EP4638644A1

EP4638644A1 - Electrically heated pyrolysis systems and methods

Info

Publication number: EP4638644A1
Application number: EP23825509.5A
Authority: EP
Inventors: Sabriye FREDRIKSSON; Raul VELASCO PELAEZ
Original assignee: SABIC Global Technologies BV
Current assignee: SABIC Global Technologies BV
Priority date: 2022-12-20
Filing date: 2023-12-14
Publication date: 2025-10-29
Also published as: WO2024134405A1; CN120418386A

Abstract

An electrically heated pyrolysis system and methods. In embodiments, the system may include a pyrolysis stage reactor. The pyrolysis stage reactor may include one or more electrically heated screws or augers made of or coated with one or more of a catalytic, a ferromagnetic, a superparamagnetic, or an electrically conductive material and positioned in the inner space of the pyrolysis stage reactor. Each of the one or more electrically heated screws or augers comprise one or more zones including an independently controlled heating element. The system may include an induction coil per zone positioned circumferentially around the exterior surface. The system may include a gas duct positioned within an inner space of the pyrolysis stage reactor, the gas duct held under a partial vacuum and to collect gaseous products from each zone. The proposed design is sustainable in terms of both reducing energy losses and reduction in greenhouse gas emissions.

Description

ELECTRICALLY HEATED PYROLYSIS SYSTEMS AND METHODS

FIELD OF DISCLOSURE

[0001] The present disclosure generally relates to electrically heated pyrolysis systems for endothermic reactions and processes. More specifically, the present disclosure relates to electrically heated pyrolysis systems, including one or more pyrolysis stage zones, for endothermic reactions and processes, particularly for pyrolysis.

BACKGROUND

[0002] Chemical recycling of mixed plastic waste is one solution for recycling or reusing plastic waste. The chemical recycling of the mixed plastic waste, e.g., via a pyrolysis reactor, is a highly endothermic process. The temperature used and product composition of the mixed plastic waste are dependent on several variables. Those variables may include whether the mixed plastic waste is introduced as a solid feed, whether solid catalyst is used, and/or whether liquid and/or gaseous products are desired. A typical pyrolysis reactor may include two or three stages. Further, residence time and the pyrolysis reactor temperature profile may affect the pyrolysis reactor effluent composition. To maximize olefinic gases, temperatures higher than 800°C and short residence times are utilized. Current continuous pyrolysis reactors cannot economically operate at these conditions.

[0003] Fluidized bed reactors may address the high heat transfer rates at a substantially uniform reactor temperature, but will typically exhibit catalyst attrition or de-fluidization problems due to molten plastic. Plastic feed particles do not conduct heat well and feed particle size is a constraint for both heat transfer and fluid dynamic reasons.

BRIEF SUMMARY

[0004] In view of the foregoing, Applicant has recognized these problems and has recognized a need for enhanced systems and methods for processing mixed plastic waste, including electrically heated pyrolysis systems (e.g., such as electrically heated screw kiln reactors/extruders) and arrangements that beneficially reduce the production of deleterious by-products (greenhouse gases et al.) and advantageously enhance the efficiency of such processes and reduces carbon footprint.

[0005] Such systems and methods may include an electrically heated screw kiln reactor/extruder or pyrolysis stage reactor. The pyrolysis stage reactor may include an induction coil positioned around the exterior, outside, outer surface, or outer covering of the pyrolysis stage reactor. Further, the auger or screw, positioned within the pyrolysis stage reactor, may be electrically heated. Further still the auger or screw may be coated with or comprised of a catalytic material, catalytically active material, and/or electromagnetic material. The systems and methods may further include an electrically heated preheating stage reactor.

[0006] A Screw kiln reactor/extruder prevents the issues exhibited by fluidized bed reactors described herein. Feed particle size, for example, is not a constraint for a screw kiln reactor/extruder. While heat transfer may remain an issue if heat is introduced through screw kiln reactor/extruder walls, introducing heat through the walls of the screw kiln reactor/extruder and via or to an auger or screw may alleviate such issues and further allow for precise control of temperature, as well as for determination of a corrected temperature and adjustment of one or more different zones of the screw kiln reactor/extruder to the corrected temperature. Further, since the screw kiln reactor/extruder is heated electrically (e.g., via induction coils wrapped around the screw kiln reactor/extruder and/or via the auger or screw), rather than via burning of various materials (e.g., coke produced during pyrolysis and/or other hydrocarbon based materials or fuels), the carbon footprint of the screw kiln reactor/extruder may be reduced further. Thus, such systems and methods may provide solutions for recycling or reusing mixed plastic waste, while reducing carbon emissions.

[0007] Embodiments of the disclosure include an electrically heated pyrolysis system. The system may include a pyrolysis stage reactor. The pyrolysis stage reactor may be configured to receive a preheated plastic containing waste or mixed plastic waste and one or more heating particles or catalyst and output a gaseous product, solid residue, and used or spent one or more of heating particles or catalyst. The pyrolysis stage reactor may comprise or include one or more or two or more electrically heated screws or augers made of or coated with one or more of a catalytic material, catalytically active material, a ferromagnetic material, a superparamagnetic material, or an electrically conductive heating material and positioned in an inner space of the pyrolysis stage reactor. Each of the one or more electrically heated screws or augers may be configured to generate heat based on induction or direct electrical conduction, to rotate in a forward direction to agitate and transport the preheated plastic containing waste and one or more of heating particles or catalyst through the pyrolysis stage reactor. Each of the one or more electrically heated screws or augers may comprise or define one or more zones. Each of the one or more zones may include an independently controlled heating element. Further, the system may include an induction coil per each of the one or more zones positioned circumferentially around the exterior surface of the pyrolysis stage reactor to provide additional heat to the preheated plastic containing waste via the one or more electrically heated screws or augers. The pyrolysis stage reactor may include a gas duct positioned within the inner space of the pyrolysis stage reactor. The gas duct may be configured to support a partial vacuum environment and to collect gaseous products. The gaseous products may be released from the preheated plastic containing waste during heating.

[0008] In an embodiment, the system may include a preheating stage reactor configured to receive the plastic containing waste and output the preheated plastic containing waste. The preheating stage reactor may comprise or include a second electrically heated screw or auger positioned in an inner space of the preheating stage reactor. The second electrically heated screw or auger may be configured to rotate in a forward direction to agitate, heat the plastic containing waste to a selected temperature, and transport a heated plastic containing waste to an outlet of the preheating stage reactor. The second electrically heated screw may generate heat based on one or more of induction or direct electrical conduction. The second electrically heated screw or auger may comprise and/or be coated with one or more of a catalytic material, a ferromagnetic material, a superparamagnetic material, or an electrically conductive heating material. The preheating stage reactor may comprise or include a second induction coil positioned circumferentially around an exterior surface of the preheating stage reactor to provide additional heat to the plastic containing waste.

