JP2023548389A - Systems and methods for converting waste plastic materials into useful products and solids compression units - Google Patents

Abstract

A system may be provided for converting waste plastic materials into useful products. The system includes a sequential heat treatment arrangement comprising a melting stage and a thermal to catalytic pyrolysis stage downstream of the melting stage for subjecting the molten mixture to a thermal pyrolysis process followed by a catalytic pyrolysis process. Can be done. The thermal to catalytic pyrolysis stage can include at least two catalyst feed points distributed along the thermal to catalytic pyrolysis stage. The thermal to catalytic pyrolysis stage is a thermal to catalytic pyrolysis stage in which the thermal to catalytic pyrolysis stage may be operable to selectively feed catalyst through any one or more of the at least two catalyst feed points to convert a thermal pyrolysis process to a catalytic pyrolysis process. . [Selection diagram] None

Description

Detailed description of the invention

[Technical field]
Various embodiments generally relate to systems and methods for converting waste plastic materials into useful products, and solids compaction units for the systems. In particular, the various embodiments relate generally to pyrolysis systems and methods for converting waste plastic materials into useful products, and solids compression units for the present pyrolysis systems.

[background]
Generally, waste plastics can be converted into useful gas, liquid and/or solid products by pyrolysis processes. However, a number of challenges lie in the adoption of pyrolysis processes for waste plastics. For example, challenges include inconsistent quality and mixtures of waste plastic raw materials/feedstocks, or contaminants that require costly separation and/or pretreatment to ensure the quality of raw materials/feedstocks for pyrolysis processes. This includes some waste plastic raw materials/raw materials. Another challenge is that it is difficult to control and achieve the desired pyrolysis products, resulting in dedicated pyrolysis systems/equipment for certain waste plastic product raw materials/feedstocks, which is costly.

Therefore, there is a need to provide a more efficient and versatile system and method for pyrolysis of waste plastic materials that addresses the above problems.

[Summary of the invention]
According to various embodiments, a system for converting waste plastic materials into useful products can be provided. The system can include a continuous heat treatment arrangement. According to various embodiments, the continuous heat treatment arrangement can include a melting stage to melt compressed waste plastic feed produced from waste plastic material to form a molten mixture. According to various embodiments, the sequential heat treatment arrangement includes a thermal to catalytic pyrolysis stage downstream of the melting stage that subjects the molten mixture to a thermal pyrolysis process, followed by a pyrolysis gas product and a pyrolysis solid. It can further include a catalytic pyrolysis process to produce a residue. According to various embodiments, the thermal to catalytic pyrolysis stage can include at least two catalyst feed points distributed along the thermal to catalytic pyrolysis stage. According to various embodiments, the thermal to catalytic pyrolysis step includes a thermal to catalytic pyrolysis step in which the thermal to catalytic pyrolysis step includes a change in the proportions of the thermal to catalytic pyrolysis process. selectively feeding catalyst at various points along the targeted to catalytic pyrolysis stage by any one or more of at least two catalyst feed points to convert the thermal pyrolysis process to a catalytic pyrolysis process; may be operable to do so. According to various embodiments, the continuous heat treatment arrangement can further include a termination stage downstream of the thermal to catalytic pyrolysis stage to heat the pyrolysis solid residue to convert it to a solid product. .

According to various embodiments, a method of converting waste plastic materials into useful products may be provided. According to various embodiments, the method includes the step of introducing a compressed waste plastic feed produced from waste plastic material into a melting stage of a continuous heat treatment arrangement of a system for converting waste plastic material into useful products. can include. According to various embodiments, the melting step can melt the compressed waste plastic feed to form a molten mixture. The method includes selectively feeding a catalyst through any one or more of at least two catalyst feed points of a thermal to catalytic pyrolysis stage of a continuous heat treatment arrangement of the system to produce output from the system. Varying the proportions of thermal and catalytic pyrolysis processes within the thermal to catalytic pyrolysis stages based on the desired end product or the characteristics of the waste plastic material or feed introduced into the system. The method may further include: According to various embodiments, a thermal to catalytic pyrolysis stage can be present downstream of the melting stage, subjecting the molten mixture to the pyrolysis process and then subjecting the molten mixture to pyrolysis gas products and pyrolysis solid residues. ) can be subjected to a catalytic pyrolysis process to produce The method can further include removing solid products from the termination stage of the continuous heat treatment arrangement of the system. According to various embodiments, the termination stage may be downstream of the thermal to catalytic pyrolysis stage, heating the pyrolysis solid residue to convert it to a solid product.

According to various embodiments, a solids compression unit comprises at least two rotating screws arranged in series from an inlet of the solids compression unit to an outlet of the solids compression unit, the at least two rotating screws moves the solid material from an inlet of the solids compression unit to an outlet of the solids compression unit, the solids compression unit is configured such that at least two rotating screws are operable in cooperation to compress the solid material. provided.

In the drawings, like reference features generally refer to the same part throughout the different drawings. The drawings are not necessarily to scale, emphasis instead generally being placed upon illustrating the principles of the invention. In the following description, various embodiments are described with reference to the following drawings.

1 is a schematic diagram of a system for converting waste plastic materials into useful products, according to various embodiments. FIG. 1B is a schematic diagram of a compression unit of the system of FIG. 1A, according to various embodiments. FIG. 1A is a schematic diagram of a secondary compression unit of the system of FIG. 1A, according to various embodiments; FIG.

[Detailed Description of Preferred Embodiments]
Embodiments described below in the context of devices are equally valid for the individual methods, and vice versa. Furthermore, it will be appreciated that the embodiments described below may be combined, eg, portions of one embodiment may be combined with portions of another embodiment.

"on", "over", "top", "bottom", "down", "side", "back" , "left", "right", "front", "lateral", "side", "up", "down" When used in the following description, terms such as ``are used for convenience and to aid in understanding relative position or orientation, and refer to any device or structure, or any device or structure. It should be understood that it is not intended to limit the orientation of any part of the body. Additionally, the singular words "a," "an," and "the" include plural references unless the context clearly dictates otherwise. Similarly, the term "or" is intended to include "and" unless the context clearly dictates otherwise.

Various embodiments generally relate to systems for converting waste plastic materials into useful products and methods for converting waste plastic materials into useful products. According to various embodiments, waste plastic materials can include municipal waste, which can include various types of polymers, such as, but not limited to, polypropylene, polyethylene, and the like. According to various embodiments, useful products include, but are not limited to, hydrocarbons having carbon atoms in the range of C2 to C34, preferably petrochemical process or fuels (e.g., naphtha, diesel or other Hydrocarbon products) and solid products can include suitable hydrocarbons. According to various embodiments, solid products can include, but are not limited to, solid carbon (eg, carbon black) or other solids contained in waste plastic materials. Various embodiments generally relate to pyrolysis systems for converting waste plastic materials into useful products, and pyrolysis methods for converting waste plastic materials into useful products. Accordingly, various embodiments may explore implementing systems and methods for pyrolyzing or degrading waste plastic materials into useful products. According to various embodiments, the system may include an apparatus or arrangement or equipment for performing heat treatment for pyrolysis of waste plastic materials.

According to various embodiments, the system can include a heat treatment arrangement or apparatus or equipment for performing pyrolysis of waste plastic materials. According to various embodiments, the heat treatment arrangement may be configured to perform a heat treatment sequence that includes a thermal pyrolysis process followed by a catalytic pyrolysis process. According to various embodiments, the heat treatment arrangement performs a thermal pyrolysis process on the waste plastic material within the heat treatment arrangement to modify or change the final product produced from the waste plastic material by the system. and the catalytic pyrolysis process, or may be configured to adjust or modify the ratio. Therefore, depending on the desired end product, the proportions of thermal and catalytic pyrolysis processes within the heat treatment arrangement will vary as necessary to produce the desired end product. Variations may be made or adjusted or varied to subject the waste plastic material to a heat treatment sequence having a proportion with the pyrolysis process. According to various embodiments, the ratio of thermal pyrolysis process to catalytic pyrolysis process is the ratio of the duration (or retention period) of the thermal pyrolysis process to the duration (or retention period) of the catalytic pyrolysis process. It can be done.

According to various embodiments, the heat treatment arrangement converts a thermal pyrolysis process into a catalytic pyrolysis process at various points along the heat treatment arrangement to change points along the heat treatment arrangement; At least two (e.g., two or more) catalyst feed points along the heat treatment arrangement can be included for feeding catalyst to the heat treatment arrangement, such that the thermal pyrolysis process is a catalytic pyrolysis process. Switch to . According to various embodiments, the systems and methods can include selectively varying points along the heat treatment arrangement where a catalyst is added to produce the desired amount of output from the system. The thermal pyrolysis process is converted or changed to a catalytic pyrolysis process or switched or converted based on the characteristics of the final product or the waste plastic material or feed introduced into the system. For example, according to various embodiments, the catalyst comprises at least two catalyst feed ports of the heat treatment arrangement to achieve, obtain, or realize the required ratio of thermal pyrolysis process to catalytic pyrolysis process. may be selectively added to any one or more of the following: the thermal pyrolysis process being converted to a catalytic pyrolysis process by feed or addition of catalyst at the necessary points along the heat treatment arrangement; or change or switch or transform. Thus, the catalyst may be added or fed or dosed at the point where the catalytic pyrolysis process is to take place. For example, according to various embodiments, the catalyst may be added selectively to the zone, or stage, or chamber, or reactor in which the catalytic pyrolysis process is to take place. Various embodiments are distinct and different from conventional catalytic pyrolysis systems and methods whereby the catalyst is typically mixed with waste plastic material in a feed stage (e.g., feedstock feed zone). .

According to various embodiments, the ratio of thermal pyrolysis processes and catalytic pyrolysis processes along the heat treatment arrangement can be varied to produce the desired end product produced from the system. , or adjustable, the various embodiments provide a versatile and efficient system and method. Various embodiments can accommodate a wide variety of waste plastic materials, including, but not limited to, inconsistent quality and mixtures of waste plastic materials, or waste plastic materials with contaminants, and along with heat treatment arrangements. By varying the proportions of thermal and catalytic pyrolysis processes, it may be possible to produce the desired final product produced. Additionally, various embodiments also monitor the final product output from the system and vary the proportions of thermal and catalytic pyrolysis processes along the heat treatment configuration. Simple and easy feedback control for the system may also be enabled or implemented to adjust or fine-tune the final product produced from the system.

According to various embodiments, the point(s) along the system at which the catalyst is added is selectively varied so that the catalyst is added to the same zone, stage, or chamber where the catalytic pyrolysis actually takes place. Or by selective addition to the reactor, the ideal amount of catalyst can be determined, measured, and added to the system without waste of catalyst. Further, the catalyst may be added to the systems of various embodiments to the point where the waste plastic material contained therein has already been disrupted to a size small enough to fit into the pore sites of the catalyst used. good. Therefore, any catalyst added to the systems and methods according to the various embodiments can perform its catalytic function with minimal or no waste. According to various embodiments, the catalyst is not mixed with the waste plastic feed at the beginning of the system or process (eg, in the crude feed zone). Accordingly, various embodiments may include molecules of the waste plastic feed that are too large to enter the pore sites of the catalyst, or those large molecules of the waste plastic feed that block the pore sites of the catalyst before the catalyst can be activated. Waste or deactivation of the catalyst due to molecules or the like can be avoided or minimized. Accordingly, systems and methods according to various embodiments can provide cost savings due to no or minimized catalyst wastage.

