 3022 can include a sealable discharge opening (e.g., a port which can be selectively opened or sealed and closed).
  • the fluidized bed pyrolysis reactor 3000 also includes a vapor outlet 3024.
  • the vapor outlet 3024 defines an internal opening (positioned within the reactor vessel’s internal volume 3018) and an external opening (positioned outside of the reactor vessel 3010).
  • the vapor outlet 3024 which can comprise, for example, a pipe, extends into the reactor vessel 3010 through the reactor vessel’s ellipsoidal head 3014 and enables vapor produced during pyrolysis of the plastic feedstock within the reactor vessel 3010 to exit the reactor vessel 3010.
  • the reactor s vapor outlet 3024 is configured to provide a conduit for hydrocarbon vapor exiting the reactor 3000 and thus extends upwardly from the reactor vessel 3010.
  • the vapor outlet 3024 can be connected (e.g., via additional piping or a ducting manifold) to a product recovery system.
  • the vapor outlet 3024 is configured to direct vapor exiting the reactor vessel 3010 following pyrolysis to a product collection system 3036 configured for product recovery (e.g., production of gas).
  • the product collection system 3036 can include, for example, a condenser, a reflux unit, and/or a catalyst bed.
  • the fluidized bed pyrolysis reactor 3000 further includes a plurality of reactor sensors 3030.
  • the reactor sensors 3030 can be configured for measuring dynamic properties of the liquid plastic within the reactor vessel 3010, as well as the dynamic properties of the reactor’s input (e.g., feedstock input) and output (e.g., vapor production).
  • the reactor sensors 3030 can comprise thermocouples, pressure sensors, flow meters, and the like. In this way, feedstock input (e.g., from the extruder 400) and product output can be monitored and/or adjusted based on the observed variations in the liquid plastic within the reactor 3000.
  • a plurality of fluidized bed pyrolysis reactor 3000 can also be provided for use in the production of pyrolysis products, such as gas.
  • pyrolysis products such as gas.
  • three fluidized bed pyrolysis reactor 3000 are used and can be operational in any combination with one another (e.g., such that all three pyrolysis reactors 3000 are processing feedstock simultaneously, or such that two of the pyrolysis reactors 3000 are processing feedstock while a third remains on standby in the event one of the other reactors requires service or maintenance).
  • the fluidized bed pyrolysis reactor 3000 can be alternatively configured as a packed bed reactor.
  • the distributor 3028 can be configured for supporting a solid catalytic material through which liquid plastic is forced upwardly (into the reactor vessel 3010).
  • Figure 23 shows a side view of a batch pyrolysis reactor 4000 according to one implementation.
  • the batch pyrolysis reactor 4000 is generally configured for pyrolyzing feedstock in batches (e.g., not continuously).
  • the batch pyrolysis reactor 4000 is configured for receiving and pyrolyzing semi-molten feedstock (e.g., received from an extruder).
  • the batch pyrolysis reactor 4000 is configured for receiving and pyrolyzing solid or semi-solid plastic feedstock (e.g., loose film, baled film, rigids, thermoforms, sheets, foams, non-wovens, strips, pellets, powder, purge patties, densified, shredded, and other postconsumer and/or post-industrial plastics).
  • the batch pyrolysis reactor 4000 can be used in the methods described herein for producing hydrocarbon-based compositions derived from pyrolysis of feedstock comprising post-consumer and/or post-industrial plastics, including gas.
  • Figure 24 provides a top view of the batch pyrolysis reactor 4000 shown in Figure 23. Certain elements depicted in Figure 23 are also depicted in Figure 24 and, accordingly, reference to either figure can be regarded as a reference to both figures.
  • the batch pyrolysis reactor 4000 includes a reactor vessel 4010 within which plastic feedstock is deposited and pyrolyzed.
  • the reactor vessel 4010 is comprised of a cylindrical body 4012, a removable head 4014 positioned at an upper end of the cylindrical body 4012 (herein the upper head 3014), and a base 4016 positioned at a lower end of the cylindrical body 4012. Together, the cylindrical body 4012, removable head 4014, and the base 4016 define an internal volume 4018 of the reactor vessel 4010 (shown in Figure 23).
  • the cylindrical body 4012, removable head 4014, and the base 4016 can be constructed from stainless steel (or other materials with suitable structural and thermal properties).
  • the batch pyrolysis reactor 4000 is configured for pyrolyzing plastic feedstock in batches (e.g., one by one) Accordingly, the reactor vessel’s removable head 4014 is secured to the upper portion of the reactor vessel 4010 by a seal interface 4026 and seal interface fasteners 4027.
  • the combination of the seal interface 4026 and fasteners 4027 e.g., high-strength fasteners ensures that, when the removable head 4014 is secured to the upper portion of the reactor vessel 4010, the vessel 4010 can maintain desired conditions during pyrolysis.
  • the batch pyrolysis reactor 4000 further comprises a discharge manifold 4022, a vapor outlet 4024, a seal interface 4026, seal interface fasteners 4027, a plurality of reactor sensors 4030, one or more external heating elements 4034, and a product collection system 4036.
  • the plastic feedstock is deposited into the reactor vessel’ s internal volume 4018 by way of the removable head 4020 for processing.
  • the batch pyrolysis reactor 4000 includes a plurality of external heating elements 4034 configured for heating the internal volume 4018 of the reactor vessel 4010.
  • the external heating elements 4034 comprise both electric heaters (positioned externally around the sides of the reactor vessel’s cylindrical body 4012 in Figure 23) and gas heaters (positioned beneath the reactor vessel’s base 4016 in Figure 23). When activated, the transfer of heat from the heating elements 4034 through the reactor vessel’s cylindrical body 4012 thereby heats the internal volume 4018 of the reactor vessel 4010.
  • the heating elements 4034 can comprise all electric, all gas, or a combination of gas and electric heating elements and can be positioned internally or externally to the reactor vessel 4010.
  • the heating elements 4034 are generally configured to provide the heat needed to raise temperatures inside the reactor vessel 4010 to a point where pyrolysis takes place.
  • the heating elements 4034 can also be configured to provide the heat needed to maintain temperatures inside the reactor barrel 4010 at a point where pyrolysis takes place.
  • the heating elements 4034 can be controlled to provide a prescribed temperature and heat density (W/in 2 ) that results in a controlled heat flux into the liquid feedstock bath within the reactor vessel 4010.
  • W/in 2 prescribed temperature and heat density
  • the pyrolysis reaction within the reactor vessel 4010 can be controlled to provide a desired reaction temperature and average energy density (kW/lb).
  • one or more heat inlets can be positioned around the reactor vessel 4010.
  • the heat inlets can be configured for receiving heated elements (e.g., heated ceramic balls) deposited into the reactor vessel’s internal volume 4018 for transferring heat directly to the liquid plastic feedstock within the reactor vessel 4010.
  • the heat inlets can be configured for receiving heated gas directed around or within the reactor vessel 4010 to heat the reactor vessel’s internal volume 4018.
  • the batch pyrolysis reactor 4000 further includes a discharge manifold 4022.
  • the discharge manifold 4022 is configured to provide an outlet for material within the reactor vessel 4010.
  • the discharge manifold 4022 can be used to transfer or otherwise remove liquid plastic (or other material generated during the pyrolysis process) from the reactor vessel 4010.
  • various implementations of the discharge manifold 4022 can include a sealable discharge opening (e.g., a port which can be selectively opened or sealed and closed).
  • the batch pyrolysis reactor 4000 also includes a vapor outlet 4024.
  • the vapor outlet 4024 defines an internal opening (positioned within the reactor vessel’s internal volume 4018) and an external opening (positioned outside of the reactor vessel 4010).
  • the vapor outlet 4024 which can comprise, for example, a pipe, extends into the reactor vessel 4010 through the reactor vessel’s removable head 4014 and enables vapor produced during pyrolysis of the plastic feedstock within the reactor vessel 4010 to exit the reactor vessel 4010.
  • the reactor As noted above, during the pyrolysis process, the hydrocarbon plastic chains and groups of rings within the liquid plastic are split apart by the heating process into smaller segments until they are small and light enough to vaporize and exit the reactor as a vapor. Accordingly, the reactor’s vapor outlet 4024 is configured to provide a conduit for hydrocarbon vapor exiting the reactor 4000 and thus extends upwardly from the reactor vessel 4010. In various implementations, the vapor outlet 4024 can be connected (e.g., via additional piping or a ducting manifold) to a product recovery system.
  • the vapor outlet 4024 is configured to direct vapor exiting the reactor vessel 4010 following pyrolysis to a product collection system 4036 configured for product recovery (e.g., production of gas).
  • the product collection system 4036 can include, for example, a condenser, a reflux unit, and/or a catalyst bed.
  • the batch pyrolysis reactor 4000 further includes a plurality of reactor sensors 4030.
  • the reactor sensors 4030 can be configured for measuring dynamic properties of the liquid plastic bath within the reactor vessel 4010, as well as the dynamic properties of the reactor’s input (e.g., feedstock input) and output (e.g., vapor production).
  • the reactor sensors 4030 can comprise thermocouples, pressure sensors, flow meters, and the like. In this way, feedstock input (e.g., from the extruder 400) and product output can be monitored and/or adjusted based on the observed variations in the liquid plastic bath within the reactor 4000.
  • a plurality of batch pyrolysis reactors 4000 can also be provided for use in the production of pyrolysis products, such as gas.
  • pyrolysis products such as gas.
  • three batch pyrolysis reactors 4000 are used and can be operational in any combination with one another (e.g., such that all three pyrolysis reactors 4000 are processing feedstock simultaneously, or such that two of the pyrolysis reactors 4000 are processing feedstock while a third remains on standby in the event one of the other reactors requires service or maintenance).
  • Figure 25 shows a continuously stirred pyrolysis reactor 5000 according to one implementation.
  • the continuously stirred pyrolysis reactor 5000 is generally configured for pyrolyzing feedstock (e.g., semi-molten feedstock received from an extruder). Accordingly, the continuously stirred pyrolysis reactor 5000 can be used in the methods described herein for producing hydrocarbon-based compositions derived from pyrolysis of feedstock comprising post-consumer and/or post-industrial plastics, including gas.
  • Figure 26 provides a top view of the continuously stirred pyrolysis reactor 5000 shown in Figure 25. Certain elements depicted in Figure 25 are also depicted in Figure 26 and, accordingly, reference to either figure can be regarded as a reference to both figures.
  • the continuously stirred pyrolysis reactor 5000 includes a reactor vessel 5010 within which solid, molten, or semi-molten feedstock is deposited and pyrolyzed.
  • the reactor vessel 5010 is comprised of a cylindrical body 5012, a first ellipsoidal head 5014 positioned at an upper end of the cylindrical body 5012 (herein the upper ellipsoidal head 5014), and a second ellipsoidal head 5016 positioned at a lower end of the cylindrical body 5012 (herein the lower ellipsoidal head 5016).
  • the cylindrical body 5012 and ellipsoidal heads 5014, 5016 define an internal volume 5018 of the reactor vessel 5010 (shown in Figure 25).
  • the cylindrical body 5012 and ellipsoidal heads 5014, 5016 can be constructed from stainless steel (or other materials with suitable structural and thermal properties). As shown in Figure 25, the reactor vessel 5010 can be mounted in a substantially upright position (e.g., such that its longitudinal axis is substantially vertical).
  • the reactor vessel’s cylindrical body 5012 includes an inlet port 5020, a discharge manifold 5022, a vapor outlet 5024, and a plurality of reactor sensors 5030.
  • Semi-molten feedstock e.g., received from an extruder
  • the inlet port 5020 defines an external opening and extends into the reactor vessel 5010.
  • the plastic feedstock e.g., semi-molten feedstock received from an extruder
  • the inlet port’s external inlet opening is positioned outside of the reactor vessel 5010 and defines an aperture through which plastic feedstock can enter the inlet port 5020.
  • the inlet port 5020 which can comprise, for example, a pipe, extends into the internal volume 5018 and includes an outlet opening positioned within the reactor vessel’s internal volume 5018.
  • plastic feedstock e.g., semi-molten feedstock
  • the plastic feedstock will be directed through the inlet port and deposited within the reactor vessel’ s internal volume 5018 for processing.
  • the plastic feedstock can be deposited into the reactor’s internal volume 5018 continuously (e.g., such that as the plastic feedstock pyrolyzes and vapor exits the reactor, additional plastic feedstock is deposited into the reactor 5000 to continue the process).
  • the continuously stirred pyrolysis reactor 5000 further includes a discharge manifold 5022.
  • the discharge manifold 5022 is configured to provide an outlet for material within the reactor vessel 5010.
  • the discharge manifold 5022 can be used to transfer or otherwise remove liquid plastic (or other material generated during the pyrolysis process) from the reactor vessel 5010.
  • various implementations of the discharge manifold 5022 can include a sealable discharge opening (e.g., a port which can be selectively opened or sealed and closed).
  • the continuously stirred pyrolysis reactor 5000 also includes a vapor outlet 5024.
  • the vapor outlet 5024 defines an internal opening (positioned within the reactor vessel’s internal volume 5018) and an external opening (positioned outside of the reactor vessel 5010).
  • the vapor outlet 5024 which can comprise, for example, a pipe, extends into the reactor vessel 5010 through the reactor vessel’s upper ellipsoidal head 5014 and enables vapor produced during pyrolysis of the plastic feedstock within the reactor vessel 5010 to exit the reactor vessel 5010.
  • the reactor As noted above, during the pyrolysis process, the hydrocarbon plastic chains and groups of rings within the liquid plastic are split apart by the heating process into smaller segments until they are small and light enough to vaporize and exit the reactor as a vapor. Accordingly, the reactor’s vapor outlet 5024 is configured to provide a conduit for hydrocarbon vapor exiting the reactor 5000 and thus extends upwardly from the reactor vessel 5010. In various implementations, the vapor outlet 5024 can be connected (e.g., via additional piping or a ducting manifold) to a product recovery system.
  • the vapor outlet 5024 is configured to direct vapor exiting the reactor vessel 5010 following pyrolysis to a product collection system 5036 configured for product recovery (e.g., production of gas).
  • the pyrolysis reactor 5000 can be configured for producing an average of 0.30 lb. or more (e.g., 0.40 lb. or more, 0.45 lb. or more, 0.50 lb. or more) of pyrolyzed product per hour per gallon of the reactor’ s internal volume for a period of 24 hours or more.