[0009] In a further embodiment, the second electrically heated screw or auger of the preheating stage reactor may be comprised of a catalytic material, and the one or more electrically heated screws or augers of the pyrolysis stage reactor may be comprised of a ferromagnetic material with a Curie temperature higher than a temperature threshold of the pyrolysis stage reactor. Each of the one or more zones may include an opening for the gas duct to transport the gaseous products at each of the one or more zones from the pyrolysis stage reactor for further use as a feedstock. Each of the one or more zones may include an independent electromagnetic induction source to provide electrical heating at a selected temperature of a corresponding section of each of the two or more electrically heated screws or augers and a heating material or particles and/or catalyst present at the corresponding section.

[0010] Embodiments of the disclosure also include an electrically heated pyrolysis reactor. The electrically heated pyrolysis reactor may comprise a preheating stage reactor. The preheating stage reactor may comprise a first housing. The first housing may comprise a first interior surface, a first inner space defined by a first space within the first interior surface, a first exterior surface, a first inlet positioned at a proximal end of a top portion of the first housing, and a first outlet positioned at a distal end of the first housing. The first inlet may be configured to allow plastic containing waste to flow therethrough to the first inner space of the first housing. The preheating stage reactor may further include a first electrically heated screw or auger positioned in the first inner space of the first housing. The first electrically heated screw or auger may be configured to rotate in a forward direction to agitate, heat the plastic containing waste to a first temperature, and transport preheated plastic containing waste to the first outlet. The preheating stage reactor may include a first induction coil positioned around the first outer surface to heat the plastic containing waste to the first temperature. The electrically heated pyrolysis reactor may include a duct comprising: a second inlet connected to the first outlet of the preheating stage reactor, a third inlet to receive one or more of heating particles or catalyst, and a second outlet. The electrically heated pyrolysis reactor may include a pyrolysis stage reactor. The pyrolysis stage reactor may comprise or include a second housing. The second housing may comprise or include a second interior surface, a second inner space defined by a second space within the second interior surface, a second exterior surface, and a fourth inlet connected to the second outlet of the duct. The fourth inlet may be configured to receive the preheated plastic containing waste from the second inlet of the duct and one or more of heating particles or catalyst from the third inlet of the duct. The pyrolysis stage reactor may include two or more electrically heated screws or augers comprising one or more of a catalytic material, a ferromagnetic material, a superparamagnetic material, or an electrically conductive heating material and positioned in the second inner space of the pyrolysis stage reactor. Each of the two or more electrically heated screws or augers may be configured to rotate in a forward direction to agitate and transport the preheated plastic containing waste and one or more of heating particles or catalyst through the pyrolysis stage reactor. Further, each of the two or more electrically heated screws or augers may comprise one or more sections corresponding to one or more zones based on composition or coating of the two or more electrically heated screws or augers, each of the one or more sections including an independently controlled heating element, a second induction coil positioned around the second exterior surface to provide additional heat to the preheated plastic containing waste, and a gas duct positioned within the second inner space of the pyrolysis stage reactor. The gas duct may be configured to support a partial vacuum and to collect gaseous products released from the plastic containing waste. In an embodiment, the pyrolysis stage reactor may include a third outlet. The third outlet may be connected to the gas duct and configured to remove gaseous products. The pyrolysis stage reactor may include a fourth outlet positioned at a distal end of the pyrolysis stage reactor and configured to remove solid residue from generated from the plastic containing waste and one or more of heating particles or catalyst.

[0011] In an embodiment, the gas duct is positioned adjacent a top portion of the second interior surface of the pyrolysis stage reactor. The one or more of heating particles or catalyst may comprise one or more of ferromagnetic, superparamagnetic, or electrically conductive particles. Each of the one or more sections may include one or more temperature sensors to measure one or more of a temperature in a corresponding section, a temperature of the preheated plastic containing waste in the corresponding section, or a temperature of pyrolysis products in the corresponding section. A temperature provided by each of the one or more sections may be based on one or more of the temperature in a corresponding section, a temperature of the preheated plastic containing waste in the corresponding section, or a temperature of pyrolysis products in the corresponding section. The temperature provided by each of the one or more sections may be sufficient and/or optimized to minimize char and/or carbon from forming in the corresponding section. The gas duct may be a grid separated gas duct. The one or more of heating particles or catalyst may comprise a size and material sufficient to manage temperature in the pyrolysis stage reactor.

[0012] Embodiments of the disclosure also include a method for operating an electrically heated pyrolysis reactor. The method may include or comprise introducing a plastic containing waste to a preheating stage reactor. The preheating stage reactor may include: a first electrically heated screw or auger positioned in a first inner space of the preheating stage reactor, the first electrically heated screw or auger configured to rotate in a forward direction to agitate, heat to a first temperature, and transport the plastic containing waste to a first outlet of the preheating stage reactor, and a first induction coil positioned around an exterior surface of the preheating stage reactor to provide additional heat to the plastic containing waste. The method may include operating the preheating stage reactor to the first temperature, via the first electrically heated screw or auger or the first induction coil of the preheating stage reactor, sufficient to prepare the plastic containing waste for pyrolysis. The method may include transferring prepared plastic containing waste and one or more of heating particles or catalyst to a pyrolysis stage reactor. The pyrolysis stage reactor may include: two or more electrically heated screws or augers coated with a catalytic material and positioned in the second inner space of the pyrolysis stage reactor. Each of the two or more electrically heated screws or augers may be configured to rotate in a forward direction to agitate and transport the pre-heated plastic containing waste and one or more of heating particles or catalyst through the pyrolysis stage reactor. Each of the two or more electrically heated screws or augers may comprise one or more zones. Each of the one or more zones may include an independently controlled heating element. The pyrolysis stage reactor may include a second induction coil positioned around a second exterior surface to provide additional heat to the pre-heated plastic containing waste. The pyrolysis stage reactor may include a gas duct positioned within the second inner space of the pyrolysis stage reactor. The gas duct may be configured to support a partial vacuum and to collect gaseous products. The gaseous products may be released from the preheated plastic containing waste during heating. The method may include operating each of the one or more zones of the pyrolysis stage reactor at a corresponding temperature, via the two or more electrically heated screws or augers or the second induction coil of the pyrolysis stage reactor, to produce a gaseous product and solid residue. The method may include transferring the gaseous product from the pyrolysis stage reactor for further use. [0013] In an embodiment, the method may include, during operation of each of the one or more zones of the pyrolysis stage reactor at the corresponding temperature, determining, via signals from one or more temperature sensors positioned in each of the one or more zones, a current corresponding temperature of each of the one or more zones. The method may include, in response to any of the current corresponding temperatures being outside of one or more of (1) a first selected threshold temperature range at which the plastic containing waste forms char or carbon or (2) a second selected threshold temperature range at which high value chemical yield is increased, determining corrected corresponding temperatures for each of the one or more zones of the pyrolysis stage reactor and driving a temperature within each of the one or more zones of the pyrolysis stage reactor to the corrected corresponding temperature.