Various embodiments also relate to solids compression units for the systems described herein. According to various embodiments, the system can include at least one solids compaction unit for compacting waste plastic material before feeding it to the heat treatment arrangement. Accordingly, the at least one solids compression unit is capable of compressing the waste plastic material to remove moisture and air so as to prevent moisture and air from entering the heat treatment arrangement. According to various embodiments, the system may also include at least one other solids compression unit for removing solid products from the heat treatment arrangement. According to various embodiments, solid product can be removed from the system by at least one other solids compression unit without shutting down the process. According to various embodiments, the solids compression unit includes at least two solids compression units operably arranged in series to reduce the volumetric flow rate of solids from one rotating screw to a subsequent rotating screw. may include a rotating screw. Because the volumetric flow rate produced by each of the at least two rotating screws is reduced, the solids (e.g. waste plastic material or solid products) are compressed as the solids move along the at least two rotating screws. Can be compressed into solids. Thus, by reducing the volumetric flow rate of at least two rotating screws arranged in series, the solids can be moved at different volumetric flow rates along different segments of the solids compression unit, which , the volumetric flow rate between different segments decreases from the inlet to the outlet of the solids compression unit. According to various embodiments, solids (e.g., waste plastic material or solid products) are compressed or compacted by a solids compression unit to operate the system or feed the waste plastic material. and/or during solid product removal, air may be prevented from entering the system and/or gaseous products generated from the system may be prevented from escaping to the atmosphere.

The following examples relate to various embodiments:
Example 1 is a system for converting useful products from waste plastic materials that includes a continuous heat treatment arrangement. The continuous heat treatment arrangement may include a melting stage for melting compressed waste plastic feed produced from waste plastic material to form a molten mixture. The sequential heat treatment arrangement includes a thermal to catalytic pyrolysis stage downstream of the melting stage in which the molten mixture is subjected to a thermal pyrolysis process, followed by a catalytic pyrolysis stage to produce a pyrolysis gas product and a pyrolysis solid residue. Further processes may be included. The thermal to catalytic pyrolysis stage can include at least two catalyst feed points distributed along the thermal to catalytic pyrolysis stage. The thermal to catalytic pyrolysis stage is a thermal to catalytic pyrolysis stage in which the thermal to catalytic pyrolysis stage In various respects, any one or more of the at least two catalyst feed points may be operable to selectively feed catalyst to convert a thermal pyrolysis process to a catalytic pyrolysis process. The continuous heat treatment arrangement can further include a termination stage downstream of the thermal to catalytic pyrolysis stage to heat the pyrolysis solid residue to convert it to a solid product.

In Example 2, the subject matter of Example 1 may optionally include a waste material compression unit upstream of the continuous heat treatment arrangement. The waste material compression unit may be operable to compress waste plastic material to remove air and moisture to produce a compressed waste plastic feed for feeding into a continuous heat treatment arrangement.

In Example 3, the subject matter of Example 1 or Example 2 is that the temperature range of the termination stage is higher than the temperature range of the thermal to catalytic pyrolysis stage, and the temperature range of the thermal to catalytic pyrolysis stage is higher than the temperature range of the melting stage. may optionally include higher than the range.

In Example 4, the subject matter of any one of Examples 1-3 is such that the thermal to catalytic pyrolysis stage heats the molten mixture received from the melting stage at or above the pyrolysis temperature of the molten mixture. a first thermal pyrolysis zone, one or more intermediate variable zones, each intermediate variable zone having a catalyst feed port at the beginning of the intermediate variable zone; a catalyst feed port serving as one of at least two catalyst feed points along the thermal to catalytic pyrolysis stage, and at least two catalyst feed points along the thermal to catalytic pyrolysis stage for receiving catalyst; may optionally include including a last catalytic pyrolysis zone having a catalyst feed port at the beginning of the last catalytic pyrolysis zone that serves as the final catalyst feed point of the catalytic pyrolysis zone. At various points along the thermal to catalytic pyrolysis stage, the catalyst can be placed in one or more intermediate variable zone catalyst feed ports or at the final catalytic pyrolysis process to convert the thermal pyrolysis process into a catalytic pyrolysis process. It may be fed from the catalyst feed port of the catalytic pyrolysis zone.

In Example 5, the subject matter of Example 4 optionally provides that the last catalytic pyrolysis zone of the thermal to catalytic pyrolysis stage includes at least one pyrolysis gas outlet for discharging pyrolysis gas products. May be included by choice.

In Example 6, the subject matter of any one of Examples 1-5 may optionally include that the termination stage includes at least one pyrolysis gas outlet for releasing pyrolysis gas products. good.

In Example 7, the subject matter of any one of Examples 1-6 may optionally include that the termination stage includes at least one solid product outlet for removing solid product.

In Example 8, the subject matter of any one of Examples 1-7 may optionally include that the continuous heat treatment arrangement includes a reactor that includes a thermal to catalytic pyrolysis stage.

In Example 9, the subject matter of any one of Examples 1-7 may optionally include a continuous heat treatment arrangement comprising a reactor containing a melting stage and a thermal to catalytic pyrolysis stage.

In Example 10, the subject matter of any one of Examples 1-7 may optionally include a continuous heat treatment arrangement comprising a reactor including a thermal to catalytic pyrolysis stage and a termination stage.

In Example 11, the subject matter of any one of Examples 1-7 may optionally include a continuous heat treatment arrangement comprising a reactor comprising a melting stage, a thermal to catalytic pyrolysis stage, and a termination stage. good.

In Example 12, the subject matter of any one of Examples 8-11 may optionally include that the reactor comprises a cylindrical shaped reactor.

In Example 13, the subject matter of any one of Examples 8-12 may optionally include that the reactor includes a conveyor mechanism configured to transport the material along the length of the reactor. .

In Example 14, the subject matter of Example 13 may optionally include that the conveyor mechanism includes at least one screw conveyor extending along the entire length of the reactor.

In Example 15, the subject matter of any one of Examples 8-14 may optionally include that the reactor is tilted with a rate of rise per horizontal distance of 1:250 to 1:20.

In Example 16, the subject matter of any one of Examples 8-15 may optionally include that the reactor is tilted with a rate of rise per horizontal distance of 1:200 to 1:50.

In Example 17, the subject matter of any one of Examples 8-16 may optionally include that the reactor is tilted with a rate of rise per horizontal distance of 1:150 to 1:80.

In Example 18, the subject matter of any one of Examples 1 to 17 is such that the waste material compression unit includes at least a first rotating screw and a second rotating screw arranged in series, and the waste plastic material is optionally comprising being fed to the waste material compression unit at the first end of the first rotating screw and being transferred from the waste material compression unit via the first rotating screw and then the second rotating screw. But that's fine.

In Example 19, the subject matter of Example 18 may optionally include that the rotational speed of the first rotating screw of the waste material compression unit is greater than the rotational speed of the second rotating screw of waste material compression.

In Example 20, the subject matter of Example 18 may optionally include that the diameter of the screw shaft of the first rotating screw is smaller than the diameter of the screw shaft of the second rotating screw.

In Example 21, the subject matter of Example 18 may optionally include that the pitch range of the first rotating screw is greater than the pitch of the second rotating screw.

In Example 22, the subject matter of Examples 1 to 21 is at least one solid product compression unit for compressing a solid product withdrawal from a terminal stage of a continuous heat treatment arrangement, the solid product compression unit comprising: , optionally including at least one solid product compression unit downstream of the termination stage of the continuous heat treatment arrangement.

In Example 23, the subject matter of Example 22 may optionally include that the solid product compression unit includes a first rotating screw and a second rotating screw.

In Example 24, the subject matter of Example 23 may optionally include that the first rotating screw of the solid product compression unit and the second rotating screw of the solid product compression unit are arranged in series.

In Example 25, the subject matter of Example 23 or Example 24 is that the first rotating screw of the solid product compression unit and the second rotating screw of the solid product compression unit have the same pitch range of 70 mm to 220 mm or 80 mm to 200 mm. may optionally include having.

In Example 26, the subject matter of Examples 23 to 25 is such that the second rotating screw of the solid product compression unit has a rotational speed of 40% to 100%, or 55% of the rotational speed of the first rotating screw of the solid product compression unit. Optionally may include having a rotation speed of ˜98%, or 70% to 97%, or 80% to 95%.

In Example 27, the subject matter of any one of Examples 22-26 may optionally include that the solid product compression unit further includes a third rotating screw.

In Example 28, the subject matter of Example 27 is such that the first rotating screw of the solid product compression unit, the second rotating screw of the solid product compression unit and the third rotating screw of the solid product compression unit are arranged in series. may optionally include that the

In example 29, the subject matter of example 27 or example 28 is such that the first rotating screw of the solid product compression unit, the second rotating screw of the solid product compression unit and the third rotating screw of the solid product compression unit are may optionally include having the same pitch range.

In Example 30, the subject matter of any one of Examples 27-29 is such that the third rotating screw of the solid product compression unit has a rotational speed of 35% to 35% of the rotational speed of the first rotating screw of the solid product compression unit. It may optionally include having a rotation speed of 97%, or 40% to 95%, or 50% to 90%, or 60% to 88%, or 70% to 85%.

In Example 31, the subject matter of Examples 23-30 may optionally include that the solid product compression unit further comprises one or more additional rotating screws.

In Example 32, the subject matter of Example 23 is that the pitch range of the first rotating screw of the solid product compression unit is greater than the pitch range of the second rotating screw of the solid product compression unit; Optionally, the pitch range of the second rotating screw is 70% to 100% or 75% to 99% or 78% to 98% of the pitch range of the first rotating screw of the solid product compression unit. But that's fine.

In Example 33, the subject matter of Example 23 is a third rotating screw, wherein the pitch range of the first rotating screw of the solid product compression unit is greater than the pitch range of the second rotating screw of the solid product compression unit. is also greater, and the pitch range of the second rotating screw of the solid product compression unit is equal to or greater than the pitch range of the third rotating screw of the solid product compression unit; the pitch range of the first rotating screw of the solid product compression unit is 70% to 100% or 75% to 99% or 78% to 98% of the pitch range of the first rotating screw of the solid product compression unit; The third rotary screw has a pitch range of 65% to 98%, or 75% to 95%, or 80% to 93% of the pitch range of the first rotary screw of the solid product compression unit. A rotating screw may optionally be included.

In Example 34, the subject matter of Examples 23 to 26 is such that the shaft diameter of the first rotating screw of the solid product compression unit is smaller than the shaft diameter of the second rotating screw of the solid product compression unit, Optionally, the shaft diameter of the second rotating screw of the unit may be 100% to 135%, or 105% to 130% of the shaft diameter of the first rotating screw of the solid product compression unit.

In Example 35, the subject matter of Examples 23 to 26 is a third rotating screw, wherein the shaft diameter of the first rotating screw of the solid product compression unit is such that the shaft diameter of the second rotating screw of the solid product compression unit is the shaft diameter of the second rotating screw of the solid product compression unit is equal to or greater than the shaft diameter of the third rotating screw of the solid product compression unit; The shaft diameter of the second rotating screw is 100% to 135% or 105% to 130% of the shaft diameter of the first rotating screw of the solid product compression unit, and the shaft diameter of the third rotating screw of the solid product compression unit is Optionally, a third rotating screw as described above may be included, the shaft diameter of which is 105% to 155% or 108% to 145% of the shaft diameter of the first rotating screw of the solid product compression unit.

In Example 36, the subject matter of any one of Examples 23-35 is such that the solid product compression unit further includes a cooling jacket around at least one rotating screw of the solid product compression unit, and wherein the solid product compression unit further includes a cooling jacket around at least one rotating screw of the solid product compression unit; may optionally include circulating a cooling jacket to cool the solid product being compressed.