  • the product collection system 5036 can include, for example, a condenser, a reflux unit, and/or a catalyst bed.
  • the continuously stirred pyrolysis reactor 5000 includes a plurality of external gas heating elements 5034 configured for heating the internal volume 5018 of the reactor vessel 5010.
  • the external heating elements 5034 are gas heaters positioned both laterally on the sides of the reactor vessel’s cylindrical body 5012 and beneath the reactor’s lower ellipsoidal head 5016 (proximate to the lower portion of the reactor vessel 5010). When activated, the transfer of heat from the gas heating elements 5034 through the reactor vessel’s cylindrical body 5012 thereby heats the internal volume 5018 of the reactor vessel 5010.
  • the gas heating elements 5034 are generally configured to provide the heat needed to raise temperatures inside the reactor vessel 5010 to a point where pyrolysis takes place.
  • the heating elements 5034 can also be configured to provide the heat needed to maintain temperatures inside the reactor barrel 5010 at a point where pyrolysis takes place.
  • the heating elements 5034 can be controlled to provide a prescribed temperature and heat density (W/in 2 ) that results in a controlled heat flux into the liquid feedstock bath within the reactor vessel 5010.
  • W/in 2 prescribed temperature and heat density
  • the pyrolysis reaction within the reactor vessel 5010 can be controlled to provide a desired reaction temperature and average energy density (kW/lb).
  • the reactor vessel’s upper ellipsoidal head 5014 defines an agitator drive mount configured to enable a motor 5026 to be coupled to an agitator 5028 positioned within the pyrolysis reactor 5000.
  • the motor-driven agitator 5028 is positioned within the reactor vessel 5010 and is configured to agitate the liquid plastic bath within the vessel 5010 during pyrolysis.
  • the agitator drive mount includes a sealed agitator opening through which the agitator’s drive shaft can be accessed and coupled to the drive motor 5026.
  • the agitator opening is configured to provide a seal between the agitator’s drive shaft and the agitator drive mount in order to maintain desired operating conditions within the reactor vessel 5010.
  • the agitator opening can comprise a mechanical seal, bellows- style seal, split-ring stuff box, stuffing box-style seal, or the like.
  • the agitator 5028 is rotated by the electric motor 5026 and configured to produce liquid flow velocities inside the reactor vessel 5010 such that the heat necessary for pyrolysis is distributed throughout the liquid plastic bath. Furthermore, the agitator 5028 is configured to circulate the liquid plastic bath in a manner that avoids long residence times at heated surfaces.
  • the agitator 5028 includes a vertical drive shaft and a plurality of impellers 5029 spaced along the length of the drive shaft.
  • the agitator’s drive shaft is vertically oriented within the reactor vessel 5010 (e.g., such that the longitudinal axis of the drive shaft is parallel with the longitudinal axis of the reactor vessel’s cylindrical body 5012).
  • the drive shaft is centrally located within the reactor vessel 5010 (e.g., such that the longitudinal axis of the drive shaft 5042 is aligned with the longitudinal axis of the cylindrical body 5012).
  • the drive shaft includes an upper end, which is operatively coupled to the drive motor 5026 via the agitator drive mount (e.g., such that the drive shaft’s upper end extends through the sealed agitator opening).
  • the agitator 5028 includes a plurality of impellers 5029.
  • the impellers 5029 are attached to the drive shaft and spaced along the drive shaft’s length.
  • the impellers 5029 can be positioned along the length of the drive shaft in order to provide sufficient agitation throughout the liquid plastic bath within the reactor vessel 5010.
  • each impeller 5029 can comprise one or more impeller blades (e.g., four impeller blades).
  • the impeller blades can be configured to extend radially outwardly from the drive shaft.
  • the agitator 5028 are configured for continuously rotating (i.e., stirring) such that the liquid plastic inside the reactor vessel is kept in continuous motion.
  • the agitator 5028 is configured for producing liquid flow velocities inside the reactor vessel 5010 necessary for the liquid plastic bath to acquire sufficient heat for pyrolysis to occur and/or while also avoiding overheating at the heated surfaces.
  • the agitator 5028 continuously circulates the liquid plastic throughout the reactor vessel’s internal volume 5018 such that the entire liquid bath is agitated (e.g., substantially none of the liquid bath is static). In doing so, the motion of the agitator 5028 fosters rapid heat transfer from the heating elements 5034 to the liquid plastic.
  • the continuously stirred pyrolysis reactor 5000 further includes a plurality of reactor sensors 5030.
  • the reactor sensors 5030 can be configured for measuring dynamic properties of the liquid plastic bath within the reactor vessel 5010, as well as the dynamic properties of the reactor’s input (e.g., feedstock input) and output (e.g., vapor production).
  • the reactor sensors 5030 can comprise thermocouples, pressure sensors, flow meters, and the like.
  • the reactor sensors 5030 can comprise instrumentation probes having thermocouples arranged vertically along the length of a respective instrumentation probe to measure the liquid plastic bath level with the reactor vessel 5010. Additionally, one or more of the instrumentation probes can be configured for measuring reactor vapor pressure. In this way, feedstock input (e.g., from the extruder 400) and product output can be monitored and/or adjusted based on the observed variations in the liquid plastic bath within the reactor 5000.
  • a plurality of continuously stirred pyrolysis reactors 5000 can also be provided for use in the production of pyrolysis products, such as gas.
  • three continuously stirred pyrolysis reactors 5000 are used and can be operational in any combination with one another (e.g., such that all three pyrolysis reactors 5000 are processing feedstock simultaneously, or such that two of the pyrolysis reactors 5000 are processing feedstock while a third remains on standby in the event one of the other reactors requires service or maintenance).
  • the multiple pyrolysis reactors 5000 can be connected to a common manifold to direct vapor flow resulting from the pyrolysis process in each reactor.
  • Figure 27 shows another implementation of the continuously stirred pyrolysis reactor 5000 (like numbers refer to like elements throughout the figures).
  • Figure 28 provides a top view of the continuously stirred pyrolysis reactor 5000 shown in Figure 27. Certain elements depicted in Figure 27 are also depicted in Figure 28 and, accordingly, reference to either figure can be regarded as a reference to both figures.
  • the continuously stirred pyrolysis reactor 5000 includes a combination of gas-powered heating elements 5034 and electrically powered heating elements 5032.
  • the gas-powered heating elements 5034 are positioned laterally on the sides of the reactor vessel’s cylindrical body 5012.
  • the internal heating elements 5032 comprise electric heaters (e.g., electric heating elements positioned within drywells) positioned such that they extend inwardly into the reactor vessel’s internal volume 5018.
  • the internal heating elements 5032 extend laterally into the reactor vessel’s internal volume 5018 from the sides of the reactor vessel 5010.
  • Figure 29 shows another implementation of the continuously stirred pyrolysis reactor 5000 (like numbers refer to like elements throughout the figures).
  • Figure 30 provides a top view of the continuously stirred pyrolysis reactor 5000 shown in Figure 29. Certain elements depicted in Figure 29 are also depicted in Figure 30 and, accordingly, reference to either figure can be regarded as a reference to both figures.
  • the continuously stirred pyrolysis reactor 5000 includes an extruder inlet pipe 5020 having an inlet opening (positioned outside of the reactor vessel 5010) through which semi-molten feedstock can enter the extruder inlet pipe 5020.
  • the extruder inlet pipe 5020 extends into the reactor’s internal volume 5018 and includes an outlet opening positioned at a height below the inlet opening.
  • the extruder inlet pipe 5020 is mounted to the interior of the cylindrical body 5012 by an inlet pipe brace.
  • the reactor 5000 includes a plurality of internal electric heaters 5033 positioned within the reactor vessel 5010 and a plurality of external electric heaters 5035 positioned around the sidewalls of the reactor’s cylindrical body 5012.
  • the internal electric heaters 550 can comprise, for example, one or more heating elements positioned within dry wells.
  • the internal electric heaters 5033 are vertically oriented and extend from the reactor vessel’s upper ellipsoidal head 5014 and into the reactor’s internal volume 5019.
  • the internal electric heaters 5033 each define a longitudinal axis that is parallel to the longitudinal axis of the reactor vessel’s cylindrical body 5012.
  • each of the internal electric heaters 5033 extends into the reactor vessel’s internal volume 5018 to a depth sufficient to allow energy transfer throughout the liquid plastic bath.
  • the electric heaters 5033, 5035 are generally configured to provide the energy needed to raise temperatures inside the pyrolysis reactor 5000 to a point where pyrolysis takes place. In various implementations, the electric heaters 5033, 5035 are configured to provide the energy needed to maintain temperatures inside the pyrolysis reactor 5000 at a point where the pyrolysis process takes place.
  • the output of the electric heaters 5033, 5035 is controlled to provide a prescribed temperature and heat density (W/in 2 ) that results in a controlled heat flux into the liquid feedstock bath.
  • the pyrolysis reaction within the reactor vessel 5010 can be controlled to provide a desired reaction temperature and energy density (kW/lb).
  • the pyrolysis reaction within the reactor 5000 can be driven without producing conditions that promote char formation.
  • various implementations of the pyrolysis reactor 5000 are configured for driving the pyrolysis process using only electricity (e.g., without using gas as a direct heat source).
  • a plurality of internal electric heaters 5033 are provided within the reactor vessel 5010 and are arranged in a spaced-apart relationship within the reactor vessel 5010.
  • numerous internal electric heaters 5033 can be used (e.g., two, three, four, five, six, seven, eight, nine ten, eleven, twelve, thirteen, fourteen, or fifteen or more internal electrical heaters 5033).
  • the number of internal electric heaters within the reactor 5000 can be selected based on the size of the reactor and/or the size and power of the heaters.
  • the internal electric heaters 5033 are arranged in an array within the reactor 5000 (e.g., a circular or semi-circular array).
  • the internal electric heaters 5033 can be substantially evenly spaced around the internal volume 5018 of the reactor vessel 5010. By distributing the internal electric heaters 5033 throughout the internal volume 5018 in this way, the reactor 5000 can precisely control and evenly distribute heat input into the liquid feedstock bath.
  • the agitator 5028 further includes a distal impeller 5027.
  • the agitator’s distal impeller 5027 is positioned at a distal end of the agitator drive shaft 5042.
  • the distal impeller 5027 comprises an end plate and plurality of upwardly extending fins.
  • the reactor 5000 is configured to maintain the temperature of the liquid reactor bath within the reactor vessel 5010 to within 10% of less of a target temperature values (e.g., within 10% above or below the target temperature value, within 5% above or below the target temperature values, or within 2% above or below the target temperature value).
  • the reactor 5000 is configured for maintaining the temperature of the liquid plastic within the reactor vessel 5010 at a temperature within 15° C of a set point. Examples of control systems for maintaining the temperature of the liquid plastic within a suitable tolerance of a set point or target temperature are described in further detail herein.
  • the reactor 5000 can heat the liquid plastic to sufficient temperatures for pyrolysis without causing localized overheating of the liquid plastic.
  • the reactor 5000 can additionally maintain the liquid plastic at sufficient temperatures for pyrolysis without causing localized overheating or the liquid plastic. In this way, the reactor 5000 avoids charring during the pyrolysis process.
  • the reactor’s ability to provide more precise heat application and temperature maintenance — thereby avoiding (or reducing) charring — can improve the overall efficiency of the production process for the pyrolysis products, such as gas. This reduced charring can also lead to an increased uptime, since the reactor will not have to be shut down and cleaned out as frequently.
  • the reactor 5000 can be configured for operating to pyrolyze the plastic feedstock for a cumulative period of 324 hour or more during a time period of 360 hours or more (e.g., 324 hour or more during a time period of 360 hours, 342 hours or more during a time period of 360 hours, 576 hours or more during a time period of 720 hours, or 756 hours or more during a time period of 1080 hours).
  • the reactor 5000 can be configured for operating to pyrolyze the plastic feedstock with increased uptime over a time period (e.g., 90% uptime over 15 days, 95% uptime over 15 days, 80% uptime over 30 days, or 70% uptime over 45 days).
  • improved temperature precision higher average temperatures can be maintained in the liquid plastic (without causing charring or with minimal charring) and thereby increase overall throughput in the reactor 5000.
  • FIG 31 shows a side view of a molten material reactor 6000 according to one implementation.
  • the molten material reactor 6000 is generally configured for pyrolyzing feedstock (e.g., semi-molten feedstock received from an extruder). Accordingly, the molten material reactor 6000 can be used in the methods described herein for producing hydrocarbonbased compositions derived from pyrolysis of feedstock comprising post-consumer and/or postindustrial plastics, including gas.
  • the molten material reactor 6000 is configured for receiving and pyrolyzing solid or semi-solid plastic feedstock (e.g., loose film, baled film, rigids, thermoforms, sheets, foams, non-wovens, strips, pellets, powder, purge patties, densified, shredded, and other post-consumer and/or post-industrial plastics).
  • solid or semi-solid plastic feedstock e.g., loose film, baled film, rigids, thermoforms, sheets, foams, non-wovens, strips, pellets, powder, purge patties, densified, shredded, and other post-consumer and/or post-industrial plastics.
  • the molten material reactor 6000 can be used in the methods described herein for producing hydrocarbon-based compositions derived from pyrolysis of feedstock comprising post-consumer and/or post-industrial plastics, including gas.
  • the molten material reactor 6000 includes a reactor vessel 6010 within which plastic feedstock is deposited and pyrolyzed.
  • the reactor vessel 6010 can be a vessel of any suitable geometry or shape for containing a molten material 6015 and plastic feedstock.
  • the reactor vessel can, for example, comprise a cylindrical body 6012 extending between a first end 6006 and a second end 6008. Together, the cylindrical body 6012, first end 6006 and second end 6008 define an internal volume 6018.
  • the cylindrical body 6012, first end 6006, and second end 6008 can be constructed from stainless steel (or other materials with suitable structural and thermal properties).
  • the reactor vessel 6010 can be mounted in a substantially horizontal position (e.g., such that its longitudinal axis is substantially horizontal).
  • the molten material reactor 6000 further comprises a feedstock inlet 6020, a material inlet 6021, a discharge manifold 6022, a vapor outlet 6024, a plurality of reactor sensors 6030, one or more external heating elements 6034, and a product collection system 6036.
