IL319004A

IL319004A - Liquid reclamation and solid foam recycling/reclamation: compositions and methods

Info

Publication number: IL319004A
Application number: IL319004A
Authority: IL
Original assignee: Chemours Co Fc Llc
Priority date: 2022-08-31
Filing date: 2023-08-30
Publication date: 2025-04-01
Also published as: MX2025002306A; WO2024049866A3; KR20250061738A; AU2023335908A1; JP2025531060A; CN119789939A; WO2024049866A2; CA3264301A1; EP4580850A2

Claims

FL20 CLAIMS What is claimed is:

1. A process comprising: a) treating foam waste and/or spent halogenated liquids to produce reclaimed foam polymer or reclaimed halogenated liquids, wherein the foam waste or spent halogenated liquids is selected from the group consisting of refrigerants, refrigerant blends, blowing agents, solvent, and immersion coolants, and b) collecting or packaging the reclaimed foam polymer or reclaimed halogenated liquids.

2. The process of claim 1, wherein spent halogenated liquids are treated and comprise at least one of hydrochloroolefin (HCO), hydrofluoroolefin (HFO), hydrochlorofluoroolefin (HCFO), hydrofluoroether (HFE), hydrofluoroolefinic ether (HFOE), chlorofluoroolefin (CFO), fluoroketone, or hydrofluoroketone (HFK).

3. The process of claim 1, wherein foam waste is treated by crushing.

4. The process of any of claims 1-3, wherein the foam waste and/or spent halogenated liquids are collected from unreclaimed foam waste or unreclaimed halogenated liquids prior to a).

5. The process of claim 4, wherein the unreclaimed halogenated liquids are analyzed to determine the composition of the unreclaimed halogenated liquids and the presence and nature of any contaminants prior to a).

6. The process of claim 4, wherein physical and chemical properties of the unreclaimed halogenated liquids are determined prior to a).

7. The process of claim 5, wherein the treating of the foam waste and/or spent halogenated liquids comprises physical and chemical treatments.

8. The process of claim 5, wherein the treating of foam waste and/or spent halogenated liquids comprises at least one of moisture removal, contaminant removal and distillation. FL20

9. A process comprising steps of: a) identifying unreclaimed halogenated liquids selected from the group consisting of hydrochloroolefins (HCO), hydrofluoroolefins (HFO), hydrochlorofluoroolefins (HCFO), hydrofluoroethers (HFE), hydrofluoroolefinic ethers (HFOE), hydrofluoroketone (HFK), and mixtures of two or more, b) optionally identifying contaminants of the unreclaimed halogenated liquids of step a) c) selecting physical and/or chemical treatments based on step a) and optionally on step b), c) treating the unreclaimed halogenated liquids of steps a) and b) using the physical and/or chemical treatments selected in step c) to produce at least a partially reclaimed halogenated liquid, d) comparing the purity of the at least partially reclaimed halogenated liquid of step c) against an industry standard, e) optionally, further treating the partially unreclaimed halogenated liquid of step c) to produce a completely reclaimed halogenated liquid, f) optionally comparing the purity of the at least partially reclaimed halogenated liquid of step e) against an industry standard, g) optionally, compositionally rebalancing the partially or completely reclaimed halogenated liquid to be an industry compliant product; and h) collecting or packaging the product of step g).

10. The process of claim 1 wherein the foam waste comprises halogenated hydrocarbon generated foams which are crushed under vacuum to produce crushed foam and a vapor stream.

11. The process of claim 10, wherein the vapor stream is removed from the crushed foam.

12. The process of claim 11, wherein the crushed foam is isolated and pelletized.

13. The process of any of claims 1-9, wherein the halogenated liquid is selected from the group consisting of E 1,2-dichloroethene, HFO-E/Z-1336mzz, HCFO- FL20 E/Z-1224yd, HCFO-E/Z-1233zd, R-514A (HCO +HFO) olefin blend comprised of cis-1,1,1,4,4,4-hexafluorobut-2-ene and (R-1336mzz(Z)) and trans-1,2-dichloroethene (R-1130(E)), HFO-Z/E 1336mzz blends, liquid HFC-245fa, and 1,1,1,2,3,4,4,5,5,5-decafluoropentane.