In Example 37, the subject matter of any one of Examples 1 to 36 is that the termination step includes a first heating zone that raises the temperature of the solid product and a second heating zone that maintains the solid product at an elevated temperature. may optionally include.

In Example 38, the subject matter of any one of Examples 5-37 may optionally include, in combination with Example 5 or Example 6, that at least one pyrolysis gas outlet includes a vacuum pump.

In Example 39, the subject matter of any one of Examples 5 to 38, in combination with Example 5 or Example 6, provides at least one pyrolysis gas for condensing long chain carbon compounds in the pyrolysis gas product. It may optionally include at least one heat exchanger unit coupled to the outlet.

In Example 40, the subject matter of Example 39 is such that the at least one heat exchanger unit is configured to minimize pressure drop in the thermal to catalytic pyrolysis stage, and the at least one heat exchanger is configured to pipe heat exchangers or shell and tube heat exchangers, preferably at least one heat exchanger may optionally include a double pipe heat exchanger.

In Example 41, the subject matter of Example 39 or Example 40 comprises at least one heat exchanger unit downstream of at least one heat exchanger unit for removing residual particulates or heavy hydrocarbons, or a combination thereof, from the pyrolysis gas product. One gas separator unit may optionally be included.

In Example 42, the subject matter of Example 41 may optionally include at least one gas separator unit comprising a cyclone separator or a drum separator.

In example 43, the subject matter of example 41 or example 42 comprises, downstream of the at least one gas separator unit, at least one product separation for separating and purifying the pyrolysis gas products to obtain the desired final product. A separation and purification unit may optionally be included.

Example 44 is a method of converting waste plastic materials into useful products. The method can include introducing a compressed waste plastic feed produced from waste plastic material according to any one of Examples 1-43 or Example 121 into a continuous heat treatment arrangement of the system. The method includes feeding a catalyst through one or more of at least two catalyst feed points of a thermal to catalytic pyrolysis stage in a continuous heat treatment arrangement; The method may include varying the proportions of the catalytic pyrolysis process and the catalytic pyrolysis process. The method may include removing solid product from the termination stage of the system.

In Example 45, the subject matter of Example 44 is that adjusting the proportions of the thermal and catalytic pyrolysis processes within the thermal to catalytic pyrolysis step produces the desired final product produced from the system. The method may optionally include monitoring at least one property of the final product produced from the system to determine whether it is necessary for the process to proceed.

In Example 46, the subject matter of Example 45 provides a catalyst feed through one or more of the at least two catalyst feed points based on the proportions of thermal and catalytic pyrolysis processes determined to be necessary. may optionally include the step of feeding.

In Example 47, the subject matter of Example 45 or Example 46 may optionally include that at least one property of the final product that is monitored is specific gravity.

In Example 48, the subject matter of any one of Examples 44-47 may optionally include withdrawing pyrolysis gas products from a continuous heat treatment arrangement.

In Example 49, the subject matter of any one of Examples 44-48 provides that the system, when according to any one of Examples 39-43, removes pyrolysis gas products by at least one heat exchanger unit. Optionally, a step of condensing long chain carbon compounds may be included.

In Example 50, the subject matter of Example 49 may optionally include returning the long chain carbon compound to the thermal to catalytic pyrolysis stage.

In Example 51, the subject matter of any one of Examples 44-50 provides that the system, when according to any one of Examples 41-43, removes residual gas from pyrolysis gas products by at least one gas separator unit. Optionally may include removing particulates or heavy hydrocarbons, or a combination thereof.

In Example 52, the subject matter of Example 51 may optionally include returning residual particulates or heavy hydrocarbons, or a combination thereof, to the thermal to catalytic pyrolysis stage.

In Example 53, the subject matter of Examples 44-52 is that the catalytic pyrolysis process °C, or at a temperature in the range of 350°C to 400°C.

In Example 54, the subject matter of any one of Examples 44-53, when the system is according to any one of Examples 2-43 in combination with Example 2, provides 2.0 The method may optionally include compressing the waste plastic material by a compression ratio in the range of ˜5.0.

In Example 55, the subject matter of Example 54 compresses waste plastic material to remove air through a waste material compression unit, such that the compressed waste plastic feed output from the compression unit is between 2% and 16% by weight. %, preferably in the range of 5% to 10% by weight.

In Example 56, the subject matter of Example 54 or 55 compresses the waste plastic material to remove moisture through a waste material compression unit, such that the compressed waste plastic feed output from the compression unit is between 2% and 2% by weight. It may optionally include having a moisture content of 16% by weight, preferably in the range of 5% to 10% by weight.

In Example 57, the subject matter of any one of Examples 54-56 provides that the compaction of waste plastic material through the waste material compaction unit is between 80°C and 170°C, or between 90°C and 140°C, or between 90°C and 160°C. , or 110°C to 120°C, or 130°C to 150°C, or 120°C to 155°C.

In Example 58, the subject matter of any one of Examples 54-57 provides that the compression of waste plastic material through the waste material compression unit is between 100 kPa and 150 kPa (or between 0 bar gauge pressure and 0.5 bar gauge pressure or between 1 bar gauge pressure and 1 bar gauge pressure). .5 bar), preferably in the range 100 kPa to 110 kPa (or 0 bar gauge pressure to 0.1 bar gauge pressure or 1 bar to 1.1 bar).

In Example 59, the subject matter of any one of Examples 54-58 provides that the compaction of waste plastic material through the waste material compaction unit has a retention time of 30 seconds to 120 seconds (or 0.5 minutes to 2 minutes). may optionally include being between.

In Example 60, the subject matter of any one of Examples 44-59 melts the compressed waste plastic feed via a melting step by heating to a temperature equal to or greater than the melting point of the compressed waste plastic feed. Preferably, the temperature is 110°C to 350°C, or 110°C to 160°C, or 120°C to 140°C, or 200°C to 350°C, or 240°C to 320°C, or 250°C to It may optionally include a step of melting, at a temperature in the range of 300°C.

In Example 61, the subject matter of any one of Examples 44-60 is that the thermal pyrolysis process is performed at a temperature suitable for reducing the molecular size to be equal to or smaller than the pore size of the catalyst. and preferably the temperature is from 130°C to 380°C, or from 130°C to 370°C, or from 130°C to 280°C, or from 150°C to 250°C, or from 300°C to 380°C, or from 310°C to 360°C, or Optionally, it may include a temperature range of 320°C to 350°C.

In Example 62, the subject matter of any one of Examples 44 to 61 includes heating the pyrolyzed solid residue by a termination step to a temperature suitable for breaking remaining carbon-hydrogen bonds; The method may optionally include removing residual hydrogen and moisture from the solid residue, preferably at a temperature of at least 350<0>C.

In Example 63, the subject matter of Example 62 is combined with Example 60, such that the melting of the compressed waste plastic feed, the thermal pyrolysis process, the catalytic pyrolysis process and the heating of the pyrolysis solid residue are at the same pressure, preferably , the same pressure is 100 kPa to 110 kPa, or 120 kPa to 180 kPa, or 140 kPa to 160 kPa (or 0 bar gauge pressure to 0.1 bar gauge pressure, 0.2 bar gauge pressure to 0.8 bar gauge pressure, or 0.4 bar gauge pressure to 0.5 bar gauge pressure). 6 bar gauge pressure or 1 bar to 1.1 bar, 1.2 bar to 1.8 bar or 1.4 bar to 1.6 bar).

In Example 64, the subject matter of Example 60 is such that the step of melting the compacted waste plastic feed by the melting stage comprises from 10 seconds to 120 seconds or from 18 seconds to 90 seconds (i.e. from 0.16 minutes to 2 minutes or from 0.3 minutes to 1.5 minutes).

In Example 65, the subject matter of any one of Examples 44-64 is that the ratio of the thermal pyrolysis process and the catalytic pyrolysis process is the same as the retention time of the thermal pyrolysis process and the retention time of the catalytic pyrolysis process. may optionally include a proportion of .

In Example 66, the subject matter of Example 62 is that the step of heating the pyrolyzed solid residue through the terminating step is 10 seconds to 120 seconds or 18 seconds to 210 seconds (i.e., 0.16 minutes to 2 minutes or 0.3 and 3.5 minutes).

In Example 67, the subject matter of Example 62 or Example 66 is that the moisture is removed by heating the pyrolyzed solid residue through a termination stage, such that the solid product is between 5% and 35% by weight, preferably 10% by weight. having a moisture content ranging from 60% to 95%, preferably 70% to 90% or more preferably at least 90% by weight; may optionally be included.

In Example 68, the subject matter of any one of Examples 44-67 is that the system is according to any one of Examples 22-43 in combination with Example 22, wherein the system Optionally, the particle size of the product may include a range of 30 nm to 500 nm.

In Example 69, the subject matter of Example 68 is such that the solid product has a bulk density in the range of 1.0 g/cm ^{3 to} 3.0 g/cm ³ , preferably 1.4 g/cm ^{3 to} 2.2 g/cm ³ . The solid product compression unit may optionally include reducing the bulk density so that the solid product compression unit has a reduced bulk density.

Example 70 is a solids compaction unit that includes a first screw conveyor and a second screw conveyor.

In Example 71, the subject matter of Example 70 may optionally include that the first screw conveyor and the second screw conveyor are arranged in series.

In example 72, the subject matter of example 70 or example 71 may optionally include that the first screw conveyor and the second screw conveyor have the same pitch range of 70 mm to 220 mm or 80 mm to 200 mm.

In Example 73, the subject matter of any one of Examples 70-72 provides that the second screw conveyor has a rotational speed of 40% to 100%, or 55% to 98%, or 70% of the rotational speed of the first screw conveyor. Optionally may include having a rotation speed of ˜97%, or 80% to 95%.

In example 74, the subject matter of any one of examples 70-72 may optionally include a third screw conveyor.

In Example 75, the subject matter of Example 74 may optionally include that the first screw conveyor, the second screw conveyor, and the third screw conveyor are arranged in series.

In Example 76, the subject matter of Example 74 or Example 75 may optionally include that the first screw conveyor, the second screw conveyor, and the third screw conveyor have the same pitch range.

In Example 77, the subject matter of any one of Examples 74-76 provides that the third screw conveyor has a rotational speed of 35% to 97%, or 40% to 95%, or 50% of the rotational speed of the first screw conveyor. Optionally may include having a rotation speed of ˜90%, or 60% to 88%, or 70% to 85%.

In Example 78, the subject matter of any one of Examples 70-77 may optionally include one or more additional screw conveyors.

In Example 79, the subject matter of Example 70 is that the pitch range of the first screw conveyor is greater than the pitch range of the second screw conveyor, and the pitch range of the second screw conveyor is greater than the pitch range of the first screw conveyor. may optionally include between 70% and 100%, or between 75% and 99%, or between 78% and 98%.

In Example 80, the subject matter of Example 79 is a third screw conveyor, wherein the pitch range of the first screw conveyor is greater than the pitch range of the second screw conveyor, and the pitch range of the second screw conveyor is greater than the pitch range of the second screw conveyor. , the pitch range of the second screw conveyor is the same as or larger than the pitch range of the third screw conveyor, and the pitch range of the second screw conveyor is 70% to 100%, or 75% to 99% of the pitch range of the first screw conveyor, or 78% to 98%, and the pitch range of the third screw conveyor is 65% to 98%, or 75% to 95%, or 80% to 93% of the pitch range of the first screw conveyor. The third screw conveyor may optionally be included.

In Example 81, the subject matter of Example 70 is that the shaft diameter of the first screw conveyor is smaller than the shaft diameter of the second screw conveyor, and the shaft diameter of the second screw conveyor is smaller than the shaft diameter of the first screw conveyor. may optionally include 100% to 135% or 105% to 130%.