[0014] The following includes definitions of various terms and phrases used throughout this specification.

[0015] The terms “about” or “approximately” are defined as being close to as understood by one of ordinary skill in the art. In one non-limiting embodiment the terms are defined to be within 10%, preferably, within 5%, more preferably, within 1%, and most preferably, within 0.5%.

[0016] The terms “wt.%”, “vol.%” or “mol.%” refer to a weight, volume, or molar percentage of a component, respectively, based on the total weight, the total volume, or the total moles of material that includes the component. In a non-limiting example, 10 moles of component in 100 moles of the material is 10 mol.% of component. [0017] The term “substantially” and its variations are defined to include ranges within 10%, within 5%, within 1%, or within 0.5%.

[0018] The terms “inhibiting” or “reducing” or “preventing” or “avoiding” or any variation of these terms, when used in the claims and/or the specification, include any measurable decrease or complete inhibition to achieve a desired result.

[0019] The term “effective,” as that term is used in the specification and/or claims, means adequate to accomplish a desired, expected, or intended result.

[0020] The use of the words “a” or “an” when used in conjunction with the term “comprising,”

“including,” “containing,” or “having” in the claims or the specification may mean “one,” but it is also consistent with the meaning of “one or more,” “at least one,” and “one or more than one.” [0021] The words “comprising” (and any form of comprising, such as “comprise” and “comprises”), “having” (and any form of having, such as “have” and “has”), “including” (and any form of including, such as “includes” and “include”) or “containing” (and any form of containing, such as “contains” and “contain”) are inclusive or open-ended and do not exclude additional, unrecited elements or method steps.

[0022] The process of the present disclosure can “comprise,” “consist essentially of,” or “consist of’ particular ingredients, components, compositions, etc., disclosed throughout the specification.

[0023] As used herein, “pyrolysis” refers to the process of thermal decomposition of materials at elevated temperatures. The thermal degradation may occur in an inert, or substantially inert atmosphere or, in some embodiments, in the presence of or with an amount of inert gases.

[0024] Other objects, features and advantages of the present disclosure will become apparent from the following figures, detailed description, and examples. It should be understood, however, that the figures, detailed description, and examples, while indicating specific embodiments of the disclosure, are given by way of illustration only and are not meant to be limiting. Additionally, it is contemplated that changes and modifications within the spirit and scope of the disclosure will become apparent to those skilled in the art from this detailed description. In further embodiments, features from specific embodiments may be combined with features from other embodiments. For example, features from one embodiment may be combined with features from any of the other embodiments. In further embodiments, additional features may be added to the specific embodiments described herein. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] These and other features, aspects, and advantages of the disclosure will become better understood with regard to the following descriptions, claims, and accompanying drawings. It is to be noted, however, that the drawings illustrate only several embodiments of the disclosure and, therefore, are not to be considered limiting of the scope of the disclosure:

[0026] FIG. 1A and FIG. IB show schematic diagrams of an electrically heated pyrolysis system, according to embodiments of the disclosure;

[0027] FIG. 2 shows schematic flowcharts for a method of utilizing an electrically heated pyrolysis system, according to embodiments of the disclosure; and

[0028] FIG. 3 shows a schematic diagram of a controller to control an electrically heated pyrolysis system, according to embodiments of the disclosure.

DETAILED DESCRIPTION

[0029] As noted, Chemical recycling of mixed plastic waste is one solution for recycling or reusing plastic waste. The chemical recycling of the mixed plastic waste, e.g., via a pyrolysis reactor, is a highly endothermic process. The temperature used and product composition of the mixed plastic waste are dependent on several variables. Those variables may include whether the mixed plastic waste is introduced as a solid feed, whether solid catalyst is used, and/or whether liquid and/or gaseous products are desired. A typical pyrolysis reactor may include two or three stages. Further, residence time and the pyrolysis reactor temperature profile may affect the pyrolysis reactor effluent composition. To maximize olefinic gases, temperatures higher than 800°C and short residence times are utilized, although optimum temperatures may vary based on the type of plastic waste. Current continuous pyrolysis reactors cannot operate at these conditions and be economically scaled up.

[0030] In view of the foregoing, Applicant has recognized these problems and has recognized a need for enhanced systems and methods for processing mixed plastic waste, including electrically heated pyrolysis systems (e.g., such as electrically heated screw kiln reactors/extruders) and arrangements that beneficially reduce the production of deleterious by-products (greenhouse gases et al.) and advantageously enhance the efficiency of such processes and reduces carbon footprint.

[0031] Such systems and methods may include an electrically heated screw kiln reactor/extruder or pyrolysis stage reactor. The pyrolysis stage reactor may include an induction coil positioned around the outside, outer surface, or outer covering of the pyrolysis stage reactor. Further, the auger or screw, positioned within the pyrolysis stage reactor, may be electrically heated. Further still the auger or screw may be coated with or comprised of a catalytic material, catalytically active material, and/or electromagnetic material. The systems and methods may further include an electrically heated preheating stage reactor.

[0032] A Screw kiln reactor/extruder prevents the issues exhibited by fluidized bed reactors described herein. Feed particle size, for example, is not a constraint for a screw kiln reactor/extruder. While heat transfer may remain an issue if heat is introduced through screw kiln reactor/extruder walls, introducing heat through the walls of the screw kiln reactor/extruder and via or to an auger or screw may alleviate such issues and further allow for precise control of temperature, as well as for determination of a corrected temperature and adjustment of one or more different zones of the or within the screw kiln reactor/extruder to the corrected temperature. Further, since the screw kiln reactor/extruder is heated electrically (e.g., via induction coils wrapped around the screw kiln reactor/extruder and/or via the auger or screw), rather than via burning of various materials (e.g., coke produced during pyrolysis and/or other hydrocarbon based materials or fuels), the carbon footprint of the screw kiln reactor/extruder may be reduced further. Thus, such systems and methods may provide solutions for recycling or reusing mixed plastic waste, while reducing carbon emissions.