  • Semi-molten feedstock e.g., received from an extruder
  • the feedstock inlet 6020 defines an external opening and extends into the reactor vessel 6010.
  • the plastic feedstock e.g., semi-molten feedstock received from an extruder
  • the feedstock inlet’s external inlet opening is positioned outside of the reactor vessel 6010 and defines an aperture through which plastic feedstock can enter the feedstock inlet 6020.
  • the feedstock inlet 6020 which can comprise, for example, a pipe, extends into the internal volume 6018 and includes an outlet opening positioned within the reactor vessel’s internal volume 6018.
  • plastic feedstock e.g., semi-molten feedstock
  • the plastic feedstock will be directed through feedstock inlet and deposited within the reactor vessel’s internal volume 6018 for processing.
  • the material utilized for heat transfer in the molten material reactor 6000 is deposited into the reactor vessel’s internal volume 6018 by way of the material inlet 6021.
  • the material inlet 6021 is positioned substantially below the feedstock inlet 6020 at the first end 6006 of the reactor vessel 6010.
  • the material inlet 6021 includes an external inlet opening positioned outside of the reactor vessel 6010 and defines an aperture through which material can enter the material inlet 6021.
  • the material inlet 6021 which can comprise, for example, a pipe, extends into the internal volume 6018 and includes an outlet opening positioned within the reactor vessel’s internal volume 6018.
  • the material e.g., a metal or salt
  • the plastic feedstock will be directed through feedstock inlet and deposited within the reactor vessel’s internal volume 6018 for processing.
  • the molten material reactor 6000 can include at least one heating element 6034 configured for heating the internal volume 6018 of the reactor vessel 6010.
  • the heating elements 6034 can comprise both electric heaters (positioned externally around the sides of the reactor vessel’s cylindrical body 6012) and gas heaters (positioned beneath or around the reactor vessel’s cylindrical body 6012).
  • the heating element 6034 comprises an external gas heater positioned beneath the reactor vessel’s cylindrical body 6012. When activated, the transfer of heat from the heating elements 6034 through the reactor vessel’s cylindrical body 6012 thereby heats the internal volume 6018 of the reactor vessel 6010.
  • the heating elements 6034 can comprise all electric or all electric heating elements and can be positioned internally or externally to the reactor vessel 6010.
  • the heating elements 6034 are generally configured to provide the heat needed to raise temperatures inside the reactor vessel 6010 to a point where pyrolysis takes place.
  • the heating elements 6034 can also be configured to provide the heat needed to maintain temperatures inside the reactor barrel 6010 at a point where pyrolysis takes place.
  • a material such as a metal (e.g., zinc) or a salt, is heated by the heating element(s) 6034.
  • the molten material 6015 transfers heat directly to the liquid plastic feedstock within the reactor vessel 6010.
  • the heating elements 6034 can be controlled to provide a prescribed temperature and heat density (W/in 2 ) that results in a controlled heat flux into the mixture of liquid feedstock bath and molten material 6015 within the reactor vessel 6010.
  • the pyrolysis reaction within the reactor vessel 6010 can be controlled to provide a desired reaction temperature and energy density (kW/lb).
  • the molten material reactor 6000 can further include a discharge manifold 6022.
  • the discharge manifold 6022 is configured to provide an outlet for material within the reactor vessel 6010.
  • the discharge manifold 6022 can be used to transfer or otherwise remove liquid plastic (or other material generated during the pyrolysis process) or molten material 6015 from the reactor vessel 6010.
  • various implementations of the discharge manifold 6022 can include a sealable discharge opening (e.g., a port which can be selectively opened or sealed and closed).
  • the molten material reactor 6000 also includes a vapor outlet 6024.
  • the vapor outlet 6024 defines an internal opening (positioned within the reactor vessel’s internal volume 6018) and an external opening (positioned outside of the reactor vessel 6010).
  • the vapor outlet 6024 which can comprise, for example, a pipe, extends into the reactor vessel 6010 through the reactor vessel’s cylindrical body 6012 and enables vapor produced during pyrolysis of the plastic feedstock within the reactor vessel 6010 to exit the reactor vessel 6010.
  • the reactor’s vapor outlet 6024 is configured to provide a conduit for hydrocarbon vapor exiting the reactor 6000 and thus extends upwardly from the reactor vessel 6010.
  • the vapor outlet 6024 can be connected (e.g., via additional piping or a ducting manifold) to a product recovery system.
  • the vapor outlet 6024 is configured to direct vapor exiting the reactor vessel 6010 following pyrolysis to a product collection system 6036 configured for product recovery (e.g., production of gas).
  • the product collection system 6036 can include, for example, a condenser, a reflux unit, and/or a catalyst bed.
  • the molten material reactor 6000 further includes a plurality of reactor sensors 6030.
  • the reactor sensors 6030 can be positioned in various locations throughout the reactor vessel 6010.
  • the reactor sensors 6030 can be configured for measuring dynamic properties of the liquid plastic bath within the reactor vessel 6010, the molten material 6015, as well as the dynamic properties of the reactor’s input (e.g., feedstock input) and output (e.g., vapor production).
  • the reactor sensors 6030 can comprise thermocouples, pressure sensors, flow meters, and the like. In this way, feedstock input (e.g., from the extruder 400) and product output can be monitored and/or adjusted based on the observed variations in the liquid plastic bath within the reactor 6000.
  • a plurality of molten material reactors 6000 can also be provided for use in the production process of pyrolysis products, such as gas.
  • three molten material reactors 6000 are used and can be operational in any combination with one another (e.g., such that all three molten material reactors 6000 are processing feedstock simultaneously, or such that two of the molten material reactors 6000 are processing feedstock while a third remains on standby in the event one of the other reactors requires service or maintenance).
  • FIG 32 shows a supercritical water reactor system 7000 according to one implementation.
  • the water reactor system 7000 is generally configured for pyrolyzing feedstock (e.g., semi-molten feedstock received from an extruder). Accordingly, the supercritical water reactor system 7000 can be used in the methods described herein for producing hydrocarbonbased compositions derived from pyrolysis of feedstock comprising post-consumer and/or postindustrial plastics, including gas.
  • the supercritical water reactor system 7000 can generally include a water tank 7002, a feedstock tank 7004, and a reactor 7006.
  • the water tank 7002 can, in some implementations, be configured to heat and/or pressurize water to a supercritical state, for use in pyrolyzing feedstock.
  • the reactor 7006 can be configured to heat and/or pressurize water to a supercritical state, for use in pyrolyzing feedstock.
  • the feedstock tank 7004 can be configured to contain pyrolyzing feedstock (e.g., semi-molten feedstock received from an extruder.)
  • the supercritical water reactor system 7000 can also include pumps 7005 for supplying the supercritical water and the pyrolyzing feedstock into the reactor 7006 in a continuous or semi-continuous configuration.
  • the supercritical water reactor system 7000 can be configured to receive water and/or pyrolyzing feedstock in a continuous or semi -continuous manner, eliminating or otherwise reducing the need for input (e.g., water and pyrolyzing feedstock) tanks.
  • the reactor 7006 can comprise a reactor vessel 7010 within which solid, molten, or semi-molten feedstock is deposited and pyrolyzed.
  • the reactor 7006 can comprise, for example, a continuously stirred reactor or a batch reactor.
  • the solid, molten, or semi-molten feedstock and water can be deposited periodically, semi-continuously, or continuously within reactor vessel 7010.
  • the mixture of supercritical water with the pyrolyzing feedstock promotes or otherwise facilitates the pyrolysis of the pyrolyzing feedstock.
  • the reactor vessel 7010 can comprise a cylindrical body 7012, a first ellipsoidal head 7014 positioned at an upper end of the cylindrical body 7012 (herein the upper ellipsoidal head 7014), and a second ellipsoidal head 7016 positioned at a lower end of the cylindrical body 7012 (herein the lower ellipsoidal head 7016). Together, the cylindrical body 7012 and ellipsoidal heads 7014, 7016 define an internal volume 7018 of the reactor vessel 7010 (shown in Figure 32).
  • the cylindrical body 7012 and ellipsoidal heads 7014, 7016 can be constructed from stainless steel (or other materials with suitable structural and thermal properties). As shown in Figure 32, the reactor vessel 7010 can be mounted in a substantially upright position (e.g., such that its longitudinal axis is substantially vertical).
  • the reactor vessel’s cylindrical body 7012 includes a feedstock inlet port 7020, a water inlet 7021, a discharge manifold 7022, a vapor outlet 7024, and a plurality of reactor sensors 7030.
  • Plastic feedstock e.g., semi-molten feedstock, for example received from an extruder
  • Supercritical water is deposited into the reactor vessel’s internal volume 7018 by way of the water inlet port 7021.
  • the feedstock inlet port 7020 defines an external opening and extends into the reactor vessel 7010.
  • the plastic feedstock (e.g., semi-molten feedstock received from an extruder) is deposited into the reactor vessel’s internal volume 7018 by way of the inlet port 7020.
  • the inlet port’s external inlet opening is positioned outside of the reactor vessel 7010 and defines an aperture through which plastic feedstock can enter the inlet port 7020.
  • the inlet port 7020 which can comprise, for example, a pipe, extends into the internal volume 7018 and includes an outlet opening positioned within the reactor vessel’s internal volume 7018.
  • plastic feedstock e.g., semi-molten feedstock
  • the plastic feedstock will be directed through the inlet port and deposited within the reactor vessel’s internal volume 7018 for processing.
  • the plastic feedstock can be deposited into the reactor’s internal volume 7018 continuously (e.g., such that as the plastic feedstock pyrolyzes and vapor exits the reactor, additional plastic feedstock and/or supercritical water is deposited into the reactor 7006 to continue the process).
  • the reactor 7006 further includes a discharge manifold 7022.
  • the discharge manifold 7022 is configured to provide an outlet for material within the reactor vessel 7010.
  • the discharge manifold 7022 can be used to transfer or otherwise remove liquid plastic (or other material generated during the pyrolysis process) from the reactor vessel 7010.
  • various implementations of the discharge manifold 7022 can include a sealable discharge opening (e.g., a port which can be selectively opened or sealed and closed).
  • the reactor 7006 also includes a vapor outlet 7024.
  • the vapor outlet 7024 defines an internal opening (positioned within the reactor vessel’s internal volume 7018) and an external opening (positioned outside of the reactor vessel 7010).
  • the vapor outlet 7024 which can comprise, for example, a pipe, extends into the reactor vessel 7010 through the reactor vessel’s upper ellipsoidal head 7014 and enables vapor produced during pyrolysis of the plastic feedstock within the reactor vessel 7010 to exit the reactor vessel 7010.
  • the reactor 7006 can include external heating elements 7035 and internal heating elements 7033.
  • the heating elements 7035, 7033 can be configured to maintain the water at its supercritical state.
  • the heating elements 7035, 7033 can be configured to bring the water to a supercritical state.
  • the heating elements 7035, 7033 can be configured to maintain or achieve a temperature for the mixture of the supercritical water and pyrolyzing feedstock to promote pyrolysis within the reactor 7006.
  • the reactor’s vapor outlet 7024 is configured to provide a conduit for hydrocarbon vapor exiting the reactor 7006 and thus extends from the ellipsoidal heads 7014 of the reactor vessel 7010.
  • the vapor outlet 7024 can be connected (e.g., via additional piping or a ducting manifold) to a product recovery system.
  • the vapor outlet 7024 is configured to direct vapor exiting the reactor vessel 7010 following pyrolysis to a product collection system 7036 configured for product recovery (e.g., production of gas as described herein).
  • the product collection system 7036 can include, for example, a condenser, a reflux unit, and/or a catalyst bed.
  • the supercritical water reactor system can additionally include a heat exchanger 7040 after the vapor outlet 7024 and before the product collection system 7036.
  • the heat exchanger 7040 can be utilized to selectively reduce or increase the temperature of the pyrolysis output prior to the product collection system 7036.
  • the reactor 7006 includes a plurality of external heating elements 7034 configured for heating the internal volume 7018 of the reactor vessel 7010.
  • the external heating elements 7034 are electric heaters positioned both laterally on the sides of the reactor vessel’s cylindrical body 7012. When activated, the transfer of heat from the gas heating elements 7034 through the reactor vessel’s cylindrical body 7012 thereby heats the internal volume 7018 of the reactor vessel 7010.
  • the heating elements 7034 are generally configured to provide the heat needed to raise temperatures inside the reactor vessel 7010 to a point where pyrolysis takes place.
  • the heating elements 7034 can also be configured to provide the heat needed to maintain temperatures inside the reactor vessel 7010 at a point where pyrolysis takes place.
  • the heating elements 7034 can be controlled to provide a prescribed temperature and heat density (W/in 2 ) that results in a controlled heat flux into the liquid feedstock bath within the reactor vessel 7010.
  • W/in 2 temperature and heat density
  • the pyrolysis reaction within the reactor vessel 7010 can be controlled to provide a desired reaction temperature and energy density (kW/lb).
  • the reactor 7006 further includes a plurality of reactor sensors 7030.
  • the reactor sensors 7030 can be configured for measuring dynamic properties of the liquid plastic bath within the reactor vessel 7010, as well as the dynamic properties of the reactor’s input (e.g., feedstock input) and output (e.g., vapor production).
  • the reactor sensors 7030 can comprise thermocouples, pressure sensors, flow meters, and the like.
  • the reactor sensors 7030 can comprise instrumentation probes having thermocouples arranged vertically along the length of a respective instrumentation probe to measure the liquid plastic bath level with the reactor vessel 7010. Additionally, one or more of the instrumentation probes can be configured for measuring reactor vapor pressure. In this way, feedstock input (e.g., from the extruder 400) and product output can be monitored and/or adjusted based on the observed variations in the liquid plastic bath within the reactor 7006.
  • a plurality of pyrolysis reactors 7006 can also be provided for use in the production of a pyrolysis product, such as gas.
  • a pyrolysis product such as gas.
  • three reactors 7006 are used and can be operational in any combination with one another (e.g., such that all three reactors 7006 are processing feedstock simultaneously, or such that two of the reactors 7006 are processing feedstock while a third remains on standby in the event one of the other reactors requires service or maintenance).
  • the multiple pyrolysis reactors 7006 can be connected to a common manifold to direct vapor flow resulting from the pyrolysis process in each reactor.
  • Figure 33 shows a side view of a conical spouted bed pyrolysis reactor 8000 according to one implementation.