In Example 82, the subject of Example 81 is a third screw conveyor, wherein the shaft diameter of the first screw conveyor is smaller than the shaft diameter of the second screw conveyor, and the shaft diameter of the second screw conveyor is , is the same as or smaller than the shaft diameter of the third screw conveyor, preferably, the shaft diameter of the second screw conveyor is 100% to 135% or 105% of the shaft diameter of the first screw conveyor. ~130%, preferably the shaft diameter of the third screw conveyor is the same as the shaft diameter of the second screw conveyor, or the shaft diameter of the third screw conveyor is the same as the shaft diameter of the first screw conveyor. A third screw conveyor as described above may optionally be included, which is between 105% and 155% or between 108% and 145% of the diameter.

In Example 83, the subject matter of any one of Examples 70-81 may optionally include a cooling jacket around at least one screw conveyor.

In Example 84, the subject matter of Example 4 provides that the continuous heat treatment arrangement includes at least one pyrolysis gas outlet for discharging pyrolysis gas products, and the at least one pyrolysis gas outlet is configured to The at least one pyrolysis gas outlet present in the last catalytic pyrolysis section of the catalytic pyrolysis stage or the termination stage, or both, may optionally include a vacuum pump.

In Example 85, the subject matter of Example 84 is at least one heat exchanger unit coupled to at least one pyrolysis gas outlet for condensing long-chain carbon compounds in the pyrolysis gas product, comprising: The at least one heat exchanger unit is configured to minimize pressure drop during the thermal to catalytic pyrolysis stage, and the at least one heat exchanger is a dual pipe heat exchanger or a shell and tube heat exchanger. The at least one heat exchanger unit may optionally include a heat exchanger unit.

In Example 86, the subject matter of Example 85 includes at least one gas downstream of the at least one heat exchanger unit for removing residual particulates or heavy hydrocarbons, or a combination thereof, from the pyrolysis gas product. A separator unit may optionally be included.

In Example 87, the subject matter of any one of Examples 1-4 and Examples 84-86 optionally includes the termination step including at least one solid product outlet for removing solid product. But that's fine.

In Example 88, the subject matter of any one of Examples 1-4 and Examples 84-87 is that the continuous heat treatment arrangement comprises any one of the melting stage, the thermal to catalytic pyrolysis stage, or the termination stage, or Optionally, including a reactor containing the combination may be included.

In Example 89, the subject matter of Example 88 may optionally include that the reactor is tilted with a rate of rise per horizontal distance of 1:250 to 1:20.

In Example 90, the subject matter of any one of Examples 2-4 and Examples 84-89 is combined with Example 2 such that the waste material compaction unit is arranged from an inlet of the waste material compaction unit to an outlet of the waste material compaction unit. It may optionally include at least two rotating screws arranged in series, the direction of solids transfer being from the inlet of the waste material compression unit to the outlet of the waste material compression unit.

In Example 91, the subject matter of Example 90 is that the volumetric flow rate produced by each of the at least two rotating screws of the waste material compression unit decreases successively one after the other from the inlet of the waste material compression unit to the outlet of the waste material compression unit. and may optionally include compressing the waste plastic material into a compressed waste plastic feed.

In Example 92, the subject matter of Example 91 is such that the diameter of the screw shaft of each of the at least two rotating screws of the waste material compression unit is successively one after the other from the inlet of the waste material compression unit to the outlet of the waste material compression unit. may optionally include increasing.

In Example 93, the subject matter of Example 91 is that the pitch range of each of the at least two rotating screws of the waste material compression unit is one revolution in succession from the inlet of the waste material compression unit to the outlet of the waste material compression unit. It may optionally include lowering from one screw to another rotating screw one after the other.

In Example 94, the subject matter of any one of Examples 1-4 and Examples 84-93 includes at least one solid product compression for compressing the solid product output from the termination stage of the continuous heat treatment arrangement. The unit may optionally include at least one solid product compression unit downstream of the termination stage of the continuous heat treatment arrangement.

In Example 95, the subject matter of Example 94 provides that the solid product compression unit includes at least two rotating screws arranged in series from the inlet of the solid product compression unit to the outlet of the solid product compression unit; Optionally, the direction of material transfer may include from an inlet of the solid product compression unit to an outlet of the solid product compression unit.

In Example 96, the subject matter of Example 95 is such that the volumetric flow rate produced by each of the at least two rotating screws of the solid product compression unit is continuous from the inlet of the solid product compression unit to the outlet of the solid product compression unit. It may optionally include compressing the solid product in successive steps.

In Example 97, the subject matter of Example 95 is such that the pitch range of each of the at least two rotating screws of the solid product compression unit is 1 in succession from the inlet of the solid product compression unit to the outlet of the solid product compression unit. It may optionally include lowering from one rotating screw of the book to another rotating screw one after the other.

In Example 98, the subject matter of Example 95 is such that the diameter of the screw shaft of each of the at least two rotating screws of the solid product compression unit is continuous from the inlet of the solid product compression unit to the outlet of the solid product compression unit. may optionally include increasing one after the other.

In Example 99, the subject matter of Example 95 is such that the rotational speed of each of the at least two rotating screws of the solid product compression unit is sequentially one after the other from the inlet of the solid product compression unit to the outlet of the solid product compression unit. may optionally include lowering.

In Example 100, the subject matter of any one of Examples 95-99 may optionally include that the solid product compression unit further comprises at least three rotating screws.

Example 101 makes waste plastic material useful, comprising introducing a compressed waste plastic feed produced from waste plastic material into the melting stage of a continuous heat treatment arrangement of a system for converting waste plastic material into a useful product. the melting step melts the compressed waste plastic feed to form a molten mixture. The method includes selectively feeding a catalyst through any one or more of at least two catalyst feed points of the thermal to catalytic pyrolysis stage of the continuous heat treatment arrangement of the system to provide thermal to catalytic cracking. Varying the proportions of thermal and catalytic pyrolysis processes within the pyrolysis stage (e.g., the desired end product output from the system or the waste plastic material or feed introduced into the system) (based on the characteristics of , and then subjecting it to a catalytic pyrolysis process. The method includes removing a solid product from a terminal stage of a continuous heat treatment arrangement of the system, the terminal stage being downstream of a thermal to catalytic pyrolysis stage, for converting it to a solid product; The method may further include heating the pyrolysis solid residue.

In Example 102, the subject matter of Example 101 is that adjusting the proportions of the thermal and catalytic pyrolysis processes within the thermal to catalytic pyrolysis stage produces the desired final product produced from the system. monitoring at least one property of the final product produced from the system to determine whether a thermal pyrolysis process and a catalytic pyrolysis process are required; may optionally include selectively feeding the catalyst through any one or more of the at least two catalyst feed points.

In Example 103, the subject matter of Example 101 or 102 may optionally include withdrawing pyrolysis gas products from the continuous heat treatment arrangement via at least one pyrolysis gas outlet of the continuous heat treatment arrangement.

In Example 104, the subject matter of Example 103 includes condensing long-chain carbon compounds from a pyrolysis gas product by at least one heat exchanger unit coupled to at least one pyrolysis gas outlet; Optionally, a step of returning the carbon compound to the thermal to catalytic pyrolysis stage may be included.

In Example 105, the subject matter of Example 104 removes residual particulates or heavy hydrocarbons, or a combination thereof, from the pyrolysis gas product by at least one gas separator unit downstream of the at least one heat exchanger unit. and returning residual particulates or heavy hydrocarbons, or a combination thereof, to the thermal to catalytic pyrolysis stage.

In example 106, the subject matter of example 104 or 105 is compressing waste plastic material via a waste material compression unit, the waste material compression unit for converting waste plastic material into a useful product. The system may optionally include a compressing step upstream of the continuous heat treatment arrangement.

In Example 107, the subject matter of any one of Examples 104-106 is that the thermal pyrolysis process is carried out at a temperature suitable for reducing the molecular size to be equal to or smaller than the pore size of the catalyst. and the temperature is 130°C to 380°C, or 130°C to 280°C, or 150°C to 250°C, or 150°C to 320°C, or 300 to 380°C, or 310 to 360°C, or 320°C to 350°C. may optionally include being in the range of °C.

In Example 108, the subject matter of any one of Examples 104-107 provides that the catalytic pyrolysis process , or from 320°C to 420°C, or from 350°C to 400°C.

In Example 109, the subject matter of any one of Examples 104 to 108 includes heating the pyrolysis solid residue by a termination step to a temperature suitable for breaking remaining carbon-hydrogen bonds; Optionally further comprising the step of removing residual hydrogen and moisture from the solid residue, preferably at a temperature of at least 350°C or at least 400°C or at least 410°C. good.

In Example 110, the subject matter of any one of Examples 104-109 is that the proportion of the thermal pyrolysis process and the catalytic pyrolysis process is the same as the retention time of the thermal pyrolysis process and the retention time of the catalytic pyrolysis process. Optionally may include including a percentage.

In Example 111, the subject matter of any one of Examples 101-110 is the step of removing solid product from a terminal stage of a continuous heat treatment arrangement of the system by a solid product compression unit, the step of removing solid product from a terminal stage of a continuous heat treatment arrangement of the system, The compression unit includes at least two rotating screws arranged in series from an inlet of the solid product compression unit to an outlet of the solid product compression unit, the direction of solids transfer being at the inlet of the solid product compression unit. to the outlet of the solid product compression unit.

In Example 112, the subject matter of Example 111 is such that the volumetric flow rate produced by each of the at least two rotating screws of the solid product compression unit is continuous from the inlet of the solid product compression unit to the outlet of the solid product compression unit. It may optionally include compressing the solid product in successive steps.

In Example 113, the subject matter of Example 111 is such that the rotational speed of each of the at least two rotating screws of the solid product compression unit is sequentially one after the other from the inlet of the solid product compression unit to the outlet of the solid product compression unit. may optionally include lowering.

Example 114 is a solids compression unit that includes at least two rotating screws arranged in series from the inlet of the solids compression unit to the outlet of the solids compression unit. The at least two rotating screws cooperate to compress the solid material as the at least two rotating screws move the solid material from the inlet of the solid product compression unit to the outlet of the solid product compression unit. It may become possible to operate.

In Example 115, the subject matter of Example 114 is operated in concert to compress the solid material as it is being moved from the inlet of the solid product compression unit to the outlet of the solid product compression unit. , from the inlet of the solids compression unit to the outlet of the solids compression unit, the volumetric flow rate produced by each of the at least two rotating screws of the solids compression unit may optionally include successive successive reductions. .

In Example 116, the subject matter of Example 115 is that the rotational speed of each of the at least two rotating screws of the solids compression unit decreases one after the other in succession from the inlet of the solids compression unit to the outlet of the solids compression unit. may optionally include.

In Example 117, the subject matter of Example 115 is such that the diameter of the screw shaft of each of the at least two rotating screws of the solids compression unit is successively one after the other from the inlet of the solids compression unit to the outlet of the solids compression unit. may optionally include increasing.

In Example 118, the subject matter of Example 115 is such that the pitch range of each of the at least two rotating screws of the solid product compression unit is 1 in succession from the inlet of the solid product compression unit to the outlet of the solid product compression unit. It may optionally include lowering from one rotating screw of the book to another rotating screw one after the other.

In Example 119, the subject matter of any one of Examples 114-118 may optionally include at least three rotating screws.

In Example 120, the subject matter of any one of Examples 114-119 may optionally further include a cooling jacket around the at least one rotating screw.

In Example 121, the subject matter of any one of Examples 1-43 may optionally include that the melting stage comprises at least one auxiliary catalyst feed point for feeding catalyst in the melting stage.