[0033] FIG. 1A and FIG. IB show schematic diagrams of an electrically heated pyrolysis system, according to embodiments of the disclosure. Turning first to FIG. 1 A, the electrically heated pyrolysis system 100 may include a preheating stage reactor 102, a pyrolysis stage reactor 104, and a duct 124 or conduit connecting the preheating stage reactor 102 to the pyrolysis stage reactor 104. Plastic containing waste 106 may be fed into the preheating stage reactor 102, pass therethrough to the duct 124 or conduit, and then pass to and through the pyrolysis stage reactor 104. After such a process, the plastic containing waste 106 may be converted, via an endothermic reaction, to gas products 136 and/or solid residue with, in an embodiment, heating particles and/or catalyst 144.

[0034] The preheating stage reactor 102 may include a housing 103. The housing 103 may include an inner surface 156 and an outer surface 154. The housing 103 may be a tubular or cylindrical shaped structure comprised of metal or another material configured to withstand high temperatures and/or pressure, as will be understood by one skilled in the art. An inlet 108 may be positioned at a distal end of the preheating stage reactor 102. The inlet 108 may be configured to allow plastic containing waste 106 to pass or flow into the preheating stage reactor 102. The preheating stage reactor 102 may include an induction coil 116 wrapped or positioned circumferentially about the preheating stage reactor 102. The induction coil 116 may be connected or electrically connected to a power source. The amount of current flowing through the induction coil 116 may cause the heat to increase or decrease. In other words, to increase heat or decrease heat, the amount of current provided to the induction coil 116 may be increased or decreased, respectively.

[0035] The preheating stage reactor 102 may further include a screw or auger 114. The screw or auger 114 may reside completely, substantially completely, or partially within the space defined by the portion of the preheating stage reactor 102 inside or within the inner surface 156 of the preheating stage reactor 102. The screw or auger 114 may be connected to the same power source or a separate (e.g., the same as or separate from the power source providing current to the induction coil 116) and/or independent power source. Thus, the screw or auger 114 may provide heat to the preheating stage reactor 102 via the current provided to the screw or auger 114. The screw or auger 114 may be made of, comprised of, and/or coated with a catalytic material and/or electromagnetic material. In another embodiment, the screw or auger 114 may be heated via magnetic induction. The screw or auger 114 may be configured to begin generating heat in the presence of a magnetic field with an amplitude of about 5 miliTesla (mT) to about 1000 mT or about 5 mT to about 200 mT and a frequency of about 0.5 kiloHertz (kHz) to about 400 kHz. In such embodiments, the induction coil 116 may generate such a magnetic field. The screw or auger 114 may also rotate, as indicated by direction 112, to push or move the plastic containing waste 106 in a forward direction towards a proximal end of the preheating stage reactor 102. Further, the screw or auger 114 may, as the screw or auger 114 moves in a forward direction, agitate the plastic containing waste 106. The preheating stage reactor 102 may heat the plastic containing waste 106 and/or may generate heat within the preheating stage reactor 102 to a specified or preselected temperature (e.g., about 300 degrees Celsius to about 350 degrees Celsius). The preheating stage reactor 102 may utilize a residence time for plastic containing waste 106 of about 5 minutes to about 1 hour, depending on the type of plastic containing waste 106.

[0036] In an embodiment, the preheating stage reactor 102 may operate at about 300 degrees Celsius to about 350 degrees Celsius. Further, the preheating stage reactor 102 may include a vent or outlet 162. In such an embodiment, as the temperature of plastic containing waste 106 increases, some gas products 164 may be produced. As such, a vent or outlet 162 may be positioned near the proximal end of the preheating stage reactor 102. The vent and/or additional vents may be positioned at other locations along the upper portion or top of the preheating stage reactor 102. Thus, any gas products, produced intentionally or otherwise, may be collected for further use. Further use may include, but is not limited to, producing polymers (e.g., polyethylene and/or polypropylene from olefins and/or polycarbonate and/or polyethylene terephthalate from benzene, toluene, and three xylene isomers (BXT)).

[0037] Once the plastic containing waste 106 is preheated (e.g., to aid in pyrolysis in the pyrolysis stage reactor 104) and moved or passed to the end or proximal end of the preheating stage reactor 102, then the plastic containing waste 106 may move down a conduit or duct 124 to the pyrolysis stage reactor 106. The conduit or duct 124 may additionally include an inlet 120. The inlet 120 may be configured to accept a preselected amount of heating material or particles and/or catalyst 118. The heating material or particles and/or catalyst may flow or move down the conduit or duct 124 with the preheated plastic containing waste 106 to the pyrolysis stage reactor 104. The heating material or particles and/or catalyst 118 may be comprised of one or more of ferromagnetic (FM), superparamagnetic (SPM), electrically conductive particles, HZSM-5, Si-Al, CaCO3, used or spent FCC catalyst, other zeolites, iron, chromium, nickel, and/or other nanoparticles. Such heating particles and/or catalyst may be selected based on the type of feed and the temperature used for the pyrolysis reaction of that type of feed. In such embodiments, heating particles may carry heat (e.g., larger amounts of heat in relation to the plastic containing waste 106, which may lower amounts of heat), thereby increasing heat in the pyrolysis stage reactor. Further, catalyst may aid in the pyrolysis reaction.