  • the conical spouted bed pyrolysis reactor 8000 is generally configured for pyrolyzing feedstock.
  • conical spouted bed pyrolysis reactor 8000 is configured for receiving and pyrolyzing semi-molten feedstock (e.g., received from an extruder).
  • conical spouted bed pyrolysis reactor 8000 is configured for receiving and pyrolyzing solid or semi-solid plastic feedstock (e.g., loose film, baled film, rigids, thermoforms, sheets, foams, non-wovens, strips, pellets, powder, purge patties, densified, shredded, and other post-consumer and/or post-industrial plastics). Accordingly, the conical spouted bed pyrolysis reactor 8000 can be used in the methods described herein for producing hydrocarbon -based compositions derived from pyrolysis of feedstock comprising post-consumer and/or post-industrial plastics, including gas.
  • solid or semi-solid plastic feedstock e.g., loose film, baled film, rigids, thermoforms, sheets, foams, non-wovens, strips, pellets, powder, purge patties, densified, shredded, and other post-consumer and/or post-industrial plastics.
  • the conical spouted bed pyrolysis reactor 8000 includes a reactor vessel 8010 within which plastic feedstock is deposited and pyrolyzed.
  • the reactor vessel 8010 is comprised of a cylindrical body 8012.
  • the cylindrical body 8012 defines an internal volume 8018 of the reactor vessel 8010 (shown in Figure 33).
  • the internal volume 8018 can include a cylindrical section 8017 and a frustoconical section 8016.
  • the reactor vessel 8010 can be constructed from stainless steel (or other materials with suitable structural and thermal properties).
  • the conical spouted bed pyrolysis reactor 8000 can further comprises an inlet 8020, a feedstock inlet 8021, a discharge manifold 8022, a vapor outlet 8024, a distributor 8028, a plurality of reactor sensors 8030, one or more external heating elements 8034, one or more internal heating elements 8033, and a product collection system 8036.
  • the feedstock inlet 8021 defines an external opening and extends into the reactor vessel 8010.
  • the plastic feedstock e.g., semi-molten feedstock received from an extruder
  • the feedstock inlet’s external inlet opening is positioned outside of the reactor vessel 8010 and defines an aperture through which plastic feedstock can enter the feedstock inlet 8021.
  • the feedstock inlet 8021 which can comprise, for example, a pipe, extends into the internal volume 8018 and includes an outlet opening positioned within the reactor vessel’s internal volume 8018.
  • plastic feedstock e.g., semi-molten feedstock
  • the plastic feedstock will be directed through the feedstock inlet and deposited within the reactor vessel’s internal volume 8018 for processing.
  • the feedstock inlet 8021 is configured to deposit solid, molten, or semi-molten feedstock into the reactor vessel 8010.
  • the feedstock inlet’s outlet opening is positioned in an upper portion of the reactor vessel’s internal volume 8018 and above a distributor 8028.
  • the distributor 8028 comprises a porous plate defining a plurality of apertures through which a fluid, gas, catalyst, and/or oxidant can flow through. The pressure at which the fluid, gas, catalyst, and/or oxidant enters the reactor vessel 8010 via the inlet 8020 forces the fluid, gas, catalyst, and/or oxidant through the apertures defined in the distributor 8028, and further into the reactor vessel’s internal volume 8018.
  • the distributor 8028 divides the fluid, gas, catalyst, and/or oxidant into a plurality of streams, thereby exposing a greater surface area of the liquid plastic within the reactor vessel 8010.
  • the flow of the fluid, gas, catalyst, and/or oxidant upwards can agitate pyrolysis feedstock that has entered the frustoconical section 8016 and/or cylindrical section 8017 of the internal volume 8018 via the feedstock inlet 8021.
  • the flow of fluid, gas, catalyst, and/or oxidant can suspend at least a portion of the pyrolysis feedstock within the internal volume 8018.
  • the distributor’s apertures can be dimensioned such that the feedstock provided within the reactor vessel 8010 substantially remains above the distributor 8028.
  • the inlet 8020 is positioned at a lower portion of the reactor vessel 8010 and substantially below the distributor 8028. As shown in Figure 33, the inlet 8020 defines an external opening and extends into the reactor vessel 8010 through the distributor 8028.
  • a gas, fluid, catalyst, and/or oxidant can be deposited into the reactor vessel’s internal volume 8018 by way of the inlet 8020.
  • a gas, fluid, catalyst, and/or oxidant can be heated prior to its introduction into the reactor vessel’s internal volume 8018 by way of the inlet 8020. As described, the gas, fluid, catalyst, and/or oxidant can be supplied to the reactor vessel’s internal volume 8018 at pressure.
  • the inlet’s opening is positioned outside of the reactor vessel 8010 and defines an aperture through which a material can enter the inlet 8020.
  • the feedstock inlet 8021 which can comprise, for example, a pipe, extends into the internal volume 8018 and includes an outlet opening positioned within the reactor vessel’s internal volume 8018.
  • a gas, fluid, catalyst, and/or oxidant is directed through the inlet 8020 via its inlet opening, the fluid, gas, catalyst, and/or oxidant will be directed through the inlet and deposited within the reactor vessel’s internal volume 8018.
  • conical spouted bed pyrolysis reactor 8000 is configured such that the fluid, gas, catalyst, and/or oxidant can directed into the reactor vessel 8010 (via the inlet 8020 and below the distributor 8028) with a velocity that is sufficient to reach incipient fluidization.
  • the velocity of the fluid, gas, catalyst, and/or oxidant can be sufficient to balance the weight of at least some the plastic feedstock being deposited into the reactor vessel 8010 via the catalyst inlet 8021 (e.g., such that the bath of liquid plastic and gas, fluid, catalyst, and/or oxidant mix and swirl within the reactor vessel 8010).
  • the reactor vessel’s internal volume 8018 comprises a spouted bed, which includes the gas, fluid, or oxidant and liquid plastic feedstock.
  • the gas, fluid, catalyst, and/or oxidant can be selected to accelerate the rate of pyrolysis within the reactor vessel 8010 and/or lower the temperature at which pyrolysis occurs within the reactor vessel 8010.
  • the conical spouted bed pyrolysis reactor 8000 can include a plurality of external heating elements 8034 and internal heating elements 8034 configured for heating the internal volume 8018 of the reactor vessel 8010.
  • the external heating elements 8034 and/or internal heating elements 8033 can comprise electric heaters positioned externally around the reactor vessel 8010. When activated, the transfer of heat from the electric heaters 8034 through or within the reactor vessel’s cylindrical body 8012 thereby heats the internal volume 8018 of the reactor vessel 8010.
  • the heating elements 8034, 8033 are generally configured to provide the heat needed to raise temperatures inside the reactor vessel 8010 to a point where pyrolysis takes place.
  • the heating elements 8034, 8033 can also be configured to provide the heat needed to maintain temperatures inside the reactor vessel 8010 at a point where pyrolysis takes place.
  • the heating elements 8034, 8033 can be controlled to provide a prescribed temperature and heat density (W/in 2 ) that results in a controlled heat flux into the liquid feedstock within the reactor vessel 8010.
  • W/in 2 prescribed temperature and heat density
  • the pyrolysis reaction within the reactor vessel 8010 can be controlled to provide a desired reaction temperature and energy density (kW/lb.).
  • the conical spouted bed pyrolysis reactor 8000 can be configured for driving the pyrolysis process using only electricity (e.g., without using gas as a direct heat source).
  • the external heating elements 8034 can comprise gas powered heaters positioned around the reactor vessel 8010.
  • one or more heat inlets can be positioned around the reactor vessel 8010.
  • the heat inlets can be configured for receiving heated elements (e.g., heated ceramic balls) deposited into the reactor vessel’s internal volume 8018 for transferring heat directly to the liquid plastic feedstock within the reactor vessel 8010.
  • the heat inlets can be configured for receiving heated gas directed around or within the reactor vessel 8010 to heat the reactor vessel’s internal volume 8018.
  • the conical spouted bed pyrolysis reactor 8000 further includes a discharge manifold 8022.
  • the discharge manifold 8022 is configured to provide an outlet for material within the reactor vessel 8010.
  • the discharge manifold 8022 can be used to transfer or otherwise remove molten or liquid plastic (or other material generated during the pyrolysis process) from the reactor vessel 8010.
  • various implementations of the discharge manifold 8022 can include a sealable discharge opening (e.g., a port which can be selectively opened or sealed and closed).
  • the conical spouted bed pyrolysis reactor 8000 also includes a vapor outlet 8024.
  • the vapor outlet 8024 defines an internal opening (positioned within the reactor vessel’s internal volume 8018) and an external opening (positioned outside of the reactor vessel 8010).
  • the vapor outlet 8024 which can comprise, for example, a pipe, extends into the reactor vessel 8010 near the top of the s internal volume 8018 and enables vapor produced during pyrolysis of the plastic feedstock within the reactor vessel 8010 to exit the reactor vessel 8010.
  • the reactor’s vapor outlet 8024 is configured to provide a conduit for hydrocarbon vapor exiting the reactor 8000 and thus extends from the upper portion of the reactor vessel 8010.
  • the vapor outlet 8024 can be connected (e.g., via additional piping or a ducting manifold) to a product recovery system.
  • the vapor outlet 8024 is configured to direct vapor exiting the reactor vessel 8010 following pyrolysis to a product collection system 8036 configured for product recovery (e.g., production of gas as described herein).
  • the product collection system 8036 can include, for example, a condenser, a reflux unit, and/or a catalyst bed.
  • the conical spouted bed pyrolysis reactor 8000 further includes a plurality of reactor sensors 8030.
  • the reactor sensors 8030 can be configured for measuring dynamic properties of the liquid plastic within the reactor vessel 8010, as well as the dynamic properties of the reactor’s input (e.g., feedstock input) and output (e.g., vapor production).
  • the reactor sensors 8030 can comprise thermocouples, pressure sensors, flow meters, and the like. In this way, feedstock input (e.g., from the extruder 400) and product output can be monitored and/or adjusted based on the observed variations in the liquid plastic within the reactor 8000.
  • a plurality of conical spouted bed pyrolysis reactor 8000 can also be provided for use in the production of pyrolysis products, such as gas.
  • pyrolysis products such as gas.
  • three conical spouted bed pyrolysis reactor 8000 are used and can be operational in any combination with one another (e.g., such that all three pyrolysis reactors 8000 are processing feedstock simultaneously, or such that two of the pyrolysis reactors 8000 are processing feedstock while a third remains on standby in the event one of the other reactors requires service or maintenance).
  • the various systems and methods described herein can further comprise a second pyrolysis step after the product collection systems, such as, for example, by introducing the collected product into a second pyrolysis reactor, which can be the same as the first pyrolysis reactor (e.g., the recovered product is recycled) or different a different pyrolysis reactor downstream from the first pyrolysis reactor.
  • a second pyrolysis reactor which can be the same as the first pyrolysis reactor (e.g., the recovered product is recycled) or different a different pyrolysis reactor downstream from the first pyrolysis reactor.
  • various reactor implementations according to the disclosure herein can additionally comprise a recycle loop (1070, 2070, 3070, 4070, 5070, 6070, 7070, 8070, respectively) after the product collection systems.
  • the recycle loop can direct at least a portion of the pyrolysis output into a reactor for further depolymerization (e.g., pyrolysis).
  • Various examples of reactors with a recycle loop are shown in Figure 34- Figure 44.
  • the recycle loop can, for example, direct at least a portion of the pyrolysis output (1080, 2080, 3080, 4080, 5080, 6080, 7080, 8080, respectively) after the product collection system back to the feedstock inlet for further pyrolysis.
  • the pyrolysis reactors 1000-8000 described herein can be implemented with pyrolysis control system configured for controlling the temperature of the liquid bath within the reactor vessel.
  • the pyrolysis reactors 1000-8000 can include one or more temperature sensors (e.g., configured for sensing the temperature of the plastic feedstock in the reactor vessel) and the control system can be configured to control one or more parameters of the pyrolysis reactor (e.g., output of the one or more heaters and/or agitator speed) to maintain the temperature of the reactor vessel’s liquid bath at a defined set point (e.g., within a defined range of desired temperature setting).
  • FIG 45 shows a schematic diagram of a pyrolysis control system 7500a according to an example implementation.
  • the control system 7500a includes a processing circuit 7502 having a processor 7504 and a memory device 7506, a controller module 7508a having a heater control module 7510a, an agitator control module 7510b, and a transfer line control module 7510c, and a communications interface 7512 which receives data from and/or sends instructions to one or more external systems.
  • the control system 7500a is configured to communicate (via the communications interface 7512) with external systems including reactor temperature sensors 7514a, reactor heaters 7514b, a reactor agitator 7514c, and additional system components 7514d (e.g., sensors and/or controllers for monitoring and/or controlling flow rates, pressure, gas level, and/or chemical composition).
  • the temperature sensors 7514a can be one or more sensors configured for sensing the temperature of the liquid bath within the reactor vessel.
  • the temperature sensors 7514a can comprise (e.g., a series of) thermocouples arranged along the internal wall of the reactor vessel or via a non-contact configuration, such as radar or ultrasonic sensors.
  • thermocouples e.g., 2 thermocouples, 3 thermocouples, 4 thermocouples, 5 thermocouples, 6 thermocouples, 7 thermocouples, 8 thermocouples, 9 thermocouples, 10 thermocouples, 11 thermocouples, 12 thermocouples, 13 thermocouples, 14 thermocouples, 15 thermocouples, 16 thermocouples, 17 thermocouples, 18 thermocouples, 19 thermocouples, 20 thermocouples
  • the thermocouples can simultaneously monitor the temperature of the liquid bath at multiple points within the reactor vessel and the liquid level inside the reactor (as described in further detail above).
  • the heaters 7514b and agitator 7514c can correspond to any of the one or more heaters and agitators, respectively, described in relation to the pyrolysis reactors 1000- 8000 disclosed herein.
  • the control system 7500a is configured to control the temperature of the liquid bath within the reactor vessel.
  • the modules 7510a, 7510b, 7510c of the controller module 7508a can be in the form of non-transitory machine or computer-readable media that is executable by a processor, such as the processor 7504.
  • the machine-readable media facilitates performance of operations to enable reception and transmission of data.
  • the machine-readable media can provide an instruction (e.g., command, etc.) to acquire data.