In Example 122, the subject matter of any one of Examples 44-69 optionally includes feeding catalyst through at least one auxiliary catalyst feed point of the melting stage of the continuous heat treatment arrangement of the system. But that's fine.

According to various embodiments, the term "screw shaft diameter" as used herein can refer to the diameter of the shaft of a screw conveyor or rotating screw.

According to various embodiments, the term "pitch range" as used herein can refer to the distance between screw threads (eg, adjacent screw threads) of a screw conveyor or rotating screw.

According to various embodiments, the term "final product" as used herein refers to the hydrocarbon material produced by and/or output from the system, or obtained from a separation and purification unit, and / or hydrocarbon materials emitted from these.

FIG. 1A shows a schematic diagram of a system 100 for converting waste plastic materials into useful products, according to various embodiments. According to various embodiments, the system 100 may be a pyrolysis system 100. According to various embodiments, waste plastic materials can include municipal waste, which can include various types of polymers, such as, but not limited to, polypropylene, polyethylene, and the like. According to various embodiments, useful products include C2-C34 hydrocarbons, such as, but not limited to, hydrocarbons suitable for petrochemical processes or fuels (e.g., naphtha, diesel or other hydrocarbon products). hydrocarbons having a range of carbon atoms, and solid products. According to various embodiments, solid products can include, but are not limited to, solid carbon (eg, carbon black) or other solids contained in waste plastic materials.

According to various embodiments, the system 100 may include a waste material compression unit 200 (or solids compression unit). According to various embodiments, waste material compaction unit 200 can receive waste plastic material (or waste plastic feed or raw material). Thus, waste plastic material may be fed to the waste material compaction unit 200. According to various embodiments, a feeder (not shown) may be connected to waste material compaction unit 200. The feeder may feed waste plastic material into the waste material compaction unit 200 for transportation. According to various embodiments, the feeder can include, but is not limited to, a metering feeder, a gravity feeder, a bulk feeder, a linear feeder, a screw feeder, an auger feeder, or a hopper feeder. According to various embodiments, the feeder can be at an opening or inlet of waste material compaction unit 200. According to various embodiments, the waste material compression unit 200 compresses waste plastic material to remove air (e.g., oxygen) and moisture from the waste plastic material to form or produce a compressed waste plastic feed. Can be done. Thus, by compressing or compacting the waste plastic material, the air and moisture in the waste plastic material can be forced out or squeezed out. According to various embodiments, the waste material compaction unit 200 is substantially compressed from 80°C to 170°C, or from 90°C to 140°C, or from 90°C to 160°C, or from 110°C to 120°C, or from 130°C to The waste plastic material can be compacted at a temperature or temperature range within the range of 150°C, or 120°C to 155°C. Accordingly, when the waste material compaction unit 200 is operated at high temperatures, moisture can evaporate such that the compacted waste plastic feed can be moisture-free. According to various embodiments, the waste material compaction unit 200 allows moisture within the waste material compaction unit 200 (e.g., moisture evaporated from heated waste plastic material) to escape or be discharged from the waste material compaction unit 200. at least one moisture release port (e.g., e.g., an exhaust port or outlet port or conduit or opening or vent, e.g., to the atmosphere) that allows the moisture to flow out or out of the system 100 (e.g., into the atmosphere); can include. At least one moisture release port can be located along the waste material compression unit 200 (e.g., between an inlet and an outlet of the waste material compression unit 200, or from an inlet to an outlet of the waste material compression unit 200). . According to various embodiments, each moisture release port may include a one-way valve configured to allow moisture to be directed from the waste material compaction unit 200 or out of the system 100, and may include a fluid e.g. , air from the atmosphere) from entering the waste material compression unit 200 or system 100. If moisture release is desired (e.g., if moisture increases above a water volume threshold into the following area(s)), multiple moisture release ports are provided along the waste material compaction unit 200 of the system 100. If the moisture release port(s) of the plurality of moisture release ports are distributed directly (e.g., ) may be selectively operated or opened to release moisture from the area(s) of the waste material compaction unit 200 to which it is connected. According to various embodiments, each moisture release port may be a separate opening from the inlet of the waste material compression unit 200 (in other words, it may be completely different), in which case the feeder It may be located at and/or remote from the outlet of the waste material compaction unit 200 producing the compacted waste plastic feed. According to various embodiments, the waste material compression unit 200 includes a heating arrangement, including, but not limited to, an external fire source, electrical heating, heating elements, heating coils, heating pads, etc., to compress waste material. Heating can be applied to increase the temperature within compression unit 200. According to various embodiments, the waste material compression unit 200 prepares a crude feed/feedstock of waste plastic material into a dry and compressed air-free waste plastic feed for subsequent pyrolysis processing. be able to. Further details of the waste material compression unit 200 are described below.

Referring to FIG. 1A, according to various embodiments, system 100 can include a heat treatment arrangement. According to various embodiments, the heat treatment arrangement may be configured to perform pyrolysis on the compressed waste plastic feed from the waste material compression unit 200. According to various embodiments, the heat treatment arrangement may be a continuous heat treatment arrangement 300. Thus, the continuous heat treatment arrangement 300 can perform pyrolysis in a continuous manner instead of in a batch process. In other words, waste plastic material undergoing pyrolysis may be continuously transferred to the continuous heat treatment arrangement 300 for pyrolysis treatment, rather than processing the material in batches and moving the material batch by batch. can be carried or carried or transported.

As shown, continuous heat treatment arrangement 300 may be coupled to waste material compression unit 200 at a location downstream of waste material compression unit 200. Thus, the waste material compression unit 200 may be upstream of the continuous heat treatment arrangement 300. According to various embodiments, the compressed waste plastic feed is transferred from the waste material compression unit 200 to the continuous heat treatment arrangement 300 to melt, pyrolyze, and/or heat the waste plastic feed in the continuous heat treatment arrangement 300. 300 or may be housed here. According to various embodiments, compressed waste plastic feed may be automatically fed or transported or conveyed to continuous heat treatment arrangement 300. According to various embodiments, compressed waste plastic feed may also be manually input into continuous heat treatment arrangement 300.

According to various embodiments, the continuous heat treatment arrangement 300 includes a melting stage 310, a thermal to catalytic pyrolysis stage 320, and a termination stage 330 to treat compressed waste plastic feed by melting, pyrolysis, and/or heating. can include. According to various embodiments, the thermal to catalytic pyrolysis stage 320 may be located downstream of the melting stage 310, between the melting stage 310 and the termination stage 330; Stage 330 may be located downstream of thermal to catalytic pyrolysis stage 320. Accordingly, the stages of continuous heat treatment arrangement 300 may be in the order or sequence of melting stage 310 followed by thermal to catalytic pyrolysis stage 320 followed by termination stage 330. Accordingly, the flow or movement of material into the continuous heat treatment arrangement 300 is continuous from the melting stage 310 to the thermal to catalytic pyrolysis stage 320 and then from the thermal to catalytic pyrolysis stage 320 to the termination stage 330. There may be.

According to various embodiments, the melting stage 310 of the continuous heat treatment arrangement 300 may be configured to melt the compressed waste plastic feed to form a molten mixture or a molten plastic mixture. Accordingly, the compressed waste plastic feed passing through the melting stage 310 may be heated to or above the melting temperature. According to various embodiments, melting stage 310 includes substantially 110°C to 350°C, or 110°C to 160°C, or 120°C to 140°C, or 200°C to 350°C, or 240°C to 320°C, Alternatively, the compressed waste plastic feed may be heated to form a molten mixture in melting stage 310 at a temperature or temperature range within the range of 250° C. to 300° C. According to various embodiments, the melting stage 310 includes a heating arrangement, including, but not limited to, an external fire source, electrical heating, heating elements, heating coils, heating pads, etc., for heating the compacted waste plastic feed. Can include configuration.

According to various embodiments, the molten mixture may be conveyed or transported from the melting stage 310 of the continuous heat treatment arrangement 300 to the thermal to catalytic pyrolysis stage 320.

According to various embodiments, the thermal to catalytic pyrolysis stage 320 of the continuous heat treatment arrangement 300 is configured to produce (or to produce) pyrolysis gas products and/or pyrolysis solid residues. , the molten mixture can be subjected to a thermal pyrolysis process followed by a catalytic pyrolysis process. Accordingly, the thermal to catalytic pyrolysis step 320 may perform pyrolysis in the order of a thermal pyrolysis process followed by a catalytic pyrolysis process. According to various embodiments, the thermal to catalytic pyrolysis stage 320 includes at least two catalyst feed points (or more than one catalyst feed point) distributed along the thermal to catalytic pyrolysis stage 320. catalyst feed port) 32. Accordingly, the at least two catalyst feed points may be interspersed along the thermal to catalytic pyrolysis stage 320 in the direction of material flow or movement along the thermal to catalytic pyrolysis stage 320, or It may be dispersed or spread out. According to various embodiments, the thermal to catalytic pyrolysis stage 320 has a varying ratio of thermal to catalytic pyrolysis processes, or converting or switching from a thermal pyrolysis process to a catalytic pyrolysis process at various points or positions or locations or junctions along the thermal to catalytic pyrolysis stage 320 to adjust or change the or may be operable to selectively feed or add or input or receive a catalyst through any one or more of the at least two catalyst feed points for modifying or converting. . According to various embodiments, the addition of a catalyst to a thermal pyrolysis process can convert or change or switch the thermal pyrolysis process to a catalytic pyrolysis process. or can be converted. Thus, the catalyst may be added or fed or dosed at the point where the catalytic pyrolysis takes place. Accordingly, if the catalyst is fed or added or charged at at least two different catalyst feed points, the thermal pyrolysis process is performed along the thermal to catalytic pyrolysis stage 320. The catalytic pyrolysis process may be converted or changed or switched or covered at various points or locations or points of connection. Accordingly, the proportion of the thermal to catalytic pyrolysis process in the thermal to catalytic pyrolysis stage 320 is such that the proportion of the thermal pyrolysis process and the catalytic pyrolysis process in the thermal to catalytic pyrolysis stage 320 is such that the catalyst is fed or added at various catalyst feed points of the at least two catalyst feed points; Depending on the input, it may vary or be adjusted or changed. According to various embodiments, in the thermal to catalytic pyrolysis step 320, the ratio between the thermal pyrolysis process and the catalytic pyrolysis process is the same as the duration (or holding period) of the thermal pyrolysis process and the catalytic pyrolysis process. It can be a ratio to the duration of the process (or retention period). Therefore, if the flow rate or rate of movement through the thermal to catalytic pyrolysis stage 320 is constant, the ratio between the thermal and catalytic pyrolysis processes will be the same as the rate at which the thermal to catalytic pyrolysis process is carried out. The length of the catalytic pyrolysis stage 320 can be the ratio of the length of the thermal to catalytic pyrolysis stage 320 that performs the catalytic pyrolysis process.

According to various embodiments, the final product produced by the system 100 is modified by varying the proportions of thermal and catalytic pyrolysis processes performed along the thermal to catalytic pyrolysis stage 320. 701 may be modified or modified or changed accordingly. Therefore, depending on the desired end product 701, the proportions of thermal and catalytic pyrolysis processes along the thermal to catalytic pyrolysis stage 320 are necessary to produce the desired end product 701. The process sequence may be varied or adjusted or varied to provide a process sequence having a proportion of thermal and catalytic pyrolysis processes.