[0038] The pyrolysis stage reactor 104 may include a housing 107. The housing 107 may be connected to the conduit or duct 124. The housing 107 may include an inner or interior surface 160 and outer or exterior surface 158. The pyrolysis stage reactor 104 may be a cylindrical or tubular shape. The pyrolysis stage reactor 104 may include an induction coil 134. The induction coil 134 may be wrapped or positioned around or circumferentially about the housing 107 and/or about the outer or exterior surface 158. The induction coil 134 may be connected to a power source. The induction coil 134 may generate heat as current is provided to the induction coil 134. The amount of heat may be varied based on the amount of current provided to the induction coil 134. In an embodiment, multiple power sources may be connected to each one of one or more sections of the induction coil 134 (e.g., to cause each one of the one or more sections of the induction coil 134 to generate a specified amount of heat and/or a specified magnetic field). Each one of the one or more sections of the induction coil 134 may define or be considered a zone (e.g., providing heat and/or a magnetic field to heat the screw or auger 130). Thus, the pyrolysis stage reactor 104 may include one or more zones. One or more controllers may control the amount of power provided to each one of the one or more sections of the induction coil 134 based on various factors (e.g., temperature within each zone based on temperatures sufficient to cause pyrolysis and/or temperatures sufficient to minimize char and/or to increase or maximize the amount of high value chemicals produced during pyrolysis and/or to minimize hotspots within the pyrolysis stage reactor 104). An amount of char may form as the plastic containing waste 106 contains inorganics that will be removed as char. Temperature may affect the formation of char, coke, or carbon from the organic material, and the char, coke, or carbon formed may be reduced due to the minimization of hotspots and the paraffinic nature of feedstock (e.g., the plastic containing waste 106). As shown in FIG. 1C, a pyrolysis stage reactor may include one or more zones (e.g., zone A 166A, zone B 166B, and/or zone C 166c). The pyrolysis stage reactor 104 may include additional or less zones. Each zone may include independently controlled heating elements (e.g., each zone of the pyrolysis stage reactor 104 being controlled by a controller). Further, each zone may include independently heated and/or independently controlled induction coils (e.g., the induction coils to provide a magnetic field causing the screw or auger to increase in temperature). [0039] The pyrolysis stage reactor 104 may include at least one screw or auger 130. The at least one screw or auger 130 may be positioned within (e.g., completely, substantially completely, or partially within) the space or inner space defined by the inner or interior surface 160 of the housing 107. The at least one screw or auger 130 may be connected to the same power source or a separate (e.g., separate from the power source providing current to the induction coil 134) and/or independent power source. Thus, the screw or auger 130 may provide heat to the pyrolysis stage reactor 104 via the current 126 provided to the screw or auger 130. In another embodiment, the screw or auger 130 may be heated via magnetic induction. The screw or auger 130 may be configured to begin generating heat in the presence of a magnetic field with an amplitude of about 5 mT to about 1000 mT or about 5 mT to about 200 mT and a frequency of about 0.5 kHz to about 400 kHz. In such embodiments, the induction coil 134 may generate such a magnetic field. In another embodiment, the screw or auger 130 may be comprised of an alloy configured to achieve a Curie temperature of 800 degrees Celsius. The screw or auger 130 may also rotate, as indicated by direction 128, to push or move the plastic containing waste in a forward direction towards a proximal end of the pyrolysis stage reactor 104. The pyrolysis stage reactor 104 may heat the plastic containing waste 106 to a specified or preselected temperature. In an embodiment, each zone in the pyrolysis stage reactor 104 may be based on a composition or coating of the at least one screw or auger 130. In other words, the at least one screw or auger 130 may be coated and/or comprised of different materials for each section or zone. In such an embodiment, each section or zone may generate different temperatures based on the magnetic field. Further, the magnetic field may be varied for each section or zone.

[0040] In an embodiment, multiple power sources may be connected (directly or indirectly) to each one of one or more sections of the screw or auger 130. Each one of the one or more sections of the screw or auger 130 may define or be considered a zone. Thus, the pyrolysis stage reactor 104 may include one or more zones. In an embodiment, each portion of the screw or auger 130 in the zone may be comprised of and/or coated by a one or more different materials. In other words, the each zone may be defined by or based on the composition or coating of the screw or auger 130 for that zone. In another embodiment, each section of the induction coil 134 may provide a magnetic field to cause a corresponding section of the screw or auger 130 to heat to a particular temperature. One or more controllers may control the amount of power provided to each one of the one or more sections of the screw or auger 130 based on various factors (e.g., temperatures or a temperature range within each zone based on temperatures or temperature ranges sufficient to cause pyrolysis and/or temperatures to minimize char formation and/or produce high value chemicals). Such factors may be determined based on measurements provided by one or more sensors positioned throughout the system (e.g., temperature sensors, pressure sensors, analyzers, etc.). In such embodiments, current may pass directly through the screw or auger 130. In another embodiment, rather than or in addition to current directly passing through the screw or auger 130, the material that the screw or auger 130 is coated with and/or made of may be configured or designed to steer the temperature within any zone of the pyrolysis stage reactor 104 and/or the preheating stage reactor 102 (e.g., via induction based on a magnetic field). Such a material may comprise a ferromagnetic, superparamagnetic, or an electrically conductive material that may be heated via induction as will be understood by one skilled in the art.

[0041] During pyrolysis, and for each zone, the plastic containing waste may emit gas products. The pyrolysis stage reactor 104 may include a duct 132 or gas duct and/or a plurality of vents. In such an embodiment, each zone of the pyrolysis stage reactor 104 may include a vent, each vent connected to and in fluid communication with the duct 132. The duct 132 may be kept at a slight vacuum (e.g., about 0.2 bar to about 0.9 bar). The pyrolysis stage reactor 104 may produce, as noted, gas products 136, as well as solid residue, heating particles, and/or catalyst 144. The gas products 136 may pass into the duct 132 and through the outlet 138 for further use. The outlet may include a screen or filter 140. The solid residue, heating particles, and/or catalyst 144 may pass through outlet 142 for further use or, for example for catalyst, re-use. In an embodiment, the preheating stage reactor 102 may include a duct or gas duct.

[0042] In an embodiment, the speed at which the screw or auger 114, 130 of the preheating stage reactor 102 and/or pyrolysis stage reactor 104 turns or moves may be variable. In other words, the residence time of plastic containing waste 106 may be extended or reduced based on such a speed. A controller may control the speed of either screw or auger 114, 130 based on the type of feed and/or the gas product sought. For example, the preheating stage reactor 102 and/or pyrolysis stage reactor 104 may utilize a longer than typical residence time to dechlorinate a heavily contaminated feed. In an embodiment, the residence time of each zone of one or more zones of the pyrolysis stage reactor 104 may vary. Such residence times may be from about 1 to 2 seconds to about 5 minutes.