14. The process of any of claims 1-9 wherein the halogenated liquid comprises a liquid selected from the group consisting of 1,1,1,2,3,4,4,5,5,5-decafluoropentane; MPHE; a blend comprising 94% trans-1,2-dichloroethylene, 5% MPHE and 1% 1,1,1,2,3,4,4,5,5,5-decafluoropentane; a blend comprising 94% trans-1,2-dichloroethylene, 5% MPHE and 1% Z-1336mzz; a blend comprising 98.4% Z-1336mzz and 1.6 % ethanol; a blend comprising 60% Z-1336mzz, 25% MPHE and 15% ethanol; a blend comprising 75% Z-1336mzz and 25% trans-1,2-dichloroethylene; (Z)-1,1,1,4,4,4-hexafluoro-2-butene; 1,1,1,4,5,5,5-heptafluoro-4-(trifluoromethyl)pent-2-ene; 1,1,1,2,2,3,3,6,6,7,7,8,8,8-tetradecafluoro-4-octene; 1,1,1,2,2,5,5,6,6,6-decafluorohex-3-ene; and 1,1,1,2,2,3,3,4,4,7,7,8,8,9,9,10,10,10-octadecafluorodec-5-ene.

15. The process of any of claims 1-9 wherein the halogenated liquid comprises one of a hydrofluoroether (HFE) and a hydrofluoroolefinic ether (HFOE).

16. The process of any of claims 15, wherein the hydrofluoroether (HFE) comprises a liquid selected from the group consisting of methoxy-nonafluorobutane; ethoxy-nonafluorobutane; 1,1,1,2,2,3,4,5,5,5-decafluoro 3-methoxy-4-(trfluoromethyl) pentane; 3-ethoxy-1,1,1,2,3,4,4,5,5,6,6,6-dodecafluoro-2-(trifluoromethyl)hexane; blend comprising 50% methyl nonafluorobutyl ether and 50% trans-1,2-dichloroethylene; blend comprising 52.7% methyl nonafluorobutyl ether, 44.6% trans-1,2-dichloroethylene and 2.7% ethanol; blend comprising 10% methyl nonafluorobutyl ether, 20% ethyl nonafluorobutyl ether, 68% trans-1,2-dichloroethylene and 2% isopropanol; blend comprising 10% methyl nonafluorobutyl ether, 20% ethyl nonafluorobutyl ether and 70% trans-1,2-dichloroethylene; blend comprising 95.5% methyl nonafluorobutyl ether and 4.5% isopropanol, and/or blend comprising 1,1,1,2,2,3,4,5,5,5-decafluoro 3-methoxy-4-(trfluoromethyl) pentane and trans-1,2-dichloroethylene. FL20

17. The process as in any of claims 1-9 and 13-16, wherein a tracer is added to at least one of the partially reclaimed or completely reclaimed halogenated liquid.

18. The process as in any of claims 1-9 and 13-16, where a stabilizer package is added to at least one of the partially reclaimed or completely reclaimed halogenated liquids and includes at least one antioxidant, at least one acid acceptor and at least one metal stabilizer where the antioxidant is selected from the group consisting of butylated hydroxytoluene, butylated hydroxyanisole, tertiary-butylhydroquinone, 4-methoxyphenol, propyl 3,4,5-trihydroxybenzoate, the acid acceptor is selected from epoxy butane, amine and acetaldehyde di-methylhydrazone (ADH), and the metal stabilizer is selected from N,N′-bis(salicylidene)-1,2-propanediamine, benzotriazole and its derivatives.

19. The process as in any of claims 1-9 and 13-16, wherein one of the spent and unreclaimed halogenated liquids comprises (i) HFO-E/Z-1336mzz and HFO-Z/E 1336mzz blends; (ii) HCFO-E/Z-1224yd, (iii) HCFO-E/Z-1233zd, or (iv) cis-1,1,1,4,4,4-hexafluorobut-2-ene (R-1336mzz(Z)) and trans-1,2-dichloroethene (R-1130(E)).