According to various embodiments, at various points or locations or locations or junctions along the thermal to catalytic pyrolysis stage 320, to convert or modify the thermal pyrolysis process to a catalytic pyrolysis process. Using at least two (e.g., two or more) catalyst feed points along the thermal to catalytic pyrolysis stage 320 for feeding catalyst for switching or converting, the system 100 can Points along the thermal to catalytic pyrolysis stage 320 can be operated to selectively vary, where a catalyst is added to the desired end product 701 produced from the system 100 or to the system 100. Depending on the characteristics of the waste plastic material or feed introduced, the thermal pyrolysis process is converted or changed into a catalytic pyrolysis process or switched or converted. For example, according to various embodiments, at least one of the thermal to catalytic pyrolysis stages 320 is configured to achieve, obtain, or realize the required ratio of thermal to catalytic pyrolysis processes. Catalyst may be added selectively at any one or more of the two catalyst feed points.

As shown in FIG. 1A, according to various embodiments, the thermal to catalytic pyrolysis stage 320 includes an initial thermal pyrolysis zone 321, one or more intermediate variable zones 322, and a final catalytic pyrolysis zone 321. A decomposition zone 324 may be included. According to various embodiments, a first thermal pyrolysis zone 321, one or more intermediate variable zones 322, and a last catalytic pyrolysis zone 324 may be arranged in series. Thus, the zones of the thermal to catalytic pyrolysis stage 320 may be in the order of a first thermal pyrolysis zone 321, then one or more intermediate variable zones 322, and then a last catalytic pyrolysis zone 324. or in this sequence. According to various embodiments, one or more intermediate variable zones 322 are located downstream of the first thermal pyrolysis zone 321 and between the first thermal pyrolysis zone 321 and the last catalytic pyrolysis zone 324. The last catalytic pyrolysis zone 324 may be located downstream of one or more intermediate variable zones 322. According to various embodiments, the molten mixture of compressed waste plastic feed is moved in the direction from the first thermal pyrolysis zone 321 to the last catalytic pyrolysis zone 324, and in particular from the first thermal pyrolysis zone 321 to the last catalytic pyrolysis zone 324. or may be conveyed or transported along the thermal to catalytic pyrolysis stage 320 (e.g., by a conveyor mechanism) via a plurality of intermediate variable zones 322 to a final catalytic pyrolysis zone 324. good. According to various embodiments, the at least two catalyst feed points may only be opened when catalyst is fed or added to the system 100. For example, each of the at least two catalyst feed points (e.g., catalyst feed ports) can include a lid that can be opened or closed to feed catalyst into (e.g., air/ to prevent gas from entering or escaping the catalyst feed point). According to various embodiments, at least two catalyst feed points (e.g., catalyst feed ports) prevent air (e.g., from the atmosphere) from entering system 100 and/or prevent air (e.g., from the atmosphere) from entering system 100. At least one safety valve may be included to prevent any gas from leaking or escaping to the atmosphere. According to various embodiments, catalyst may be fed or added to system 100 by at least one catalyst feeder and via at least two catalyst feed points. According to various embodiments, the catalyst feeder can include, but is not limited to, a screw feeder, an auger feeder, or a hopper feeder.

According to various embodiments, the first thermal pyrolysis zone 321 of the thermal to catalytic pyrolysis stage 320 heats the molten mixture at or above the pyrolysis temperature of the molten mixture to destroy molecules of the molten mixture. May be heated. According to various embodiments, the initial thermal pyrolysis zone 321 may be configured to apply heat to the molten mixture under hypoxic or inert atmosphere conditions to decompose or destroy the molten mixture. . According to various embodiments, the thermal pyrolysis process may be configured to decompose or break the molten mixture into suitable molecular sizes for subsequent catalytic pyrolysis processes. According to various embodiments, the initial thermal pyrolysis zone 321 comprises substantially 130°C to 380°C, or 130°C to 280°C, or 150°C to 250°C, or 300°C to 380°C, or The molten mixture can be heated at a temperature or temperature range within the range of 310°C to 360°C, or 320°C to 350°C. According to various embodiments, the initial thermal pyrolysis zone 321 includes a heating arrangement that provides heating, including, but not limited to, an external fire source, electrical heating, heating elements, heating coils, heating pads, etc. Can include configuration.

According to various embodiments, the temperature and/or duration (i.e., holding time) at which the molten mixture is subjected to heating in the first thermal pyrolysis zone 321 of the thermal to catalytic pyrolysis stage 320 is such that the molten mixture of waste plastic material and/or the type of catalyst used in the catalytic pyrolysis process and/or the desired end product 701 to be produced by the system 100 (e.g., a hydrocarbon suitable for a petrochemical process or fuel). The desired final useful hydrocarbon product or hydrocarbons having carbon atoms in the range of C2 to C34, such as naphtha, diesel, other hydrocarbon products, etc.). For example, according to various embodiments, the molten mixture in the first thermal pyrolysis zone 321 has molecules of the molten mixture that are catalysts that can later be used (or added) to the catalytic pyrolysis process. may be heated at a temperature and/or for a period of time that may result in disruption to a suitable (or ideal, eg, smaller) size (or average diameter of the pores) for entry into the pore sites of the pores.

According to various embodiments, each of the one or more intermediate variable zones 322 of the thermal to catalytic pyrolysis stage 320 has at least one catalyst feed port 32, 32a at the beginning of the intermediate variable zone 322 for receiving catalyst. can include. According to various embodiments, at least one catalyst feed port 32a of each intermediate variable zone 322 can serve as one of at least two catalyst feed points along the thermal to catalytic pyrolysis stage 320. . Therefore, if there are more intermediate variable zones 322, then the thermal to catalytic pyrolysis stage 320 will be at a point along the thermal to catalytic pyrolysis stage 320 for adding or feeding or dosing catalyst. Or it can have more catalyst feed points for varying positions or locations or connection points. According to various embodiments, when the catalyst is added to the intermediate variable zone 322 via at least one catalyst feed port 32a at the beginning of the intermediate variable zone 322, the thermal pyrolysis process begins in the intermediate variable zone with contact It can be converted or changed or switched to or converted to a pyrolysis process. Accordingly, the remaining zones of the thermal to catalytic pyrolysis stage 320 after the intermediate variable zone 322 can perform a catalytic pyrolysis process. According to various embodiments, if no catalyst is added or fed to intermediate variable zone 322, intermediate variable zone 322 performs a thermal pyrolysis process similar to initial thermal pyrolysis zone 321. I can continue.

According to various embodiments, in the one or more intermediate variable zones 322, the molten mixture is added to the one or more intermediate variable zones 322 such that the catalyst is added to the one or more intermediate variable zones 322 (e.g., (through at least one catalyst feed port 32a), either a thermal pyrolysis process or a catalytic pyrolysis process can be carried out.

According to various embodiments, one or more intermediate variable zones 322 provide heating at a temperature or temperature range for a thermal pyrolysis process or at a temperature or temperature range for a catalytic pyrolysis process. It may be possible to operate as such. Thus, according to various embodiments, depending on whether the catalyst is fed or added or injected through at least one catalyst feed port 32a of one or more intermediate variable zones 322, one or more The plurality of intermediate variable zones 322 may be heated to a temperature or temperature range for a thermal pyrolysis process or a catalytic pyrolysis process. According to various embodiments, the one or more intermediate variable zones 322 of the thermal to catalytic pyrolysis stage 320 are substantially 130°C to 480°C, or 130°C to 370°C, or 150°C to 320°C. ℃, or 280°C to 480°C, or 290°C to 440°C, or 300°C to 400°C, or 300°C to 420°C. For example, according to various embodiments, if catalyst is not fed, added, or input through at least one catalyst feed port 32a of one or more intermediate variable zones 322, one or more intermediate variable Zone 322 is substantially 130° C. to 380° C., or 130° C. to 280° C., or 150° C. to 250° C., or 300° C. to 380° C., or 310° C. to 360° C., or It may be heated (or adjusted or maintained) to a temperature within the range of 320°C to 350°C. On the other hand, according to various embodiments, if the catalyst is fed or added or injected via at least one catalyst feed port 32a of one or more intermediate variable zones 322; The one or more intermediate variable zones 322 may be used for a catalytic pyrolysis process, substantially 250°C to 440°C or 250°C to 370°C or 270°C to 320°C or 300°C to 440°C or 320°C to 420°C or 350°C. It may be heated (or adjusted or maintained) to a temperature or temperature range within the range of -400°C. According to various embodiments, each of the one or more intermediate variable zones 322 provides heating, including, but not limited to, an external fire source, electrical heating, heating elements, heating coils, heating pads, and the like. A heating arrangement may be included.

According to various embodiments, the last catalytic pyrolysis zone 324 of the thermal to catalytic pyrolysis stage 320 has at least one catalyst feed port 32, 32b at the beginning of the last catalytic pyrolysis zone 324 to receive catalyst. can include. According to various embodiments, at least one catalyst feed port 32b of the last catalytic pyrolysis zone 324 is the last of at least two catalyst feed points along the thermal to catalytic pyrolysis stage 320 for receiving catalyst. Can act as a catalyst feed point. According to various embodiments, the catalyst is in any of the one or more intermediate variable zones 322 upstream of the last catalytic pyrolysis zone 324 (i.e., this is upstream of the last catalytic pyrolysis zone 324) If the catalyst is not fed or added to the final catalytic pyrolysis zone 324 via its at least one catalyst feed port 32b, the catalyst may be fed or added to or otherwise Good too. Accordingly, the last catalytic pyrolysis zone 324 may be the last zone of the thermal to catalytic pyrolysis stage 320 in which the catalytic pyrolysis process can occur. Accordingly, the last catalytic pyrolysis zone 324 may be defined as the lowest fraction of the thermal to catalytic pyrolysis stages 320 for a catalytic pyrolysis process. According to various embodiments, the last catalytic pyrolysis zone 324 may be configured to perform only catalytic pyrolysis processes. For example, according to various embodiments, the last catalytic pyrolysis zone 324 may be operable to provide heating at a temperature or temperature range for a catalytic pyrolysis process. As another example, according to various embodiments, the last catalytic pyrolysis zone 324 is configured to have at least one catalyst feed port 32b such that the catalytic pyrolysis process always takes place in the last catalytic pyrolysis zone 324. The catalyst may also be configured to be fed, added, or injected. According to various embodiments, the catalyst is not fed, added, or input to any of the one or more intermediate variable zones 322 (i.e., it is upstream of the last catalytic pyrolysis zone 324). If not, at least one of the last catalytic pyrolysis zones 324 to convert or change or switch or convert the thermal pyrolysis process to a catalytic pyrolysis process in the last catalytic pyrolysis zone 324 All of the initial thermal pyrolysis zone 321 and one or more intermediate variable zones 322 are thermally activated until catalyst is fed or added (e.g., initially) via the catalyst feed port 32b. A pyrolysis process can be carried out.

According to various embodiments, the catalyst converts or changes or switches or converts a thermal to catalytic pyrolysis process to a catalytic pyrolysis process at various points along the thermal to catalytic pyrolysis stage 320. may be fed from at least one catalyst feed port 32a of one or more intermediate variable zones 322 and/or at least one catalyst feed port 32b of the last catalytic pyrolysis zone 324 to, or for, . Therefore, depending on the final product 701 produced from the system 100, the thermal to catalytic pyrolysis stage 320 may vary in proportion between the thermal and catalytic pyrolysis processes within the thermal to catalytic pyrolysis stage 320. selectively feeding catalyst from at least one catalyst feed port 32a of one or more intermediate variable zones 322 and/or at least one catalyst feed port 32b of the last catalytic pyrolysis zone 324 to vary , or may be operated to add or inject.