  • the computer readable program code can be executed on one processor, multiple colocated processors, multiple remote processors, or any combination of local and remote processors. Remote processors can be connected to each other through any type of network (e.g., CAN bus, etc.).
  • the modules 7510a, 7510b, 7510c of the controller module 7508a can be implemented as hardware apparatuses, such as electronic control apparatuses.
  • the modules 7510a, 7510b, 7510c of the controller module 7508a can be implemented as one or more circuitry components including, but not limited to, processing circuitry, network interfaces, peripheral devices, input devices, output devices, sensors, etc.
  • the modules 7510a, 7510b, 7510c of the controller module 7508a can take the form of one or more analog circuits, electronic circuits (e.g., integrated circuits (IC), discrete circuits, system on a chip (SOCs) circuits, microcontrollers, etc.), telecommunication circuits, hybrid circuits, and any other type of “circuit.”
  • a circuit as described herein can include one or more transistors, logic gates (e.g., NAND, AND, NOR, OR, XOR, NOT, XNOR, etc.), resistors, multiplexers, registers, capacitors, inductors, diodes, wiring, and so on).
  • the modules 7510a, 7510b, 7510c of the controller module 7508a can also include programmable hardware devices such as field programmable gate arrays, programmable array logic, programmable logic devices or the like.
  • the modules 7510a, 7510b, 7510c of the controller module 7508a can include one or more memory devices for storing instructions that are executable by the processor(s) of the modules 7510a, 7510b, 7510c of the controller module 7508a.
  • the modules 7510a, 7510b, 7510c of the controller module 7508a can be geographically dispersed throughout separate locations.
  • the modules 7510a, 7510b, 7510c of the controller module 7508a can be implemented in or within a single apparatus/housing, which is shown as the control system 7500a.
  • control system 7500a includes the processing circuit 7502 having the processor 7504 and the memory device 7506.
  • the processing circuit 7502 can be structured or configured to execute or implement the instructions, commands, and/or control processes described herein with respect to the modules 7510a, 7510b, 7510c of the controller module 7508a.
  • the depicted configuration represents the modules 7510a, 7510b, 7510c of the controller module 7508a as machine or computer-readable media.
  • modules 7510a, 7510b, 7510c of the controller module 7508a or at least one circuit of the modules 7510a, 7510b, 7510c of the controller module 7508a, is configured as a hardware apparatus. All such combinations and variations are intended to fall within the scope of the present disclosure.
  • the hardware and data processing components used to implement the various processes, operations, illustrative logics, logical blocks, modules and circuits described in connection with the implementations disclosed herein can be implemented or performed with a general purpose single- or multi-chip processor, a digital signal processor (DSP), an application specific integrated circuit (ASIC), a field programmable gate array (FPGA), or other programmable logic device, discrete gate or transistor logic, discrete hardware components, or any combination thereof designed to perform the functions described herein.
  • a general purpose processor can be a microprocessor, or, any conventional processor, or state machine.
  • a processor also can be implemented as a combination of computing devices, such as a combination of a DSP and a microprocessor, a plurality of microprocessors, one or more microprocessors in conjunction with a DSP core, or any other such configuration.
  • the memory device 7506 (e.g., memory, memory apparatus, storage device) can include one or more devices (e.g., RAM, ROM, Flash memory, hard disk storage) for storing data and/or computer code for completing or facilitating the various processes, layers and modules described in the present disclosure.
  • the memory device 7506 can be communicab ly connected to the processor 7504 to provide computer code or instructions to the processor 7504 for executing at least some of the processes described herein.
  • the memory device 7506 can be or include tangible, non-transient volatile memory or non-volatile memory. Accordingly, the memory device 7506 can include database components, object code components, script components, or any other type of information structure for supporting the various activities and information structures described herein.
  • the heater control module 7510a is configured to adjust the energy output of the one or more heaters 7514b that heat the liquid bath within the reactor vessel.
  • the heater control module 7510a can be set up as a feedback loop.
  • the heater control module 7510a is configured to at least temporarily store a target temperature value for the plastic feedstock in the reactor vessel (e.g., a user-defined target temperature value received and stored by the control system 7500a or a target temperature value retrieved from a remote source, such as a remote device or a cloud computing entity).
  • the heater control module 7510a communicates with the temperature sensors 7514a to monitor the temperature of the plastic feedstock in the reactor vessel.
  • the heater control module 7510a adjusts the energy output of the one or more heaters 7514b to maintain the temperature of the plastic feedstock within a defined tolerance relative to the target temperature value.
  • the heater control module 7510a can be set up as a feedforward loop.
  • the heater control module 7510a can be configured to store a target temperature value for the plastic feedstock in the reactor vessel, monitor the temperature of the plastic feedstock before/as it enters the reactor vessel as measured by the one or more temperature sensors, and, in response to the temperature measured by the one or more temperature sensors, control the one or more heaters to maintain the temperature of the plastic feedstock within a defined tolerance relative to the target temperature value.
  • the heater control module 7510a can implement both a feedback loop and a feedforward loop, for example, the feedback and feedforward loops described above.
  • the agitator control module 7510b is configured to adjust the rotational speed of the agitator 7514c.
  • the agitator control module 7510b can be set up as a feedback loop.
  • the agitator control module 7510b can be configured to store a target temperature value for the plastic feedstock in the reactor vessel, monitor the temperature of the plastic feedstock in the reactor vessel as measured by the one or more temperature sensors, and, in response to the temperature measured by the one or more temperature sensors, control the rotational speed of the agitator.
  • the agitator control module 7510b can be set up as a feedforward loop.
  • the agitator control module 7510b can be configured to store a target temperature value for the plastic feedstock in the reactor vessel, monitor the temperature of the plastic feedstock before/as it enters the reactor vessel as measured by the one or more temperature sensors, and, in response to the temperature measured by the one or more temperature sensors, control the rotational speed of the agitator.
  • the agitator control module 7510b can implement both a feedback loop and a feedforward loop, for example, the feedback and feedforward loops described above.
  • the transfer line control module 7510c is configured to adjust the energy output of the one or more heaters 7514b that heat viscous material (e.g., plastic feedstock, liquid bath) that is transferred into and/or out of the reactor vessel via one or more transfer lines, thereby controlling the flow of the viscous material (e.g., decreasing temperature of the viscous material increases its viscosity and, subsequently, decreases its flowability).
  • the transfer line control module 7510c can be set up as a feedback loop.
  • the transfer line control module 7510c is configured to at least temporarily store a target temperature value for the viscous material in the one or more transfer lines (e.g., a user-defined target temperature value received and stored by the control system 7500a or a target temperature value retrieved from a remote source, such as a remote device or a cloud computing entity).
  • the transfer line control module 7510c communicates with the temperature sensors 7514a to monitor the temperature of the viscous material in the one or more transfer lines.
  • the transfer line control module 7510c adjusts the energy output of the one or more heaters 7514b to maintain the temperature of the viscous material within a defined tolerance relative to the target temperature value.
  • the transfer line control module 7510c can be set up as a feedforward loop.
  • the transfer line control module 7510c can be configured to store a target temperature value for the viscous material in the one or more transfer lines, monitor the temperature of the viscous material before/as it enters the one or more transfer lines as measured by the one or more temperature sensors, and, in response to the temperature measured by the one or more temperature sensors, control the one or more heaters to maintain the temperature of the viscous material within a defined tolerance relative to the target temperature value.
  • the transfer line control module 7510c can implement both a feedback loop and a feedforward loop, for example, the feedback and feedforward loops described above.
  • control system 7500a can include any number of modules for completing the functions described herein.
  • the activities and functionalities of the modules of the controller module 7508a can be combined in multiple modules or as a single circuit. Additional modules with additional functionality can also be included. Further, the control system 7500a can further control other activity beyond the scope of the present disclosure.
  • the “modules” can be implemented in machine-readable medium for execution by various types of processors, such as the processor 7504 of Figure 45.
  • An identified circuit of executable code can, for instance, comprise one or more physical or logical blocks of computer instructions, which can, for instance, be organized as an object, procedure, or function. Nevertheless, the executables of an identified circuit need not be physically located together, but can comprise disparate instructions stored in different locations which, when joined logically together, comprise the circuit and achieve the stated purpose for the circuit.
  • a circuit of computer readable program code can be a single instruction, or many instructions, and can even be distributed over several different code segments, among different programs, and across several memory devices.
  • operational data can be identified and illustrated herein within modules, and can be implemented in any suitable form and organized within any suitable type of data structure.
  • the operational data can be collected as a single data set, or can be distributed over different locations including over different storage devices, and can exist, at least partially, merely as electronic signals on a system or network.
  • the pyrolysis control system 7500a through execution of the heater control module or the agitator control module (alone or in combination) — can maintain the temperature within the liquid reactor bath within a tolerance of a target temperature value.
  • the pyrolysis control system allows for improved reactor throughput, reduced reactor energy consumption, and/or improved reactor uptime.
  • the pyrolysis control system 7500a can be configured to maintain the temperature of the liquid reactor bath to within 10% or less of a target temperature value (e.g., within 10% above or below the target temperature value).
  • the pyrolysis control system 7500a can be configured to maintain the temperature of the liquid reactor bath to within 5% or less of a target temperature value (e.g., within 5% above or below the target temperature value). In some implementations, such as when the pyrolysis control system 7500a is implemented on the reactor 5000 shown in Figure 29, the pyrolysis control system 7500a can be configured to maintain the temperature of the liquid reactor bath to within 2% or less of a target temperature value (e.g., within 2% above or below the target temperature value).
  • the temperature control systems (8101-8111) and their respective sub-components can be individually controllable by the pyrolysis control system.
  • Figure 46 shows a schematic diagram of a pyrolysis control system 7500b configured for controlling both a pyrolysis reactor (e.g., the pyrolysis reactor 5000 of Figure 29) and an extruder configured for transferring molten or semi-molten feedstock into the pyrolysis reactor (e.g., the extruder 600 of Figure 13 or the extruder 800 of Figure 15) according to another example implementation.
  • the pyrolysis control system 7500b differs from the pyrolysis control system 7500a (shown in Figure 45) in that its controller module 7508b further comprises an extruder control module 7510d, which receives data from and/or sends instructions to one or more external systems.
  • control system 7500b is configured to communicate (via the communications interface 7512) with external systems including the reactor temperature sensors 7514a, reactor heaters 7514b, a reactor agitator 7514c, and additional system components 7514d (e.g., sensors and/or controllers for monitoring and/or controlling flow rates, pressure, gas level, and/or chemical composition) as described in further detail above with respect to control system 7500a.
  • control system 7500b is further configured to communicate (via the communications interface 7512) with additional external systems including extruder temperature control systems 7514e, an extruder feed system 75141', and the extruder screw control systems 7514g.
  • the extruder temperature control systems 7514e can include any (or all) of the extruder temperature control systems 8101- 8111.
  • the extruder feed system 7514f can include a hopper (e.g., hopper 620) and/or a pneumatic ram (e.g., pneumatic ram 6222).
  • the extruder screw control systems 7514g can comprise a drive system configured for controlling the RPM of the extruder screw (e.g., the screw 8642) and/or the torque or power applied to the extruder screw by the drive system.
  • control system 7500b is configured to control the temperature of the liquid bath within the reactor vessel (as described above with respect to control system 7500a) and the throughput of the extruder (e.g., the extruder 600 or extruder 800).
  • the modules 7510a, 7510b, 7510c, 7510d of the controller module 7508b can be in the form of non- transitory machine or computer-readable media that is executable by a processor, such as the processor 7504.
  • the machine-readable media facilitates performance of operations to enable reception and transmission of data.
  • the machine-readable media can provide an instruction (e.g., command, etc.) to acquire data.
  • the computer readable program code can be executed on one processor, multiple co-located processors, multiple remote processors, or any combination of local and remote processors. Remote processors can be connected to each other through any type of network (e.g., CAN bus, etc.).
  • the modules 7510a, 7510b, 7510c, 7510d of the controller module 7508b can be implemented as hardware apparatuses, such as electronic control apparatuses.
  • the modules 7510a, 7510b, 7510c, 7510d of the controller module 7508b can be implemented as one or more circuitry components including, but not limited to, processing circuitry, network interfaces, peripheral devices, input devices, output devices, sensors, etc.
  • the modules 7510a, 7510b, 7510c, 7510d of the controller module 7508b can take the form of one or more analog circuits, electronic circuits (e.g., integrated circuits (IC), discrete circuits, system on a chip (SOCs) circuits, microcontrollers, etc.), telecommunication circuits, hybrid circuits, and any other type of “circuit.”
  • a circuit as described herein can include one or more transistors, logic gates (e.g., NAND, AND, NOR, OR, XOR, NOT, XNOR, etc.), resistors, multiplexers, registers, capacitors, inductors, diodes, wiring, and so on).
  • the modules 7510a, 7510b, 7510c, 7510d of the controller module 7508b can also include programmable hardware devices such as field programmable gate arrays, programmable array logic, programmable logic devices or the like.
  • the modules 7510a, 7510b, 7510c, 7510d of the controller module 7508b can include one or more memory devices for storing instructions that are executable by the processor(s) of the modules 7510a, 7510b, 7510c, 7510d of the controller module 7508b.
  • the modules 7510a, 7510b, 7510c, 7510d of the controller module 7508b can be geographically dispersed throughout separate locations.
  • the modules 7510a, 7510b, 7510c, 7510d of the controller module 7508b can be implemented in or within a single apparatus/housing, which is shown as the control system 7500b.
  • the control system 7500b includes the processing circuit 7502 having the processor 7504 and the memory device 7506.
  • the processing circuit 7502 can be structured or configured to execute or implement the instructions, commands, and/or control processes described herein with respect to the modules 7510a, 7510b, 7510c, 7510d of the controller module 7508b.
  • the depicted configuration represents the modules 7510a, 7510b, 7510c, 7510d of the controller module 7508b as machine or computer-readable media.
  • modules 7510a, 7510b, 7510c, 7510d of the controller module 7508b, or at least one circuit of the modules 7510a, 7510b, 7510c, 7510d of the controller module 7508b, is configured as a hardware apparatus. All such combinations and variations are intended to fall within the scope of the present disclosure.
  • the hardware and data processing components used to implement the various processes, operations, illustrative logics, logical blocks, modules and circuits described in connection with the implementations disclosed herein can be implemented or performed with a general purpose single- or multi-chip processor, a digital signal processor (DSP), an application specific integrated circuit (ASIC), a field programmable gate array (FPGA), or other programmable logic device, discrete gate or transistor logic, discrete hardware components, or any combination thereof designed to perform the functions described herein.