[0043] Turning to FIG. IB, the pyrolysis stage reactor 105 may include two or more augers 150, 152. Each of the two or more augers 150, 152 may connect to different or the same power sources. In another embodiment, the two or more augers 150, 152 may be heated via magnetic induction (as described for the screw or auger 114, 130). The two or more augers 150, 152 may be configured to begin generating heat in the presence of a magnetic field with an amplitude of about 5 nil to about 1000 mT or about 5 mT to about 200 mT and a frequency of about 0.5 kHz to about 400 kHz. In such embodiments, the induction coil 134 may generate such a magnetic field. In an embodiment, the two augers 150, 152 may be comprised of and/or coated with the same or different material

[0044] FIG. 2 shows schematic flowcharts for a method of utilizing an electrically heated pyrolysis system, according to embodiments of the disclosure. In an embodiment, the actions of method 200 may be completed within a controller or a control system (e.g., such as controller 302) on a system (e.g., system 100). Specifically, method 200 may be included in one or more programs, protocols, or instructions loaded into a memory of the control system and executed on a processor or one or more processors of the controller or control system. The order in which the operations are described is not intended to be construed as a limitation, and any number of the described blocks may be combined in any order and/or in parallel to implement the methods. [0045] At block 202, upon initiation or during a pyrolysis operation, plastic containing waste or an amount of plastic containing waste may be introduced into the preheating stage reactor. The rate of the introduction of plastic containing waste may be based on a current pyrolysis process, the desired gas products, and/or the type of plastic containing waste. In another embodiment, the rate of the introduction may be constant or substantially constant. At block 204, the preheating stage reactor may be operated. The preheating stage reactor may be heated or may provide heat to the plastic containing waste via an induction wrapped and/or positioned around the preheating stage reactor and via an electrically heated screw or auger. The screw or auger may provide heat based on reception (e.g., by the electrically heated screw or auger) of current or of a magnetic field. The temperature of the preheating stage reactor may be based on the type and/or size of the feed (e.g., of the plastic containing waste).

[0046] At block 206, the preheated plastic containing waste may be transferred to the pyrolysis stage reactor via a duct or conduit. Further, heating particles and/or catalyst may be introduced at the duct or conduit where the plastic containing waste is transferred to the pyrolysis stage reactor. In other words, in addition to preheated plastic containing waste being supplied to the pyrolysis stage reactor, heating particles and/or catalyst may be provided to the pyrolysis stage reactor. The pyrolysis stage reactor may include one or more zones, each zone operated at a particular or selected temperature, based on, in non-limiting examples example, the type of feed (e.g., type of plastic containing waste). For example, if the pyrolysis stage reactor includes a plurality of zones, each successive zone may gradually increase in temperature, a subsequent zone may include an increased temperature and a next subsequent zone may be cooler, or each successive zone may gradually decrease in temperature.

[0047] At block 208, each zone of one or more zones of the pyrolysis stage reactor may be operated at one or more specified or selected temperatures. Each zones initial temperature may be based on a type of plastic waste and/or the gaseous products sought. At block 210, a controller may determine the current temperature of or within each of the one or more zones of the pyrolysis stage reactor. The temperature may be determined based on signals received by the controller from one or more sensors positioned within each zone of the one or more zones of the pyrolysis stage reactor. The controller may determine, at block 212, if the temperature in any of the zones or some other aspect of each of the zones are not within the preselected range or threshold. At block 214, if the temperature or other aspect is within the preselected range or threshold, then gaseous products (e.g., the results of pyrolysis) may be transferred from the pyrolysis stage reactor. At block 216, if the temperature or other aspect is not within the preselected range or threshold, then a corrected temperature for the one or more temperatures of each zone not within the range or threshold may be determined (e.g., via the controller). Such a corrected temperature may be determined based on the current temperature in a particular zone and a selected temperature range based on the type of feed (e.g., plastic containing waste) used and/or other factors (e.g., for example, the type and/or amount of gas products produced at a point during the pyrolysis reaction). Once one or more corrected temperatures are determined, each corresponding zone of the pyrolysis stage reactor may be adjusted or driven to the corrected temperature or one or more corrected temperatures (e.g., a different corrected temperature for each zone), after which gaseous products may be transferred for further use (or, in other embodiments, additional temperatures and/or other aspects subsequent to the current temperature or aspect may be determined). Such adjustments, for example of temperature, may occur via adjustment of a power source (e.g., increasing current, power, and/or strength of a magnetic field) corresponding to a section of induction coil and/or power source corresponding to a section of a screw or auger. In an embodiment, such adjustments may be incremental and may occur over a continuous or substantially continuous length of time (e.g., the length of time of a pyrolysis operation).

[0048] FIG. 3 shows a schematic diagram of a controller to control an electrically heated pyrolysis system, according to embodiments of the disclosure. In an example, the control system may include a controller 302 or one or more controllers. Further, the controller 302 may be in signal communication with various other controllers. The controller 302 may be considered a supervisory controller. In another example, a supervisory controller may include the functionality of controller 302.

[0049] Each controller 302 described above and herein may include a machine-readable storage medium (e.g., memory 306) and one or more processors (e.g., processor 304). As used herein, a “machine-readable storage medium” may be any electronic, magnetic, optical, or other physical storage apparatus to contain or store information such as executable instructions, data, and the like. For example, any machine-readable storage medium described herein may be any of random access memory (RAM), volatile memory, non-volatile memory, flash memory, a storage drive (e.g., hard drive), a solid state drive, any type of storage disc, and the like, or a combination thereof. The memory 406 may store or include instructions executable by the processor 304. As used herein, a “processor” may include, for example one processor or multiple processors included in a single device or distributed across multiple computing devices. The processor 304 may be at least one of a central processing unit (CPU), a semiconductor-based microprocessor, a graphics processing unit (GPU), a field-programmable gate array (FPGA) to retrieve and execute instructions, a real time processor (RTP), other electronic circuitry suitable for the retrieval and execution instructions stored on a machine-readable storage medium, or a combination thereof.

[0050] As used herein, “signal communication” refers to electric communication such as hard wiring two components together or wireless communication, as understood by those skilled in the art. For example, wireless communication may be Wi-Fi®, Bluetooth®, ZigBee, or forms of near field communications. In addition, signal communication may include one or more intermediate controllers or relays disposed between elements that are in signal communication with one another.

[0051] In an example, the sensors or probes positioned and/or disposed throughout the system 100 (e.g., the preheating stage temperature sensor 314 and/or the pyrolysis stage temperature sensor 320A, 320B, and up to 320N) may be pressure transducers, flow meters, mass flow meters, Coriolis meters, analyzers other measurement sensors to determine a density, flow, temperature, composition, or other variable as will be understood by those skilled in the art, or some combination thereof. In such examples, the sensors may measure the density of a fluid or material, the flow of the fluid or material (e.g., through a section or zone of the system 100 or pyrolysis stage reactor), the temperature of the fluid or material, and/or the pressure within various locations of the system (e.g., within the preheating stage reactor and/or the pyrolysis stage reactor). As noted above, the controller 302 may be in signal communication with the sensors, probes, analyzers, or meters. The controller 302 may poll or request data from the sensors at various points or substantially continuously during a pyrolysis operation.