According to various embodiments, system 100 can include at least three (or more) catalyst feed ports 32a, 32b. For example, according to various embodiments, system 100 may include at least two (or more) intermediate variable zones 322, thereby providing at least two (or more) intermediate variable zones 322. can accordingly include at least two (or more) catalyst feed ports 32a. Additionally, according to various embodiments, system 100 may include a final catalytic pyrolysis zone 324 that includes at least one catalyst feed port 32b.

Therefore, if there are two intermediate variable zones 322 and a last catalytic pyrolysis zone 324, there are at least two catalyst feed ports 32a corresponding to the two intermediate variable zones 322 and one to the last catalytic pyrolysis zone 324. One catalyst feed port 32b may be present. Thus, there are at least three catalyst feed ports in total where catalyst may be added to or fed into any one or combination of feed ports 32a, 32b. obtain. According to various embodiments, at least one catalyst feed port 32a of the at least one intermediate variable zone 322 and/or at least one catalyst feed port 32b of the last catalytic pyrolysis zone 324 is fed or added with a catalyst. The decision whether or not to do so, or where in the catalyst feed ports described above, depends on the characteristics of the final product 701 coming out of the system 100 or the waste plastic material or feed introduced into the system 100. can be based on monitoring the characteristics of According to various embodiments, the point of addition of the catalyst and the final product 701 produced from the system 100 depends on the composition of the waste plastic material, the type of catalyst used, or the desired final product from the system 100. 701 or a combination thereof.

For example, the duration of the thermal pyrolysis process required to decompose or destroy the waste plastic material to perform the catalytic pyrolysis process and/or the desired end product 701 from the system 100, according to various embodiments. The duration of the catalytic pyrolysis process (or catalytic cracking time) required to generate the desired pyrolysis gas products depends on the composition of the waste plastic material and/or the average pore size of the catalyst. It can be determined based on pore size and/or properties of the final product 701 (eg, determined specific gravity). Thus, the required ratio of thermal to catalytic pyrolysis processes within the thermal to catalytic pyrolysis stage 320 and/or the point of catalyst addition can be determined. As an example, if a catalyst is fed or added or charged at at least one catalyst feed port 32a of one or more intermediate variable zones 322, the catalytic pyrolysis process 322 can be started in each corresponding intermediate variable zone 322 before reaching the last catalytic pyrolysis zone 324 downstream of 322 . Therefore, by adding catalyst to the corresponding intermediate variable zone 322 via its catalyst feed port 32a, the thermal to catalytic pyrolysis stage A higher proportion of the catalytic pyrolysis process may take place within 320.

As another example, different desired end products 701 may require different corresponding retention times of the catalytic pyrolysis process, according to various embodiments. Thus, according to various embodiments, if it is determined that the desired end product 701 requires a longer retention time for the catalytic pyrolysis process, the catalyst may be fed into the system 100 earlier. It may be added, or it may be injected. For example, the catalyst may be used in the earlier regions of one or more intermediate variable regions 322 (e.g., , closer to the melting stage 310).

As yet another example, in accordance with various embodiments, various compositions of waste plastic materials undergo various heating treatments to decompose or break down into suitable molecular sizes due to interaction with the catalyst used. Hold times may be required. Thus, if it is determined that a particular type of waste plastic material requires a longer holding time for the thermal pyrolysis process, the catalyst may be fed or added at a later time. , or may be thrown in. For example, the catalyst may be fed or added or charged to a zone after one or more intermediate variable zones 322, or the catalyst may be fed to a zone after one or more intermediate variable zones 322, or the catalyst may be Only, it may not be fed or added, or it may not be input. According to various embodiments, all, or almost all, or most of the added catalyst is removed by feeding or adding or dosing the catalyst when the waste plastic material is sufficiently decomposed or destroyed. The action of the catalyst on the catalytic pyrolysis process can be optimized as the parts are activated and the catalyst performs its function with minimal wastage.

According to various other embodiments, the melting stage 310 includes at least one catalyst for receiving or feeding (e.g., additional catalyst) a catalyst to the melting stage 310. Auxiliary catalyst feed points (eg, auxiliary feed ports) (not shown) (ie, in addition to catalyst feed ports 32 located along thermal to catalytic pyrolysis stage 320) may optionally be further included.

Thus, according to various other embodiments, when additional catalyst is added to system 100 via at least one auxiliary catalyst feed point, the additional catalyst added to system 100 is bulkier. Alternatively, the system 100 can provide bulkier or larger size waste plastic feed or materials as it can assist or facilitate the destruction of molecules of the waste plastic feed or materials of larger size. Additionally, additional catalyst added to system 100 can partially drive or accelerate the pyrolysis of certain types of waste plastic feed or materials in system 100. Thus, in the case of system 100, the controllable realization of the desired end product is even more convenient, especially if a small or smaller sized molecular end product is desired compared to the initial waste plastic feed or material. It can be easy.

According to various other embodiments, the catalyst that is fed or added to the melting stage 310 via at least one auxiliary catalyst feed point is located downstream of the melting stage 310 in the system 100. The catalyst that may be fed or added to one or more of the catalyst feed ports 32 located along the pyrolysis stage 320 may be of the same type or composition, or may be of a different type or composition. There may be catalysts of composition.

According to various other embodiments, the amount of catalyst fed or added to melting stage 310 via the at least one auxiliary catalyst feed point is a thermal ~The amount of catalyst fed or added to the catalyst feed port 32 along the catalytic pyrolysis stage 320 may be the same or different.

According to various embodiments, and generally preferred, the melting stage 310 of the system 100 or the system 100 includes at least one auxiliary catalyst feed point (i.e., for receiving or configured to receive catalyst) in the melting stage 310 of the system 100. (in other words, does not have or contain at least one auxiliary catalyst feed point). Thus, according to various embodiments, the only point(s) or port(s) available in or within system 100 for adding or feeding catalyst to system 100 is A catalyst feed point (eg, port) 32 may be located in the catalytic pyrolysis stage 320 (ie, downstream of the melting stage 310). In other words, according to various embodiments, the system 100 may not include any auxiliary catalyst feed points, so catalyst is added to the system 100 via the catalyst feed point (e.g., port) 32 or Or it can just be fed.

According to various embodiments, a termination stage 330 of the continuous heat treatment arrangement 300 can be present downstream of the thermal to catalytic pyrolysis stage 320 and removes pyrolyzed solid residue from the thermal to catalytic pyrolysis stage 320. can be received. According to various embodiments, termination stage 330 includes converting the pyrolyzed solid residue (i.e., continuous heat treatment arrangement 300 (produced from the thermal to catalytic pyrolysis step 320) can be heated. According to various embodiments, termination step 330 is at least substantially 350°C, preferably at least substantially 400°C, more preferably at least or about 410°C (in other words, substantially 350°C or higher, Preferably, it may be heated to a temperature of substantially 400° C. or higher, more preferably substantially 410° C. or higher) and/or at this temperature. According to various embodiments, termination step 330 includes pyrolysis to maintain the pyrolyzed solid residue at an elevated temperature (e.g., 350°C or higher, preferably up to 400°C or higher, more preferably up to 410°C or higher). A first heating zone 333 that increases the temperature of the solid residue (e.g. from a lower temperature to 350° C. or higher, preferably 400° C. or higher, more preferably 410° C. or higher), and a second heating zone 334. May include. According to various embodiments, termination step 330 includes, among other things, breaking any remaining carbon-hydrogen (C-H) bonds in the pyrolyzed solid residue, removing any hydrogen from the pyrolyzed solid residue, and /or the pyrolysis solid residue can be dried to produce a solid product. According to various embodiments, termination stage 330 may include a heating arrangement that provides heating, including, but not limited to, an external fire source, electrical heating, heating elements, heating coils, heating pads, and the like. can.

According to various embodiments, the temperature or temperature range of termination stage 330 may be higher than the temperature or temperature range of thermal to catalytic pyrolysis stage 320. According to various embodiments, the temperature or temperature range of thermal to catalytic pyrolysis stage 320 may be higher than the temperature or temperature range of melting stage 310.

According to various embodiments, continuous heat treatment arrangement 300 may include reactor 350. According to various embodiments, continuous heat treatment arrangement 300 may be integrated by reactor 350. Thus, reactor 350 can impart its physical form or shape to continuous heat treatment arrangement 300. According to various embodiments, reactor 350 can be a single-stage or multi-stage/zone reactor (eg, a six-zone reactor). According to various embodiments, the reactor 350 can include any one or a combination of a melting stage 310, a thermal to catalytic pyrolysis stage 320, and a termination stage 330. For example, according to various embodiments, reactor 350 may include only thermal to catalytic pyrolysis stage 320. As another example, according to various embodiments, reactor 350 may include only a melting stage 310 and a thermal to catalytic pyrolysis stage 320. As yet another example, according to various embodiments, reactor 350 may include only thermal to catalytic pyrolysis stage 320 and termination stage 330. As a further example, according to various embodiments, reactor 350 may include all of a melting stage 310, a thermal to catalytic pyrolysis stage 320, and a termination stage.

According to various embodiments, reactor 350 may include or be a cylindrical shaped reactor. Thus, a cylindrical reactor may be segmented or compartmentalized or divided longitudinally (or along its length) into various stages or zones. good.

According to various embodiments, the continuous heat treatment arrangement 300 moves waste plastic material along the continuous heat treatment arrangement 300 from a melting stage 310, through a thermal to catalytic pyrolysis stage 320, to a termination stage 330. A conveyor mechanism 360 may also be included for conveying or transporting. Thus, according to various embodiments, when continuous heat treatment arrangement 300 includes a reactor 350, reactor 350 includes a conveyor mechanism 360 that conveys or transports waste plastic material along the length of reactor 350. can include. Accordingly, conveyor mechanism 360 may extend longitudinally along reactor 350. According to various embodiments, conveyor mechanism 360 may extend along the entire length of reactor 350. For example, conveyor mechanism 360 transports waste plastic material from the front end (or first longitudinal end) of reactor 350 to the rear end (or second longitudinal end) of reactor 350. Can be carried or transported. According to various embodiments, the conveyor mechanism 360 of the reactor 350 can include at least one screw conveyor, linear conveyor, belt conveyor, or auger conveyor.

According to various embodiments, the speed at which waste plastic material may be conveyed by the conveyor mechanism along the continuous heat treatment arrangement 300 (or along the reactor 350) is determined by the desired retention of waste plastic material required. Can be time dependent.

According to various embodiments, the reactor 350 may be inclined with respect to the ground 9 or a horizontal plane. For example, according to various embodiments, the rate of rise per horizontal distance of reactor 350 is within a range of 1:250 to 1:20; 1:200 to 1:50; 1:150 to 1:80, etc. could be. According to various embodiments, the term "rate of rise per horizontal distance" as used herein can refer to the inclination of the reactor, which is the difference between two different slopes on or along the reactor. Vertical changes (e.g., perpendicular to the ground or vertical axis on which the reactor is located) relative to horizontal changes (e.g., along a line or horizontal axis relative to the ground) between points. (difference along the line).

According to various embodiments, melting stage 310, thermal to catalytic pyrolysis stage 320, and termination stage 330 may be maintained at the same pressure. Thus, according to various embodiments, the melting of the compressed waste plastic feed in the melting stage 310, the thermal to catalytic pyrolysis process in the thermal to catalytic pyrolysis stage 320, and the pyrolysis process in the termination stage 330. Heating of the solid residue may be (or may be carried out) at the same pressure. According to various embodiments, reactor 350 may be gas-tight to maintain pressure within the reactor for melting stage 310, thermal to catalytic pyrolysis stage 320, and/or termination stage 330. , or may be hermetically sealed. According to various embodiments, the pressure is substantially between 100 kPa and 110 kPa, or between 120 kPa and 180 kPa, or between 140 kPa and 160 kPa (or between 0 bar gauge pressure and 0.1 bar gauge pressure, or between 0.2 bar gauge pressure and 0.2 bar gauge pressure). 8 bar gauge pressure, or 0.4 bar gauge pressure to 0.6 bar gauge pressure, or 1 bar to 1.1 bar, or 1.2 bar to 1.8, or 1.4 bar to 1.6 bar) .