20. The process as in claim 5, wherein the unreclaimed halogenated liquids are analyzed using at least one analytical technique selected from the group consisting of GC-FID, GC-TCD, GC-MS, FTIR, Goetz Bub, Karl Fischer, Byk-Garner Color, and wherein the contaminants include one or more of acidity, moisture, and NAG.

21. The process as in claim 9, wherein the testing of step b) includes GC-MS or FTIR, and wherein the testing is for acidity, moisture, and NAG contents.

22. The process as in 21, wherein NAG testing involves using one of infrared sensors, UV sensors, NIR sensors, ion mobility or plasma chromatographs, gas chromatography, refractometry, mass spectroscopy, high temperature thick film sensors, thin film field effect sensors, pellistor sensors, Taguchi sensors and quartz microbalance sensors .

23. The process as in claim 1 or claim 9, wherein the treating comprises at least one treatment selected from the group consisting of distillation, adsorption, desorption, cryogenic cooling, water removal by distillation and/or desiccant FL20 drying, a solids filters, acidity neutralization, and high boiling residue/chloride distillation.

24. The partially or completely reclaimed composition of any of claims 13 to 16.

25. An integrated system comprising one or more of:  an unreclaimed liquid recovery station;  a waste foam collecting station;  a weighing and testing station comprising analytical systems to determine physical and chemical properties of the unreclaimed liquid selected from the group consisting of HFO-E/Z-1336mzz; HCFO-1224yd; HCFO-1233zd; R-514A (olefin blend comprised of cis-1,1,1,4,4,4-hexafluorobut-2-ene (R-1336mzz(Z)) and trans-1,2-dichloroethene (R-1130(E)); HFO-Z/E 1336mzz blends; liquid HFC-245fa; 1,1,1,2,3,4,4,5,5,5-decafluoropentane; MPHE; a blend comprising 94% trans-1,2-dichloroethylene, 5% MPHE and 1% 1,1,1,2,3,4,4,5,5,5-decafluoropentane; a blend comprising 94% trans-1,2-dichloroethylene, 5% MPHE and 1% Z-1336mzz; a blend comprising 98.4% Z-1336mzz and 1.6 % ethanol; a blend comprising 60% Z-1336mzz, 25% MPHE and 15% ethanol; a blend comprising 75% Z-1336mzz and 25% trans-1,2-dichloroethylene; (Z)-1,1,1,4,4,4-hexafluoro-2-butene; 1,1,1,4,5,5,5-heptafluoro-4-(trifluoromethyl)pent-2-ene; 1,1,1,2,2,3,3,6,6,7,7,8,8,8-tetradecafluoro-4-octene; 1,1,1,2,2,5,5,6,6,6-decafluorohex-3-ene; and 1,1,1,2,2,3,3,4,4,7,7,8,8,9,9,10,10,10-octadecafluorodec-5-ene;  a waste foam treatment station comprising at least one crusher, at least one solids sorter, at least one pelletizer with vapor separation;  a first purification system for receiving and treating unreclaimed liquid from said weighing, testing station, vapor from said waste foam treatment station and first transport lines;  a second purification system for receiving and treating liquid from the first purification system, and second transport lines;  a target refrigerant system in flow communication with the first and second transport lines to receive treated liquid from the first and second FL20 purification systems for adjusting levels of reclaimed liquid components to target refrigerant levels of the AHRI 700 standards following purification at said first and second purification stations, including a blending station to provide reclaimed liquid blends components consistent with AHRI 7standards;  a stabilizer package dispensing station to add effective quantities of stabilizer package comprising at least one antioxidant, at least one acid acceptor and at least one metal stabilizer; and,  a purity check station to check the purity of unreclaimed liquid before purification, after the first and/or second purification treatments, and of the at least one first treated product and determining whether or not the first treated product meets or exceeds AHRI 700 standards

26. The system as in claim 25, wherein the weighing and testing station includes a scale and at least one of a GC-FID, GC-TCD, GC-MS, FTIR, Goetz Bub, Karl Fischer, and Byk-Garner Color detector.