  • a general purpose processor can be a microprocessor, or, any conventional processor, or state machine.
  • a processor also can be implemented as a combination of computing devices, such as a combination of a DSP and a microprocessor, a plurality of microprocessors, one or more microprocessors in conjunction with a DSP core, or any other such configuration.
  • the extruder control module 7510d is configured to adjust the energy output of the extruder temperature control systems 7514e that control the temperature of plastic feedstock within the extruder, adjust the feed rate of the extruder feed system 7514e (e.g., adjust the feed rate of the hopper and/or the compression of the feedstock by the pneumatic ram), and/or adjust the torque and/or revolutions per minute (RPM) of the extruder screw control systems 7514g.
  • the feed rate of the extruder feed system 7514e e.g., adjust the feed rate of the hopper and/or the compression of the feedstock by the pneumatic ram
  • RPM revolutions per minute
  • the extruder control module 7510d is configured to at least temporarily store a target throughput rate of the plastic feedstock being processed by the extruder (e.g., a user-defined target throughput rate received and stored by the control system 7500b or a target throughput rate retrieved from a remote source, such as a remote device or a cloud computing entity).
  • the extruder control module 7510d communicates with the extruder temperature control systems 7514e, the extruder feed system 7514f, and/or the extruder screw control systems 7514g to monitor the throughput of the plastic feedstock being processed by the extruder.
  • the extruder temperature control systems 7514e adjust the temperature of the plastic feedstock in the extruder
  • the extruder feed system 7514f adjusts the feed rate of the plastic feedstock into the extruder
  • the extruder screw control systems 7514g adjusts its torque and/or RPM to maintain the throughput rate of the plastic feedstock being processed by the extruder within a defined tolerance relative to the target throughput rate.
  • control system 7500d can include any number of modules for completing the functions described herein.
  • the activities and functionalities of the modules of the controller module 7508b can be combined in multiple modules or as a single circuit. Additional modules with additional functionality can also be included. Further, the control system 7500b can further control other activity beyond the scope of the present disclosure.
  • the pyrolysis control system 7500b can be configured for controlling only the extruder (e.g., the extruder 600 of Figure 13 or the extruder 800 of Figure 15). In other implementations, separate pyrolysis control systems can be used for controlling the extruder (e.g., the extruder 600 of Figure 13 or the extruder 800 of Figure 15) and the pyrolysis reactor (e.g., the pyrolysis reactor 5000 of Figure 29), respectively.
  • Vapor leaving the reactors contains a complex hydrocarbon mixture ranging from light molecules (short carbon chains) to heavy molecules (long carbon chains).
  • the process uses a production collection system comprising one or more stages to separate, condense, and/or recover the vapor product.
  • the product collection system can comprise, for example, one or more distillation columns, one or more molecular sieves, one or more pressureswing adsorptions, one or more cool/compress cycles, one or more gas separation membranes, one or more filtrations, one or more vacuum distillations, one or more cooling and/or condensation cycles, one or more quench systems (e.g., one or more quench towers), or a combination thereof.
  • the product collection system can comprise, for example, one or more distillation columns, one or more molecular sieves, one or more pressureswing adsorptions, one or more cool/compress cycles, one or more gas separation membranes, one or more filtrations, one or more vacuum distillations, one or more cooling and/or condensation cycles, or a combination thereof.
  • the vapor can be subjected to an additional processing step (e.g., further heated, distilled, filtered, etc.) before and/or after any of the above stages.
  • the process uses a product collection system comprising, for example, one or more stages of cooling and/or condensation to condense the vapor product into one or more liquid products (e.g., liquefaction).
  • the vapor can be subjected to an additional processing step (e.g., further heated, distilled, filtered, etc.) before and/or after cooling and/or condensation.
  • vapor from the reactors enters a condenser where hydrocarbons that have a boiling point at or above the temperature of the condenser are condensed.
  • the condenser can comprise any suitable condenser. Condensed liquid from the condenser can then be transferred, for example, to a storage tank. In some examples, condensed liquid from the condenser can then be distilled, for example to separate the product into one or more fractions and/or purify the product.
  • the process uses a plurality of stages of cooling and/or condensation to selectively separate reactor vapor product. In some examples, the process uses a plurality of stages of cooling and/or condensation to separate product. In some examples, there is also uncondensed gas.
  • a first condensation takes place inside a first condenser.
  • the first condenser can comprise any suitable condenser.
  • vapor from the reactors enters the first condenser where hydrocarbons that have a boiling point at or above the temperature of the first condenser are condensed.
  • Condensed liquid from the first condenser can then be transferred, for example, to a storage tank, recycled back into the reactor, and/or to a downstream element for further processing.
  • vapor phase material that passes through the first condenser can flow to a second condensing system (e.g., a second condenser).
  • the second condenser can comprise any suitable condenser.
  • vapor from the first condenser enters the second condenser where hydrocarbons that have a boiling point at or above the temperature of the second condenser are condensed.
  • Condensed liquid from the second condenser can then be transferred, for example, to a storage tank, recycled back into the reactor, and/or to a downstream element for further processing.
  • vapor phase material that passes through the second condenser can flow to a gas-liquid separator and/or to a third condenser.
  • the gas-liquid separator when present, can comprise any suitable separator.
  • vapor phase material that passes through the second condenser can flow to a third condenser.
  • the third condenser can comprise any suitable condenser.
  • vapor from the second condenser enters to the third condenser where hydrocarbons that have a boiling point at or above the temperature of the third condenser are condensed.
  • Condensed liquid from the third condenser can then be transferred, for example, to a storage tank, recycled back into the reactor, and/or to a downstream element for further processing.
  • numerous condensers can be used as part of the product recovery collection system (e.g., 1 or more, 2 or more, 3 or more, 4 or more, 5 or more, 6 or more, 7 or more, 8 or more, 9 or more, 10 or more, 11 or more, 12 or more, 13 or more, 14 or more, 15 or more, 16 or more, 17 or more, 18 or more, 19 or more, or 20 or more condensers).
  • the temperature cut-off of each of the one or more condensers can be selected in view of a variety of factors. In some examples, the temperature cut-off of the one or more condensers can be selected such that a portion of the product is not condensed. For example, a certain portion of the product can, in some examples, comprise a high concentration of contaminants, and the condensers can be configured to selectively allow this portion of the product to pass through each of the one or more condensers without condensing.
  • the temperature cut-off of the one or more condensers can be selected such that a portion of the product is condensed.
  • a certain portion of the product can, in some examples, comprise a high concentration of contaminants, and the condensers can be configured to selectively allow this portion of the product to be condensed, thereby purifying the uncondensed product.
  • the product collection system can comprise, for example, one or more cool/compress cycles (e.g., cool and compress, in any order), one or more cooling and/or condensation cycles, or a combination thereof.
  • the vapor can be subjected to an additional processing step (e.g., further heated, distilled, filtered, etc.) before and/or after any of the above stages.
  • the product collection system can comprise, for example, one or more fractionation columns.
  • the vapor can be subjected to an additional processing step (e.g., further heated, distilled, filtered, etc.) before and/or after the fractionation column(s).
  • the fractionation column can comprise any suitable fractionation column.
  • the process uses a single fractionation column to selectively separate reactor vapor product. In some examples, the process uses a plurality of fractionation columns to separate product. In some examples, there is also uncondensed gas.
  • a first fractionation takes place inside a first fractionation column.
  • the first fractionation column can comprise any suitable fractionation column.
  • vapor from one or more upstream elements e.g., the reactors, one or more distillation columns, one or more molecular sieves, one or more pressure-swing adsorption apparatuses, one or more cool/compress cycle apparatuses, one or more gas separation membranes, one or more filtration apparatuses, one or more vacuum distillation apparatuses, one or more cooling and/or condensation cycle apparatuses, one or more quench systems (e.g., one or more quench towers), or a combination thereof) enters the first fractionation column where hydrocarbons are subjected to fractionation based on their boiling point and the temperature and pressure of the first fractionation column.
  • Product from the first fractionation column can then be transferred, for example, to a storage tank, recycled back into the reactor, and/or to a downstream element for further processing.
  • liquid or vapor phase material that passes through the first fractionation column can flow to a second fractionation column.
  • the second fractionation column can comprise any suitable fractionation column.
  • liquid or vapor from the first fractionation column enters the second fractionation column where hydrocarbons that are subjected to fractionation based on their boiling point and the temperature and pressure of the second fractionation column.
  • Product from the second fractionation column can then be transferred, for example, to a storage tank, recycled back into the reactor, and/or to a downstream element for further processing.
  • fractionation columns can be used as part of the product recovery collection system (e.g., 1 or more, 2 or more, 3 or more, 4 or more, 5 or more, 6 or more, 7 or more, 8 or more, 9 or more, 10 or more, 11 or more, 12 or more, 13 or more, 14 or more, 15 or more, 16 or more, 17 or more, 18 or more, 19 or more, or 20 or more fractionation columns).
  • the temperature and/or pressure cut-off of each of the one or more fractionation columns can be selected in view of a variety of factors. In some examples, the temperature and/or pressure cut-off of the one or more fractionation columns can be selected to control the fractionation of a portion of the product. For example, a certain portion of the product can, in some examples, comprise a high concentration of contaminants, and the fractionation columns can be configured to selectively allow this portion of the product to pass through each of the one or more fractionation columns as liquid or vapor.
  • the product collection system can comprise, for example, one or more distillation columns.
  • the vapor can be subjected to an additional processing step (e.g., further heated, distilled, filtered, etc.) before and/or after the distillation column(s).
  • the distillation column can comprise any suitable distillation column.
  • the process uses a single distillation column to selectively separate reactor vapor product. In some examples, the process uses a plurality of distillation columns to separate product. In some examples, there is also uncondensed gas. In some examples, a first distillation takes place inside a first distillation column.
  • the first distillation column can comprise any suitable distillation column.
  • vapor from one or more upstream elements enters the first distillation column where hydrocarbons that have a boiling point at or below the temperature and pressure of the first distillation column are distilled. Distilled product from the first distillation column can then be transferred, for example, to a storage tank, recycled back into the reactor, and/or to a downstream element for further processing.
  • upstream elements e.g., the reactors, one or more distillation columns, one or more molecular sieves, one or more pressure-swing adsorption apparatuses, one or more cool/compress cycle apparatuses, one or more gas separation membranes, one or more filtration apparatuses, one or more vacuum distillation apparatuses, one or more cooling and/or condensation cycle apparatuses, one or more quench systems (e.g., one or more quench towers), or a combination thereof) enters the first distillation column where hydrocarbons that have a boiling point at or below the temperature and pressure of the first distillation column are distilled. Distilled product from the first distillation column
  • liquid or vapor phase material that passes through the first distillation column can flow to a second distillation column.
  • the second distillation column can comprise any suitable distillation column.
  • liquid or vapor from the first distillation column enters the second distillation column where hydrocarbons that have a boiling point at or below the temperature and pressure of the second distillation column are distilled. Distilled product from the second distillation column can then be transferred, for example, to a storage tank, recycled back into the reactor, and/or to a downstream element for further processing.
  • numerous distillation columns can be used as part of the product recovery collection system (e.g., 1 or more, 2 or more, 3 or more, 4 or more, 5 or more, 6 or more, 7 or more, 8 or more, 9 or more, 10 or more, 11 or more, 12 or more, 13 or more, 14 or more, 15 or more, 16 or more, 17 or more, 18 or more, 19 or more, or 20 or more distillation columns).
  • the temperature cut-off of each of the one or more distillation columns can be selected in view of a variety of factors. In some examples, the temperature cut-off of the one or more distillation columns can be selected to control the distillation of a portion of the product. For example, a certain portion of the product can, in some examples, comprise a high concentration of contaminants, and the distillation columns can be configured to selectively allow this portion of the product to pass through each of the one or more distillation columns as liquid or vapor.
  • the product collection system can comprise, for example, one or more quench systems (e.g., one or more quench towers).
  • the vapor can be subjected to an additional processing step (e.g., further heated, distilled, filtered, etc.) before and/or after any of the above stages.
  • the process uses a product collection system comprising, for example, one or more quench systems (e.g., one or more quench towers) to cool and/or condense the vapor product into one or more liquid products (e.g., liquefaction).
  • the vapor can be subjected to an additional processing step (e.g., further heated, distilled, fdtered, etc.) before and/or after the one or more quench systems (e.g., one or more quench towers).
  • vapor from one or more upstream elements enters a quench system (e.g., quench tower) where hydrocarbons that have a boiling point at or above the temperature of the cooler are condensed (e.g., liquefied).
  • a quench system e.g., quench tower
  • hydrocarbons that have a boiling point at or above the temperature of the cooler are condensed (e.g., liquefied).
  • the quench system (e.g., one or more quench tower) can comprise any suitable quench system (e.g., quench tower). Condensed liquid from the quench system (e.g., quench tower) can then be transferred, for example, to a storage tank. In some examples, condensed liquid from the quench system (e.g., one or more quench tower) can then be distilled, for example to separate the product into one or more fractions and/or purify the product.
  • quench system e.g., one or more quench tower
  • Condensed liquid from the quench system e.g., quench tower
  • condensed liquid from the quench system e.g., one or more quench tower
  • uncondensed vapor from the quench system can then be further cooled and/or condensed (e.g., in one or more additional quench systems, condensers, compressors, coolers, or combination thereof), for example to separate the product into one or more fractions and/or to purify the product.
  • quench system e.g., quench tower
  • condensers e.g., condensers, compressors, coolers, or combination thereof
  • the process uses a plurality of quench systems (e.g., quench towers) to selectively separate reactor vapor product. In some examples, the process uses a plurality of quench systems (e.g., quench towers) to separate product. In some examples, there is also uncondensed gas.
  • quench systems e.g., quench towers
  • numerous quench systems e.g., quench towers
  • the product recovery collection system e.g., 1 or more, 2 or more, 3 or more, 4 or more, 5 or more, 6 or more, 7 or more, 8 or more, 9 or more, 10 or more, 11 or more, 12 or more, 13 or more, 14 or more, 15 or more, 16 or more, 17 or more, 18 or more, 19 or more, or 20 or more.
  • the temperature and/or pressure cut-off of each of the one or more quench systems can be selected in view of a variety of factors.