[0052] In an embodiment, the controller 302 may include instructions 308 to obtain the temperature at various points and/or locations or of materials in the system 300. For example, a preheating stage temperature sensor 314 or probe may provide, in real-time and/or continuously or at regular intervals, a signal to the controller 302 indicative of the temperature within a section or zone of the preheating stage reactor. For example, a pyrolysis stage temperature sensor 320A, 320B, and up to 320N or probe may provide, in real-time and/or continuously or at regular intervals, a signal to the controller 302 indicative of the temperature within a section or zone of the pyrolysis stage reactor. Other temperatures sensors and/or probes may be positioned at varying locations throughout the system, e.g., including, but not limited to, at each inlet, at each outlet, and/or within each zone of the plurality of zones.

[0053] The controller 302 may include instructions 310 to determine a corrected temperature for one or more zones of the preheating stage reactor. The controller 302 may determine such a corrected temperature based on the current temperature of the or within the preheating stage reactor and/or the type and/or size of the feed (e.g., plastic containing waste). For example, the preheating temperature utilized for a particular type of plastic containing waste may vary. If the type of feed and the current temperature exceed or are not within a selected threshold temperature or temperature range (e.g., a first threshold), then the controller 302 may determine a corrected temperature and adjust or increase output (e.g., via a signal indicating a new output) from a corresponding power source for the preheating stage 316 (e.g., decrease or increase current or magnetic field in the induction coil and/or screw or auger based on the temperature desired and/or the type of feed). The selected threshold temperature or temperature range may be based on temperatures or optimized temperatures selected to minimize char or carbon formation during pyrolysis or pre-heating.

[0054] In another embodiment, the corrected temperature (e.g., preheating temperature) may be determined based on a selected threshold temperature or temperature range at which high value chemicals (e.g., olefins and high aromatics) are produced. In other words, if a temperature is not within a range to produce a high value chemical, then the temperature may be adjusted. Further, such adjustments may occur based on the composition or other measured variable of the pyrolysis products or products produced during pyrolysis. In such an embodiment, sensors or analyzers may determine the composition or other variable of the products produced during pyrolysis and the controller 302 may determine adjusted temperatures based on those compositions or variables.

[0055] The controller 302 may include instructions 312 to determine a corrected temperature for one or more zones of the preheating stage reactor. The controller 302 may determine such a corrected temperature for each zone of the pyrolysis stage reactor based on the current temperature of the or within the pyrolysis stage reactor, the current temperature within each zone of the pyrolysis stage reactor (e.g., via the pyrolysis stage temperature sensor 320 A, 320B, and up to 322N, and/or the type and/or size of the feed (e.g., plastic containing waste). For example, the pyrolysis temperature used for a particular type of plastic containing waste may vary. If the type of feed and the current temperature exceed or are not within a selected threshold temperature or temperature range (e.g., the second threshold), then the controller 302 determine a corrected temperature and adjust or increase output (e.g., via a signal indicating a new output) from a corresponding power source for the pyrolysis stage 318A, 318B, and up to 318N. (e.g., decrease or increase current or magnetic field in the induction coil and/or screw or auger based on the temperature desired and/or the type of feed). The selected threshold temperature or temperature range may be based on temperatures or optimized temperatures selected to minimize char or carbon formation during pyrolysis or pre-heating

[0056] In another embodiment, the corrected temperature (e.g., pyrolysis temperature) may be determined based on a selected threshold temperature or temperature range at which high value chemicals (e.g., olefins and high aromatics) are produced. In other words, if a temperature is not within a range to produce a high value chemical, then the temperature may be adjusted. Further, such adjustments may occur based on the composition or other measured variable of the pyrolysis products or products produced during pyrolysis. In such an embodiment, sensors or analyzers may determine the composition or other variable of the products produced during pyrolysis and the controller 302 may determine adjusted temperatures based on those compositions or variables.

[0057] Although specific terms are employed, the terms are used in a descriptive sense only and not for purposes of limitation. Embodiments of systems and methods have been described in considerable detail with specific reference to the illustrated embodiments. However, it will be apparent that various modifications and changes can be made within the spirit and scope of the embodiments of systems and methods as described in the foregoing specification, and such modifications and changes are to be considered equivalents and part of this disclosure.

Claims

CLAIMS What is claimed is:

1. An electrically heated pyrolysis system, the system comprising: a pyrolysis stage reactor configured to receive a preheated plastic containing waste and one or more heating particles or catalyst and to output a gaseous product, solid residue, and used or spent one or more of heating particles or catalyst, the pyrolysis stage reactor comprising: one or more electrically heated screws or augers made of or coated with one or more of a catalytic material, a ferromagnetic material, a superparamagnetic material, or an electrically conductive heating material and positioned in an inner space of the pyrolysis stage reactor, each of the one or more electrically heated screws or augers configured to generate heat based on induction or direct electrical conduction, to rotate in a forward direction to agitate and transport the preheated plastic containing waste and one or more of heating particles or catalyst through the pyrolysis stage reactor, each of the one or more electrically heated screws or augers comprising one or more zones, each of the one or more zones including an independently controlled heating element; an induction coil per each of the one or more zones positioned circumferentially around an exterior surface of the pyrolysis stage reactor to provide additional heat to the preheated plastic containing waste via the one or more electrically heated screws or augers; and a gas duct positioned within the inner space of the pyrolysis stage reactor, the gas duct configured to support a partial vacuum environment and to collect gaseous products released from the preheated plastic containing waste during heating.

2. The system of claim 1, further comprising: a preheating stage reactor configured to receive the plastic containing waste and output the preheated plastic containing waste, the preheating stage reactor comprising: a second electrically heated screw or auger positioned in an inner space of the preheating stage reactor, the second electrically heated screw or auger configured to rotate in a forward direction to agitate and heat the plastic containing waste to a selected temperature, and transport a heated plastic containing waste to an outlet of the preheating stage reactor, wherein the second electrically heated screw or auger generates heat based on induction or direct electrical conduction, and wherein the second electrically heated screw or auger comprises one or more of the catalytic material, the ferromagnetic material, the superparamagnetic material, or an electrically conductive heating material; and a second induction coil positioned circumferentially around an exterior surface of the preheating stage reactor to provide additional heat to the plastic containing waste and pyrolysis products through the second electrically heated screw or auger.

3. The system of claim 2, wherein the second electrically heated screw or auger of the preheating stage reactor is comprised of the catalytic material, and wherein the one or more electrically heated screws or augers of the pyrolysis stage reactor are comprised of the ferromagnetic material with a Curie temperature higher than a temperature threshold of the pyrolysis stage reactor.