27. The system as in claim 25, wherein the weighing and testing station includes one of infrared sensors, UV sensors, NIR sensors, ion mobility or plasma chromatographs, gas chromatography, refractometry, mass spectroscopy, high temperature thick film sensors, thin film field effect sensors, pellistor sensors, Taguchi sensors and quartz microbalance sensors.

28. The system as in claim 25, wherein the weighing and testing stations include a scale, GC-MS and Taguchi sensor.

29. The system as in claim 25, wherein at least one of the first and second purification systems includes one of a distillation column, and adsorption/desorption column, and cryogenic cooler.

30. The system as in claim 25, wherein at least one of the first and second purification systems includes at least one of a NCG purge unit, a water distillation or desiccant dryer unit, a solids filter unit, and an acidity neutralizer, and a high distillation residue column. FL20

31. A process of exchanging heat comprising circulating the reclaimed halogenated liquid of any of claims 1-24 and transferring heat to and from the reclaimed halogenated liquid.

32. A process of using the reclaimed halogenated liquids of any of claims 1-24 as aerosol propellants, refrigerants, cleaning agents, expansion agents for thermoplastic and thermoset foams, heat transfer media, liquid dielectrics, power cycle working fluids, polymerization media, particulate removal fluids, carrier fluids, buffing abrasive agents, and displacement drying agents heat exchanging.

33. A process of exchanging heat comprising charging a system with a working fluid selected from at least one of reclaimed hydrofluoroolefins (HFOs), hydrochlorofluoroolefin (HCFOs), hydrofluoroethers (HFEs), hydrofluoroolefinic ether (HFOEs), and circulating the working fluid.

34. A process of cooling electrical components comprising directly contacting the component with at least one of reclaimed hydrofluoroolefin (HFO), hydrochlorofluoroolefin (HCFO), hydrochloroolefin (HCO), hydrofluoroethers (HFE), hydrofluoroolefinic ether (HFOE).

35. A process comprising using the reclaimed halogenated composition of any of claims 1-24 in refrigeration, in air conditioning, in heating, in heat transfer, in conversion of heat into mechanical work in a power cycle, as a foam blowing agent, as a solvent, or in preventing or quenching an electric discharge.

36. A process comprising using the reclaimed halogenated composition of any of claims 1-24 with a refrigerant component, an air conditioning component, a heating component, a heat transfer component, a working fluid component, a blowing agent component, a solvent component, or a dielectric component.

37. The process of any of claims 1, 10, 11 and 12, wherein the foam waste is a polyurethane foam which is crushed, pelletized and converted chemically reduced a liquid polyol.

38. The system of claims 25, wherein the waste foam treatment station is adapted to crush and pelletize polyurethane foam for one of subsequent use or recycle to a liquid polyol. FL20

39. At least one of a container and tank filed with the reclaimed composition of any of claims 17 or 24.

40. The process of any of claims 1-9, wherein the halogenated liquid comprises one or more of a fluoroketone (FK) and/or a hydrofluoroketone (HFK).

41. The process of any of claims 1-9, wherein the halogenated liquid comprises one or more fluoroketones.

42. The process of claim 41, wherein the fluoroketone comprises dodecafluoro-2-methylpentan-3-one.

43. A composition comprising at least one reclaimed compound, wherein the at least one reclaimed compound is selected from one of Table 1, Table 2, Table 3, or Table 4, and comprises one or more tracers.

44. The composition of claim 43, wherein the at least one reclaimed compound is selected from Table 2.

45. The composition of claim 43, wherein the at least one reclaimed compound is selected from Table 1.

46. The composition of claim 43, wherein the at least one reclaimed compound is selected from Table 3.

47. The composition of claim 43, wherein the at least one reclaimed compound is selected from Table 4.

48. A system comprising a contained supply of reclaimed/re-blended refrigerant, a refrigerant circuit including at least a charging valve and compressor and transfer line controllable connecting said contained supply of reclaimed/re-blended refrigerant to said charging valve.

49. A system comprising a purification system, a contained supply of reclaimed/re-blended refrigerant connected to the system, a refrigerant circuit including at least a charging valve and compressor and transfer line controllable connecting said contained supply of reclaimed/re-blended refrigerant to said charging valve.