  • the temperature and/or pressure cut-off of the one or more quench systems can be selected such that a portion of the product is not condensed.
  • a certain portion of the product can, in some examples, comprise a high concentration of contaminants, and the one or more quench systems (e.g., one or more quench towers) can be configured to selectively allow this portion of the product to pass through each of the one or more quench systems (e.g., quench towers) without condensing.
  • the temperature and/or pressure cut-off of the one or more quench systems can be selected such that a portion of the product is condensed.
  • a certain portion of the product can, in some examples, comprise a high concentration of contaminants, and the quench systems (e.g., quench towers) can be configured to selectively allow this portion of the product to condense, and thereby purifying the uncondensed product.
  • the product collection system can comprise, for example, one or more cool/compress cycles, one or more cooling and/or condensation cycles, or a combination thereof.
  • the vapor can be subjected to an additional processing step (e.g., further heated, distilled, filtered, etc.) before and/or after any of the above stages.
  • the process uses a product collection system comprising, for example, one or more cooling and/or compress cycles to cool and/or compress the vapor product into one or more liquid products (e.g., liquefaction).
  • the vapor can be subjected to an additional processing step (e.g., further heated, distilled, filtered, etc.) before and/or after cooling and/or compression.
  • vapor from one or more upstream elements enters a cooler where hydrocarbons that have a boiling point at or above the temperature of the cooler are condensed (e.g., liquefied).
  • the cooler can comprise any suitable cooler.
  • Condensed liquid from the cooler can then be transferred, for example, to a storage tank.
  • condensed liquid from the cooler can then be distilled, for example to separate the product into one or more fractions and/or purify the product.
  • uncondensed vapor from the cooler can then be further cooled and/or compressed, for example to separate the product into one or more fractions and/or to purify the product.
  • vapor from one or more upstream elements enters a compressor where hydrocarbons that have a boiling point at or below the pressure of the compressor are condensed.
  • the compressor can comprise any suitable compressor. Condensed liquid from the compressor can then be transferred, for example, to a storage tank.
  • condensed liquid from the condenser can then be distilled, for example to separate the product into one or more fractions and/or purify the product.
  • uncondensed vapor from the compressor can then be transferred, for example, to a storage tank.
  • uncondensed vapor from the compressor can then be cooled and/or compressed, for example to separate the product into one or more fractions and/or to purify the product.
  • the process uses a plurality of stages of cooling and/or compression to selectively separate reactor vapor product. In some examples, the process uses a plurality of stages of cooling and/or compression to separate product. In some examples, there is also uncondensed gas.
  • numerous coolers and/or compressors can be used as part of the product recovery collection system (e.g., 1 or more, 2 or more, 3 or more, 4 or more, 5 or more, 6 or more, 7 or more, 8 or more, 9 or more, 10 or more, 11 or more, 12 or more, 13 or more, 14 or more, 15 or more, 16 or more, 17 or more, 18 or more, 19 or more, or 20 or more).
  • the temperature and/or pressure cut-off of each of the one or more coolers and/or compressors can be selected in view of a variety of factors. In some examples, the temperature and/or pressure cut-off of the one or more coolers and/or compressors can be selected such that a portion of the product is not condensed. For example, a certain portion of the product can, in some examples, comprise a high concentration of contaminants, and the coolers and/or compressors can be configured to selectively allow this portion of the product to pass through each of the one or more coolers and/or compressors without condensing.
  • the temperature and/or pressure cut-off of the one or more coolers and/or compressors can be selected such that a portion of the product is condensed.
  • a certain portion of the product can, in some examples, comprise a high concentration of contaminants, and the coolers and/or compressors can be configured to selectively allow this portion of the product to condense, and thereby purifying the uncondensed product.
  • Figure 47 depicts an example system SlOOf where the product collection uses one or more stages of cooling and/or condensation in a cooling and/or condensation apparatus SI 15.
  • the product SI 12 e.g., from any of Systems SlOOa-SlOOe in Figure 1- Figure 5
  • a cooling and/or condensation apparatus SI 15 where it is subjected to “n” stages of cooling and/or condensation, where n is 1 or more (e.g., 2 or more, 3 or more, 4 or more, 5 or more, 6 or more, 7 or more, 8 or more, 9 or more, 10 or more, 11 or more, 12 or more, 13 or more, 14 or more, 15 or more, 16 or more, 17 or more, 18 or more, 19 or more, or 20 or more).
  • the cooling and/or condensation apparatus SI 15 can be configured for removing vent gas (e.g., atmospherics, which can optionally be subsequently captured and then optionally recycled) and/or contaminants and/or liquid S 110c. In other examples, the cooling and/or compression apparatus SI 15 may not remove vent gas and/or contaminants and/or liquid.
  • the product SI 12a can optionally be subjected to post-treatment and/or contaminant removal by one or more optional post-treatment and/or contaminant removal apparatuses SI 14. The product can then be directed to a storage apparatus SI 18 (e.g., storage cylinder) and/or a pipeline apparatus SI 19 (e.g., for transport and/or delivery to an off-site location).
  • a storage apparatus SI 18 e.g., storage cylinder
  • a pipeline apparatus SI 19 e.g., for transport and/or delivery to an off-site location.
  • Figure 48 depicts an example system SlOOg where the product SI 12 (e.g., from any of Systems SlOOa-SlOOe in Figure 1- Figure 5), is optionally subjected to post-treatment and/or contaminant removal by one or more optional post-treatment and/or contaminant removal apparatuses SI 14, and subsequently directed to a cooling and/or condensation apparatus SI 15 where it is subjected to “n” stages of cooling and/or condensation, where n is 1 or more (e.g., 2 or more, 3 or more, 4 or more, 5 or more, 6 or more, 7 or more, 8 or more, 9 or more, 10 or more, 11 or more, 12 or more, 13 or more, 14 or more, 15 or more, 16 or more, 17 or more, 18 or more, 19 or more, or 20 or more).
  • n is 1 or more (e.g., 2 or more, 3 or more, 4 or more, 5 or more, 6 or more, 7 or more, 8 or more, 9 or more, 10 or more, 11 or more
  • the cooling and/or condensation apparatus SI 15 can be configured for removing vent gas (e.g., atmospherics, which can optionally be subsequently captured and then optionally recycled) and/or contaminants and/or liquid S 110c. In other examples, the cooling and/or compression apparatus SI 15 may not remove vent gas and/or contaminants and/or liquid.
  • the product SI 12a can then be directed to a storage apparatus SI 18 (e.g., storage cylinder) and/or a pipeline apparatus SI 19 (e.g., for transport and/or delivery to an off-site location).
  • a storage apparatus SI 18 e.g., storage cylinder
  • a pipeline apparatus SI 19 e.g., for transport and/or delivery to an off-site location.
  • Figure 49 depicts an example system SlOOh where the product SI 12 (e.g., from any of Systems SlOOa-SlOOe in Figure 1- Figure 5), is optionally subjected to post- treatment and/or contaminant removal by one or more optional post-treatment and/or contaminant removal apparatuses SI 14a, and subsequently directed to a cooling and/or condensation apparatus SI 15 where it is subjected to “n” stages of cooling and/or condensation, where n is 1 or more (e.g., 2 or more, 3 or more, 4 or more, 5 or more, 6 or more, 7 or more, 8 or more, 9 or more, 10 or more, 11 or more, 12 or more, 13 or more, 14 or more, 15 or more, 16 or more, 17 or more, 18 or more, 19 or more, or 20 or more).
  • n is 1 or more (e.g., 2 or more, 3 or more, 4 or more, 5 or more, 6 or more, 7 or more, 8 or more, 9 or more, 10 or more, 11
  • the cooling and/or condensation apparatus S 115 can be configured for removing vent gas (e.g., atmospherics, which can optionally be subsequently captured and then optionally recycled) and/or contaminants and/or liquid SI 10c. In other examples, the cooling and/or compression apparatus S 115 may not remove vent gas and/or contaminants and/or liquid.
  • the product SI 12a can optionally be subjected to post-treatment and/or contaminant removal by one or more optional post-treatment and/or contaminant removal apparatuses S 114b.
  • the product can then be directed to a storage apparatus Si l 8 (e.g., storage cylinder) and/or a pipeline apparatus SI 19 (e.g., for transport and/or delivery to an off-site location).
  • Figure 50 depicts an example system SlOOi where the product SI 12 (e.g., from any of systems SlOOa-SlOOe in Figure 1 - Figure 5), is optionally subjected to post- treatment and/or contaminant removal by one or more optional post-treatment and/or contaminant removal apparatuses SI 14a, and subsequently directed to a fractionation apparatus SI 19 where it is subjected to “n” stages of fractionation, where n is 1 or more (e.g., 2 or more, 3 or more, 4 or more, 5 or more, 6 or more, 7 or more, 8 or more, 9 or more, 10 or more, 11 or more, 12 or more, 13 or more, 14 or more, 15 or more, 16 or more, 17 or more, 18 or more, 19 or more, or 20 or more).
  • the fractionation apparatus SI 19 can be configured for fractionating the product into one or more fractions, such as a vapor product S 112b, a liquid product S 112c, and/or liquid drop out SI 12d.
  • the vapor product SI 12b can optionally be subjected to post-treatment and/or contaminant removal by one or more optional post- treatment and/or contaminant removal apparatuses S 114b.
  • the vapor product S 112b can then be directed to a storage apparatus SI 18b (e.g., storage cylinder) and/or a pipeline apparatus SI 19b (e.g., for transport and/or delivery to an off-site location).
  • a storage apparatus SI 18b e.g., storage cylinder
  • a pipeline apparatus SI 19b e.g., for transport and/or delivery to an off-site location.
  • the liquid product SI 12c can optionally be subjected to post-treatment and/or contaminant removal by one or more optional post-treatment and/or contaminant removal apparatuses S 114c.
  • the liquid product S 112c can then be directed to a storage apparatus SI 18c (e.g., storage cylinder) and/or a pipeline apparatus SI 19c (e.g., for transport and/or delivery to an off-site location).
  • a storage apparatus SI 18c e.g., storage cylinder
  • a pipeline apparatus SI 19c e.g., for transport and/or delivery to an off-site location.
  • Any of systems SlOOf-SlOOi can optionally be preceded by a compression and/or condensation stage in a compression and/or condensation apparatus.
  • any of the vaporized product recovery systems described herein above can be operational in any combination with one another.
  • the systems and/or methods described herein can produce the pyrolysis products (e.g., gas) at a yield of 5% or more (e.g., 10% or more, 15% or more, 20% or more, 25% or more, 30% or more, 35% or more, 40% or more, 45% or more, 50% or more, 55% or more, 60% or more, 65% or more, 70% or more, 75% or more, 80% or more, 85% or more, 90% or more, 95% or more, or 99% or more).
  • the systems and/or methods described herein can produce the pyrolysis products (e.g., gas) at a yield of 100% or less (e.g., 95% or less, 90% or less, 85% or less, 80% or less, 75% or less, 70% or less, 65% or less, 60% or less, 55% or less, 50% or less, 45% or less, 40% or less, 35% or less, 30% or less, 25% or less, 20% or less, 15% or less, or 10% or less).
  • the yield of the systems and/or methods described herein can range from any of the minimum values described above to any of the maximum values described above.
  • the systems and/or methods described herein can produce the pyrolysis products (e.g., gas) at a yield of from 5% to 100% (e.g., from 5% to 55%, from 55% to 100%, from 5% to 40%, from 40% to 70%, from 70% to 100%, from 5% to 99%, from 5% to 95%, from 5% to 90%, from 5% to 85%, from 5% to 80%, from 5% to 75%, from 5% to 70%, from 5% to 65%, from 5% to 60%, from 5% to 50%, from 5% to 45%, from 5% to 35%, from 5% to 30%, from 5% to 25%, from 5% to 15%, or from 5% to 10%, from 10% to 100%, from 15% to 100%, from 20% to 100%, from 25% to 100%, from 30% to 100%, from 35% to 100%, from 40% to 100%, from 45% to 100%, from 50% to 100%, from 60% to 100%, from 65% to 100%, from 75% to 100%, from 80% to 100%, or from 10% to 95%).
  • the methods and systems herein produce a raw pyrolysis product with a reduced level of contaminants, for example such that no further post- treatment of the product is needed (e.g., the methods substantially exclude any hydrotreatment or further refining steps after the pyrolysis).
  • the methods and systems herein can further comprise post- treating the pyrolysis products.
  • the gas can be further processed by refining, filtering, cracking, hydrotreating, distilling, etc., or a combination thereof, for example in the production of chemicals and/or polymers.
  • the post-treatment can reduce the level of one or more contaminants in the pyrolysis product (e.g., gas).
  • the post-treatment can comprise an adsorption column configured to reduce the level of one or more contaminants (e.g., chlorides, bromides, metalloids, sulfur, oxygenates, atmospherics, or a combination thereof) in the pyrolysis product (e.g., gas).
  • the post-treatment can comprise an adsorption column configured to reduce the level of chlorides and/or bromides in the pyrolysis product (e.g., gas). In some examples, the post-treatment can comprise an adsorption column configured to reduce the level of chlorides in the pyrolysis product (e.g., gas). In some examples, the post-treatment can comprise an adsorption column configured to reduce the level of bromides in the pyrolysis product (e.g., gas).
  • the methods and systems herein can further comprise post-treating the pyrolysis products, for example via use of a catalyst (e.g., Zeolites, metal catalysts, and the like).
  • a catalyst e.g., Zeolites, metal catalysts, and the like.
  • hydrocarbon product After hydrocarbon product has been recovered (and optionally post-treated), it is transferred to storage tanks.
  • the product can be transferred using any suitable means to the storage tanks.
  • the storage tanks can be constructed of any suitable material.
  • the storage tanks can further include a feedback system.
  • levels in the tanks can be monitored using an electronic sensor.
  • the feedback system can include a temperature control system (e.g., to control the temperature of the product within the storage tank, for example by heating and/or cooling).
  • the feedback system can, for example, activate the heating and/or cooling systems as needed, for example based on particular temperature setpoints.
  • at least a portion of the storage tank(s) can be insulated.
  • the system can further include heat trace components (e.g., electric or non-electric).
  • heat trace cable e.g., mineral insulated heat trace cable
  • This cable can ensure that products within the process lines remain flowable under all conditions.