4. The system of claims 1, 2, or 3, wherein each of the one or more zones includes an opening for the gas duct to transport the gaseous products from the pyrolysis stage reactor for further use as a feedstock.

5. The system of claims 1, 2, 3, or 4, wherein each of the one or more zones includes an independent electromagnetic induction source to provide electrical heating at a selected temperature of a corresponding section of each of the one or more electrically heated screws or augers and heating particles or catalyst present at the corresponding section.

6. An electrically heated pyrolysis reactor, the electrically heated pyrolysis reactor comprising: a preheating stage reactor comprising: a first housing comprising: a first interior surface, a first inner space defined by a first space within the first interior surface, a first exterior surface, a first inlet positioned at a proximal end of a top portion of the first housing, the first inlet configured to allow plastic containing waste to flow therethrough to the first inner space of the first housing, a first outlet positioned at a distal end of the housing, a first electrically heated screw or auger positioned in the first inner space of the first housing, the first electrically heated screw or auger configured to (1) rotate in a forward direction to agitate, (2) heat the plastic containing waste to a first temperature, and (3) transport preheated plastic containing waste to the first outlet, and a first induction coil positioned around the first exterior surface to heat the plastic containing waste to the first temperature; a duct comprising: a second inlet connected to the first outlet of the preheating stage reactor, a third inlet to receive one or more of heating particles or catalyst, and a second outlet; and a pyrolysis stage reactor comprising: a second housing comprising: a second interior surface, a second inner space defined by a second space within the second interior surface, a second exterior surface, a fourth inlet connected to the second outlet of the duct, the fourth inlet to receive the preheated plastic containing waste from the second inlet of the duct and one or more of heating particles or catalyst from the third inlet of the duct, two or more electrically heated screws or augers comprising one or more of a catalytic material, a FM material, a SPM material, or an electrically conductive material and positioned in the second inner space of the pyrolysis stage reactor, each of the two or more electrically heated screws or augers configured to rotate in a forward direction to agitate and transport the preheated plastic containing waste and one or more of heating particles or catalyst through the pyrolysis stage reactor, each of the two or more electrically heated screws or augers comprising one or more sections corresponding to one or more zones based on composition or coating of the two or more electrically heated screws or augers, each of the one or more sections including an independently controlled heating element, a second induction coil positioned around the second exterior surface to provide additional heat to the preheated plastic containing waste, a gas duct positioned within the second inner space of the pyrolysis stage reactor, the gas duct configured to support a partial vacuum and to collect gaseous products released from the plastic containing waste, a third outlet connected to the gas duct and configured to remove gaseous products, and a fourth outlet positioned at a distal end of the pyrolysis stage reactor and configured to remove solid residue generated from the plastic containing waste and one or more of heating particles or catalyst.

7. The electrically heated pyrolysis reactor of claim 6, wherein the gas duct is positioned adjacent a top portion of the second interior surface of the pyrolysis stage reactor.

8. The electrically heated pyrolysis reactor of claims 6 or 7, wherein the one or more of heating particles or catalyst comprise one or more of ferromagnetic, superparamagnetic , or electrically conductive particles.

9. The electrically heated pyrolysis reactor of claims 6, 7, or 8, wherein each of the one or more sections includes one or more temperature sensors to measure one or more of a temperature in a corresponding section, a temperature of the preheated plastic containing waste in the corresponding section, or a temperature of pyrolysis products in the corresponding section.

10. The electrically heated pyrolysis reactor of claim 9, wherein a temperature provided by each of the one or more sections is based on one or more of the temperature in a corresponding section, a temperature of the preheated plastic containing waste in the corresponding section, or a temperature of pyrolysis products in the corresponding section.

11. The electrically heated pyrolysis reactor of claim 10, wherein the temperature provided by each of the one or more sections is optimized to minimize char formation in the corresponding section.

12. The electrically heated pyrolysis reactor of claim 6, 7, 8, 9, 10, or 11, wherein the gas duct is a grid separated gas duct.

13. The electrically heated pyrolysis reactor of claim 6, 7, 8, 9, 10, 11, or 12, wherein the one or more of heating particles or catalyst comprises a size and material sufficient to manage temperature in the pyrolysis stage reactor.

14. A method for operating an electrically heated pyrolysis reactor, the method comprising: introducing a plastic containing waste to a preheating stage reactor, the preheating stage reactor to include: a first electrically heated screw or auger positioned in a first inner space of the preheating stage reactor, the first electrically heated screw or auger configured to rotate in a forward direction to agitate, heat to a first temperature, and transport the plastic containing waste to a first outlet of the preheating stage reactor, and a first induction coil positioned around an exterior surface of the preheating stage reactor to provide additional heat to the plastic containing waste; operating the preheating stage reactor to the first temperature, via the first electrically heated screw or auger or the first induction coil of the preheating stage reactor, sufficient to prepare the plastic containing waste for pyrolysis; transferring prepared plastic containing waste and one or more of heating particles or catalyst to a pyrolysis stage reactor, the pyrolysis stage reactor to include: one or more electrically heated screws or augers coated with a catalytic material and positioned in a second inner space of the pyrolysis stage reactor, each of the one or more electrically heated screws or augers configured to rotate in a forward direction to agitate and transport the pre-heated plastic containing waste and one or more of heating particles or catalyst through the pyrolysis stage reactor, each of the one or more electrically heated screws or augers comprising one or more zones, each of the one or more zones including an independently controlled heating element, a second induction coil positioned around a second exterior surface to provide additional heat to the pre-heated plastic containing waste, and a gas duct positioned within the second inner space of the pyrolysis stage reactor, the gas duct configured to support a partial vacuum and to collect gaseous products, the gaseous products released from the preheated plastic containing waste during heating; operating each of the one or more zones of the pyrolysis stage reactor at a corresponding temperature, via the one or more electrically heated screws or augers or the second induction coil of the pyrolysis stage reactor, to produce a gaseous product and solid residue; and transferring the gaseous product from the pyrolysis stage reactor for further use.

15. The method of claim 14, further comprising: during operation of each of the one or more zones of the pyrolysis stage reactor at the corresponding temperature: determining, via signals from one or more temperature sensors positioned in each of the one or more zones, a current corresponding temperature of each of the one or more zones; and in response to any of the current corresponding temperatures being outside of one or more of (1) a first selected threshold temperature range at which the plastic containing waste forms char or carbon or (2) a second selected threshold temperature range at which high value chemical yield is increased: determining corrected corresponding temperatures for each of the one or more zones of the pyrolysis stage reactor, and driving a temperature within each of the one or more zones of the pyrolysis stage reactor to the corrected corresponding temperature.