PROCESS FOR REPURPOSING SYNTHETIC AND ORGANIC WASTES INTO VALUABLE PRODUCTS
The present invention pertains to a process for upcycling synthetic and organic waste into valuable commodities. This invention provides a method for converting and managing mixed feedstock streams, such as plastic waste, biological waste, municipal solid waste, municipal sewage sludge, shredder residue, and other carbon- and hydrogen-rich materials. The process produces gas, oil, light hydrocarbons (e.g., circular naphtha), specialty chemicals, and carbon solids, which can be used directly or further refined or processed.
1 . A method of upcycling synthetic and organic waste, comprising the steps of:
Preparation ( 110 ) of the primary process solid ( 100 ) into a slurry ( 112 ) with the secondary process solid ( 134 ) and water,
Conveying the primary process solid ( 100 ) into the mixed storage tank ( 220 ) along with the SPS slurry ( 112 ),
Subjecting the slurry ( 112 ) to hydrolysis ( 120 ) in the hydrolysis reactor ( 1032 ),
Conducting separation ( 130 ) after hydrolysis to remove secondary process solid ( 134 ), minerals, and gases from the hydrolyzed primary process solid,
Directing the hydrolyzed primary process solid ( 500 ) to a thermal cracker reactor ( 260 ) through the extruder ( 252 ).
2 . A method of upcycling according to claim 1 , wherein the primary process solid ( 100 ) is plastic or rubber waste.
3 . A method of upcycling according to claim 1 , wherein the primary process solid ( 100 ) is selected from the group consisting of polyethylene, polypropylene, polystyrene, PET, polyester, polycarbonate, PVC, textiles, minerals, biomass, fats, rubber, tires, polyurethane, polyamide, synthetic plastics, natural plastics, or mixtures thereof.
4 . A method of upcycling according to claim 1 , wherein the secondary process solid ( 134 ) is a mineral-containing substance, preferably including various types of soil, bentonite, calcium carbonate, silicates, alumino-silicates, alkali metal compounds, alkali earth metal compounds, and transition or metal compounds.
5 . A method of upcycling according to claim 1 , wherein the temperature during the hydrolysis ( 120 ) of the slurry ( 112 ) ranges from 50° C. to 550° C., preferably from 80° C. to 500° C., more preferably from 100° C. to 450° C., and most preferably from 125° C. to approximately 400° C.
6 . A method of upcycling according to claim 1 , wherein the pressure during the hydrolysis ( 120 ) of the slurry ( 112 ) ranges from 1 bar to 200 bar, preferably from 1.2 bar to 150 bar, more preferably from 1.5 bar to 100 bar, and most preferably from 2 bar to 80 bar.
7 . A method of upcycling according to claim 1 , wherein the hydrolysis period ( 120 ) of the slurry ( 112 ) ranges from 1 minute to 1440 minutes, preferably from 2 minutes to 600 minutes, more preferably from 5 minutes to 240 minutes, and most preferably from approximately 15 minutes to 180 minutes.
8 . A method of upcycling according to claim 1 , wherein the slurry ( 112 ) has a moisture content of at least 20%, preferably over 30%, and most preferably above 40%.
9 . A method of upcycling according to claim 1 , wherein the mixed storage tank ( 220 ) is equipped with a vibratory screen ( 1043 ) for fine sizing to remove contamination.
10 . A method of upcycling according to claim 1 , wherein the hydrolysis reactor ( 1032 ) features a multi-chamber design.
11 . A method of upcycling according to claim 1 , wherein the hydrolysis reactor ( 1032 ) is selected from a batch reactor, a continuous stirred-tank reactor, an auger reactor, or any other reactor type that facilitates the heating and mixing of the solid material.
12 . A method of upcycling according to claim 1 , wherein the thermal conversion reactor ( 260 ) is selected from an auger reactor, a batch reactor, an extruder, a continuous stirred-tank reactor, a fluidized bed reactor, or any other reactor type that supports the heating and movement of the solid material.