  • Such cables can be protected through cladded insulation. Thermocouples on each independent section of heat trace can be installed to monitor heat levels within these sections and feedback mechanisms can provide an alert if piping sections may not be receiving proper heating.
  • some or all of the piping running from the extruder into the reactors can be insulated and/or include heat tracing. Such insulating and heat tracing to process lines can be particularly important during colder ambient conditions. It is imperative that all process lines always remain fully open and operable, regardless of the ambient temperature.
  • System availability and reactor uptime are typically expressed as a percentage and refers to the amount of time a system or reactor is operating, divided by the total amount of time in the period.
  • Availability and uptime are a combination of scheduled maintenance (non-operating hours) and reliability (defined as 1 minus forced outages divided by operating hours).
  • Availability and uptime are dependent on several factors, including the quality of equipment, engineering and construction employed, the degree of back-up or redundant equipment, the expertise and effort of personnel, the level of preventative, predictive and corrective maintenance, the replenishment of spare parts, the operating demand placed on a facility, and first year versus mature operation.
  • Reactor uptime in particular, can be influenced by how long a reactor can be continuously run without char buildup requiring the reactor to be shut down and cleaned out.
  • the systems and methods described herein can have an availability factor of 50% or more (e.g., 55% or more, 60% or more, 65% or more, 70% or more, 75% or more, 80% or more, 85% or more, 90% or more, or 95% or more). In some examples, the systems and methods described herein can have an availability factor of 100% or less (e.g., 95% or less, 90% or less, 85% or less, 80% or less, 75% or less, 70% or less, 65% or less, or 60% or less). The availability factor can range from any of the minimum values described above to any of the maximum values described above.
  • the systems and methods described herein can have an availability factor of from 50% to 100% (e.g., from 50% to 75%, from 75% to 100%, from 50% to 60%, from 60% to 70%, from 70% to 80%, from 80% to 90%, from 90% to 100%, from 50% to 80%, from 50% to 80%, from 50% to 70%, from 60% to 100%, from 70% to 100%, from 80% to 100%, from 90% to 100%, from 95% to 100%, from 55% to 95%, or from 60% to 90%).
  • 50% to 100% e.g., from 50% to 75%, from 75% to 100%, from 50% to 60%, from 60% to 70%, from 70% to 80%, from 80% to 90%, from 90% to 100%, from 50% to 80%, from 50% to 70%, from 60% to 100%, from 70% to 100%, from 80% to 100%, from 90% to 100%, from 95% to 100%, from 55% to 95%, or from 60% to 90%).
  • the reactor can be configured for operating to pyrolyze plastic feedstock for a cumulative period of 324 hours or more during a time period of 360 hours (e.g., 325 hours or more, 326 hours or more, 327 hours or more, 328 hours or more, 329 hours or more, 330 hours or more, 331 hours or more, 332 hours or more, 333 hours or more, 334 hours or more, 335 hours or more, 336 hours or more, 337 hours or more, 338 hours or more, 339 hours or more, 340 hours or more, 341 hours or more, 342 hours or more, 343 hours or more, 344 hours or more, 345 hours or more, 346 hours or more, 347 hours or more, 348 hours or more, 349 hours or more, 350 hours or more, 351 hours or more, 352 hours or more, 353 hours or more, 354 hours or more, 355 hours or more, 356 hours or more, 357 hours or more, 358 hours or more, 359 hours or more, or
  • the reactor can be configured for operating to pyrolyze plastic feedstock for a cumulative period of 576 hours or more during a time period of 720 hours (e.g., 577 hours or more, 578 hours or more, 579 hours or more, 580 hours or more, 581 hours or more, 582 hours or more, 583 hours or more, 584 hours or more, 585 hours or more, 586 hours or more, 587 hours or more, 588 hours or more, 589 hours or more, 590 hours or more, 591 hours or more, 592 hours or more, 593 hours or more, 594 hours or more, 595 hours or more, 596 hours or more, 597 hours or more, 598 hours or more, 599 hours or more, 600 hours or more, 601 hours or more, 602 hours or more, 603 hours or more, 604 hours or more, 605 hours or more, 606 hours or more, 607 hours or more, 608 hours or more, 609 hours or more, 610 hours or more, 611 hours or more,
  • the reactor can be configured for operating to pyrolyze the plastic feedstock for a cumulative period of 756 hours or more during a time period of 1080 hours (e.g., 758 hours or more, 760 hours or more, 762 hours or more, 764 hours or more, 766 hours or more, 768 hours or more, 770 hours or more, 772 hours or more, 774 hours or more, 776 hours or more, 778 hours or more, 780 hours or more, 782 hours or more, 784 hours or more, 786 hours or more, 788 hours or more, 790 hours or more, 792 hours or more, 794 hours or more, 796 hours or more, 798 hours or more, 800 hours or more, 802 hours or more, 804 hours or more, 806 hours or more, 808 hours or more, 810 hours or more, 812 hours or more, 814 hours or more, 816 hours or more, 818 hours or more, 820 hours or more, 822 hours or more, 824 hours or more, 826 hours or more
  • the foregoing reactor uptime ranges can be achieved using the pyrolysis reactor 5000 shown and described with respect to Figure 29. In some specific implementations, the foregoing reactor uptime ranges can be achieved using the pyrolysis system SlOOe of Figure 5, where the extruder SI 07 a comprises the extruder 800 shown and described with respect to Figure 15 and the pyrolysis reactor SI 08a comprises the pyrolysis reactor 5000 shown and described with respect to Figure 29.
  • the reactor can be configured for operating to pyrolyze plastic feedstock with 90% uptime or more over 15 days (e.g., 90.5% uptime or more, 91% uptime or more, 91.5% uptime or more, 92% uptime or more, 92.5% uptime or more, 93% uptime or more,
  • the pyrolysis reactor 5000 can be configured for operating to pyrolyze plastic feedstock with 90% uptime or more.
  • the reactor can be configured for operating to pyrolyze plastic feedstock with 80% uptime or more over 30 days (e.g., 81% uptime or more, 82% uptime or more, 83% uptime or more, 84% uptime or more, 85% uptime or more, 86% uptime or more, 87% uptime or more, 88% uptime or more, 89% uptime or more, 90% uptime or more, 90.5% uptime or more, 91% uptime or more, 91.5% uptime or more, 92% uptime or more, 92.5% uptime or more, 93% uptime or more, 93.5% uptime or more, 94% uptime or more, 94.5% uptime or more, 95% uptime or more, 95.5% uptime or more, 96% uptime or more, 96.5% uptime or more, 97% uptime or more, 97.5% uptime or more, 98% uptime or more, 98.5% uptime or more, 99% uptime or more, 99.5% uptime or more,
  • the pyrolysis reactor 5000 can be configured for operating to pyrolyze plastic feedstock with 80% uptime or more.
  • the reactor can be configured for operating to pyrolyze plastic feedstock with 70% uptime or more over 45 days (e.g., 71% uptime or more, 72% uptime or more, 73% uptime or more, 74% uptime or more, 75% uptime or more, 76% uptime or more, 77% uptime or more, 78% uptime or more, 79% uptime or more, 80% uptime or more, 81% uptime or more, 82% uptime or more, 83% uptime or more, 84% uptime or more, 85% uptime or more, 86% uptime or more, 87% uptime or more, 88% uptime or more, 89% uptime or more, 90% uptime or more, 90.5% uptime or more, 91% uptime or more, 91.5% uptime or more, 92% uptime or more, 92.5% uptime or more, 93% uptime or more, 93.5% uptime or more, 94% uptime or more, 94.5% uptime or more, 95% uptime or more, 95.
  • the foregoing reactor uptime ranges can be achieved using the pyrolysis reactor 5000 shown and described with respect to Figure 29. In some specific implementations, the foregoing reactor uptime ranges can be achieved using the pyrolysis system SlOOe of Figure 5, where the extruder SI 07a comprises the extruder 800 shown and described with respect to Figure 15 and the pyrolysis reactor SI 08a comprises the pyrolysis reactor 5000 shown and described with respect to Figure 29.
  • compositions Articles of Manufacture, Methods of Use
  • compositions comprising any of the gases disclosed herein, or any of the products of the methods or systems disclosed herein.
  • the composition derived from any of the gases disclosed herein comprises a second gas.
  • the composition is derived via the methods further comprising one or more stages of cooling and/or compression, one or more stages of cooling and/or condensation, one or more post- treatment and/or contaminant removal stages, fractionation, or a combination thereof.
  • the second gas comprises hydrocarbons that are non-condensable at ambient temperature and ambient pressure.
  • the concentration of one or more hydrocarbons can, in some examples, be increased relative to the gas from which it was derived. In the process of deriving the second gas, the concentration of one or more hydrocarbons may not be increased relative to the gas from which it was derived.
  • the concentration of one or more hydrocarbons can, in some examples, be decreased relative to the gas from which it was derived. In the process of deriving the second gas, the concentration of one or more hydrocarbons may not be decreased relative to the gas from which it was derived.
  • certain hydrocarbons can preferentially concentrate in certain fractions.
  • the concentration of said hydrocarbons can be increased or decreased in said fractions relative to the gas from which said fractions were derived.
  • certain hydrocarbons can preferentially concentrate in certain fractions, and thus, in such examples, the concentration of said hydrocarbons can be increased or decreased in said fractions relative to the gas from which said fractions were derived.
  • the second gas can, for example, have a number average molecular weight and/or a weight average molecular weight of 15 Daltons or more (e.g., 20 Daltons or more, 25 Daltons or more, 30 Daltons or more, 35 Daltons or more, 40 Daltons or more, 45 Daltons or more, 50 Daltons or more, 55 Daltons or more, 60 Daltons or more, 65 Daltons or more, or 70 Daltons or more).
  • the second gas has a number average molecular weight and/or a weight average molecular weight of 30 Daltons or more.
  • the second gas has a number average molecular weight and/or a weight average molecular weight of 45 Daltons or more.
  • the second gas can have a number average molecular weight and/or a weight average molecular weight of 75 Daltons or less (e.g., 70 Daltons or less, 65 Daltons or less, 60 Daltons or less, 55 Daltons or less, 50 Daltons or less, 45 Daltons or less, 40 Daltons or less, 35 Daltons or less, 30 Daltons or less, 25 Daltons or less, or 20 Daltons or less).
  • the second gas has a number average molecular weight and/or a weight average molecular weight of 50 Daltons or less.
  • the second gas has a number average molecular weight and/or a weight average molecular weight of 45 Daltons or less.
  • the number average molecular weight and/or weight average molecular weight of the second gas can range from any of the minimum values described above to any of the maximum values described above.
  • the second gas can have a number average molecular weight and/or a weight average molecular weight of from 15 to 75 Daltons (e.g., from 15 to 45 Daltons, from 45 to 75 Daltons, from 15 to 25 Daltons, from 25 to 35 Daltons, from 35 to 45 Daltons, from 45 to 55 Daltons, from 55 to 65 Daltons, from 65 to 75 Daltons, from 15 to 70 Daltons, from 15 to 65 Daltons, from 15 to 60 Daltons, from 15 to 55 Daltons, from 15 to 50 Daltons, from 15 to 40
  • 15 to 75 Daltons e.g., from 15 to 45 Daltons, from 45 to 75 Daltons, from 15 to 25 Daltons, from 25 to 35 Daltons, from 35 to 45 Daltons, from 45 to 55 Daltons, from 55 to 65 Daltons, from 65 to 75 Daltons, from 15 to 70 Daltons, from 15 to 65 Dal

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Abstract

L'invention concerne des compositions à base d'hydrocarbures issues de la pyrolyse d'une charge d'alimentation contenant des plastiques post-consommation et/ou post-industriels et leurs procédés de production et d'utilisation. La composition est un gaz issu de la pyrolyse d'une charge d'alimentation contenant des plastiques post-consommation et/ou post-industriels. Le gaz comprend un mélange d'hydrocarbures différents, dont l'un quelconque peut éventuellement être substitué, 70 % ou plus du mélange (p/p) comprenant des hydrocarbures C1-C6 ; et le gaz présente : une teneur totale en chlorure inférieure ou égale à 40 000 ppmv ; une teneur totale en bromure inférieure ou égale à 2000 ppmv ; une teneur en métalloïdes inférieure ou égale à 500 ppmv ; une teneur totale en soufre inférieure ou égale à 5000 ppmv ; une teneur en composés oxygénés inférieure ou égale à 4000 ppmv ; une teneur en gaz atmosphérique inférieure ou égale à 30 % en moles ; ou une combinaison de ceux-ci.
PCT/US2025/021974 2024-03-28 2025-03-28 Compositions d'hydrocarbures issues de la pyrolyse de plastiques post-consommation et/ou post-industriels et leurs procédés de production et d'utilisation Pending WO2025208005A1 (fr)

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Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2021163109A1 (fr) * 2020-02-10 2021-08-19 Eastman Chemical Company Compositions issues du recyclage chimique de flux dérivés de plastique et leurs utilisations
WO2022221286A1 (fr) * 2021-04-16 2022-10-20 Chevron Phillips Chemical Company Lp Pyrolyse de déchets plastiques pour produire des hydrocarbures gazeux légers et intégration avec un vapocraqueur
US20220402840A1 (en) * 2021-06-16 2022-12-22 Technip Energies France Process For Treating A Gas Stream From Plastic Pyrolisis And/Or Biomass Pyrolisis, And Installation For Integration Into A Steam Cracker
WO2023049034A1 (fr) * 2021-09-21 2023-03-30 Eastman Chemical Company Réduction de l'empreinte carbone d'installations de recyclage chimique

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2021163109A1 (fr) * 2020-02-10 2021-08-19 Eastman Chemical Company Compositions issues du recyclage chimique de flux dérivés de plastique et leurs utilisations
WO2022221286A1 (fr) * 2021-04-16 2022-10-20 Chevron Phillips Chemical Company Lp Pyrolyse de déchets plastiques pour produire des hydrocarbures gazeux légers et intégration avec un vapocraqueur
US20220402840A1 (en) * 2021-06-16 2022-12-22 Technip Energies France Process For Treating A Gas Stream From Plastic Pyrolisis And/Or Biomass Pyrolisis, And Installation For Integration Into A Steam Cracker
WO2023049034A1 (fr) * 2021-09-21 2023-03-30 Eastman Chemical Company Réduction de l'empreinte carbone d'installations de recyclage chimique

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