According to various embodiments, the last catalytic pyrolysis section 324 of the thermal-to-catalytic pyrolysis stage 320 includes a pyrolysis zone 324 for releasing pyrolysis gas products produced in the thermal-to-catalytic pyrolysis stage 320. At least one pyrolysis gas outlet 326 can be included. Accordingly, when continuous heat treatment arrangement 300 includes a reactor 350 that includes at least a thermal to catalytic pyrolysis stage 320, reactor 350 has at least one thermal A cracked gas outlet 326 may be included. According to various embodiments, the at least one pyrolysis gas outlet 326 may be an opening or vent in the reactor 350 at the last catalytic pyrolysis zone 324 of the reactor 350. According to various embodiments, at least one pyrolysis gas outlet 326 of the last catalytic pyrolysis zone 324 is operable to withdraw or remove pyrolysis gas products from the last catalytic pyrolysis zone 324. A pump 328 may also be included. Accordingly, the pump 328 may be coupled (eg, may be fluidly coupled) to at least one pyrolysis gas outlet 326 of the last catalytic pyrolysis zone 324. According to various embodiments, the pump can include a vacuum pump or a suction pump.

According to various embodiments, the termination stage 330 of the continuous heat treatment arrangement 300 includes at least one pyrolysis gas exhaust for releasing the pyrolysis gas products produced in the thermal to catalytic pyrolysis stage 320. An outlet 326 may be included. Thus, when continuous heat treatment arrangement 300 includes a reactor 350 that includes at least a thermal to catalytic pyrolysis stage 320 and a termination stage 330, reactor 350 includes at least one thermal decomposition stage 330 within reactor 350. A cracked gas outlet 326 may be included. According to various embodiments, the at least one pyrolysis gas outlet 326 may be an opening or vent in the reactor 350 during the termination stage 330 of the reactor 350. According to various embodiments, at least one pyrolysis gas outlet 326 of termination stage 330 may include a pump 328 operable to withdraw or remove pyrolysis gas products from termination stage 330. Accordingly, pump 328 may be coupled to at least one pyrolysis gas outlet of termination stage 330. According to various embodiments, pump 328 can include a vacuum pump or a suction pump.

According to various embodiments, termination stage 330 may include at least one pyrolysis solids outlet 332 for removing solid products produced in termination stage 330 of thermal to catalytic pyrolysis stage 320. Accordingly, when continuous heat treatment arrangement 300 includes a reactor 350 that includes at least a thermal to catalytic pyrolysis stage 320 and a termination stage 330, reactor 350 includes at least one pyrolysis stage 330 in the termination stage 330 within the reactor. A solids outlet 332 may be included. According to various embodiments, at least one pyrolysis solids outlet 332 may be an opening or passageway in the reactor at the termination stage 330 of the reactor 350.

As shown in FIGS. 1A and 1C, according to various embodiments, system 100 can include at least one solid product compression unit 400 (or solids compression unit). Solid product compression unit 400 may be coupled (e.g., may be in fluid communication) to a pyrolysis solids outlet 332 of termination stage 330 for receiving solid product removed from termination stage 330. . Accordingly, solid product compression unit 400 may be located downstream of termination stage 330 of continuous heat treatment arrangement 300 to remove solid products from continuous heat treatment arrangement 300. Thus, solid product compression unit 400 can serve as a solid product removal unit for continuous heat treatment arrangement 300. According to various embodiments, the solid product is compressed into the at least one solid product compression unit 400 to block and prevent air from entering the continuous heat treatment arrangement 300 from the at least one solid product compression unit 400. The solid product can be removed from the system 100 by at least one solid product compression unit 400 without shutting down the continuous heat treatment arrangement 300. According to various embodiments, solid product compression unit 400 can compress solid product output from termination stage 330 of continuous heat treatment arrangement 300. According to various embodiments, solid product compression unit 400 may be similar to waste material compression unit 200 with respect to compression mechanism. However, solid product compression unit 400 may differ from waste material compression unit 200 in that solid product compression unit 400 may include a cooling arrangement rather than a heating arrangement.

According to various other embodiments, the solid product (e.g., as a final product) is compressed into the system 100 of the system 100 without compression, e.g., via the solid product compression unit 400. It can be removed or obtained directly from the termination stage 330 (eg, directly from the pyrolysis solids outlet 332 of the termination stage 330). According to various embodiments, solid product may be removed from system 100 (eg, from termination stage 330 of system 100) via or with the aid of a conveyor means, such as a screw conveyor.

According to various other embodiments, the system 100 may not include the solid product compression unit 400 coupled to the pyrolysis solids outlet 332 of the termination stage 330 (i.e., the unit may not be present). good).

FIG. 1B shows a schematic diagram of the waste material compression unit 200 of the system 100 of FIG. 1A, according to various embodiments.

According to various embodiments, waste material compaction unit 200 can include at least two (or more) rotating screws. For example, waste material compression unit 200 may include at least a first rotating screw 203a and at least a second rotating screw 203b. As another example, waste material compression unit 200 may further include a third rotating screw 203c. According to various embodiments, the inclusion of a third screw 203c in the waste material compression unit 200 may enable the waste material compression unit 200 to compress waste plastic material to a higher range or compression ratio. , which provides superior prevention of air (eg, from the atmosphere) entering the system 100 and/or superior prevention of any gases in the system 100 leaking or escaping to the atmosphere. As a further example, waste material compaction unit 200 may include one or more other additional rotating screws.

According to various embodiments, the at least two rotating screws 203 of the waste material compression unit 200 may be arranged in series. For example, the first rotating screw 203a of the waste material compression unit 200, the second rotating screw 203b of the waste material compression unit 200, and the third rotating screw 203c of the waste material compression unit 200 may be arranged in series. Therefore, the at least two rotating screws 203 of the waste material compression unit 200 are arranged sequentially from the inlet 201 (or the front end) of the waste material compression unit 200 to the outlet 202 (or the rear end) of the waste material compression unit 200. may be placed one after another. According to various embodiments, the at least two rotating screws 203 of the waste material compression unit 200 are arranged with the end of one rotating screw in the direction of or towards the end of an adjacent subsequent rotating screw. They may line up in a line. According to various embodiments, the at least two rotating screws 203 may be in an end-to-end configuration, where the end of one rotating screw is adjacent to the end of an adjacent subsequent rotating screw. Adjacent to or touching or touching an edge. According to various embodiments, the at least two rotating screws 203 may be in a spaced end arrangement, in which the end of one rotating screw has a gap between them. or spaced apart from the ends of adjacent subsequent rotating screws by intervening distances. According to various embodiments, the at least two rotating screws 203 of the waste material compression unit 200 may be arranged in sequence between the inlet 201 and the outlet 202 of the waste material compression unit 200. According to various embodiments, the direction of solids transfer of the waste material compression unit 200 may be from the inlet 201 of the waste material compression unit 200 to the outlet 202 of the waste material compression unit 200. Therefore, the direction of solids transfer is continuous from the rotating screw immediately next to the inlet 201 of the waste material compacting unit 200 to the rotating screw immediately next to the outlet 202 of the waste material compacting unit 200. It may be along at least two rotating screws 203.

According to various embodiments, the waste material compression unit 200 is configured such that the volumetric flow rate produced by each of the at least two rotating screws 203 of the waste material compression unit 200 is from the inlet 201 of the waste material compression unit 200 to the waste material compression unit 200. may be configured to descend successively one after the other until the outlet 202 of the outlet 202 . Therefore, the volumetric flow rate of each successive rotating screw of the at least two rotating screws 203 of the waste material compression unit 200 may be lower than the volumetric flow rate of the corresponding previous rotating screw. The volumetric flow rate produced by each of the at least two rotating screws 203 of the waste material compaction unit 200 is therefore reduced compared to the volumetric flow rate in the case of the previous rotating screw, so that the waste plastic material is As the material moves from the inlet 201 to the outlet 202 of the compression unit 200, it may be compressed into a compressed waste plastic feed. Thus, by reducing the volumetric flow rate of at least two screws 203 arranged in series from the inlet 201 to the outlet 202 of the waste material compression unit 200, the waste plastic material fed to the waste material compression unit 200 is Different volumetric flow rates can be moved along different segments of the waste material compression unit 200, whereby the volumetric flow rate between the different segments is reduced from the inlet 201 to the outlet 202 of the waste material compression unit 200. Thus, waste plastic material with a higher volumetric flow rate from a previous segment can collide with a later segment with a lower volumetric flow rate, compressing the waste plastic material due to the change in volumetric flow rate. According to various embodiments, the waste plastic material in the waste material compaction unit 200 is processed to remove air and/or moisture, to prevent air (e.g., from the atmosphere) from entering the system 100, and/or any gas in system 100 may be compressed or compacted to prevent leaking or escaping to the atmosphere.

According to various embodiments, the waste material compaction unit 200 may be coupled directly to the melting stage 310 of the continuous heat treatment arrangement 300. According to various embodiments, outlet 202 of waste material compression unit 200 may be connected to melting stage 310. Thus, the waste plastic material fed to the waste material compaction unit 200 may be conveyed along the waste material compaction unit 200 by at least two rotating screws 203 arranged in series. For example, waste plastic material is fed into the waste material compaction unit 200 at a first end of the first rotating screw 203a and then through the first rotating screw 203a and then the successive rotating screws (e.g., (e.g. 2 rotating screws 203b)), the waste material compaction unit 200 may be moved through (or along) the waste material compression unit 200 and then fed into the melting stage 310 of the continuous heat treatment arrangement 300.

According to various embodiments, the waste material compression unit 200 is configured such that the rotational speed of each of the at least two rotating screws 203 of the waste material compression unit 200 is such that the rotation speed of each of the at least two rotating screws 203 of the waste material compression unit 200 is such that the rotational speed of each of the at least two rotating screws 203 of the waste material compression unit 200 is such that It may be operable to lower one after the other in succession until the outlet 202. Therefore, the rotational speed of each successive rotating screw of the at least two rotating screws 203 of the waste material compression unit 200 may be lower than the rotational speed of the corresponding previous rotating screw. For example, the second rotating screw 203b of the waste material compression unit 200 has a rotation speed of 40% to 100%, or 55% to 98%, or 70% to 97% of the rotational speed of the first rotating screw 203a of the waste material compression unit 200. %, or from 80% to 95%, and the third rotating screw 203c of the waste material compression unit 200 has a rotational speed of 35% to 35% of the rotational speed of the first rotating screw 203a of the waste material compression unit 200. It can have a rotation speed of 97%, or 40% to 95%, or 50% to 90%, or 60% to 88%, or 70% to 85%. Therefore, the rotational speed of each of the at least two rotating screws 203 of the waste material compression unit 200 is reduced compared to the rotational speed of the previous rotating screw, so that the rotational speed of each of the at least two rotating screws of the waste material compression unit 200 is reduced. The volumetric flow rate produced by each of the waste material compression units 203 may decrease one after the other in succession from the inlet 201 of the waste material compression unit 200 to the outlet 202 of the waste material compression unit 200. According to various embodiments, at least two rotating screws 203 of waste material compaction unit 200 may be of the same size and/or dimensions. For example, the screw shaft diameter, screw blade diameter, and pitch of at least two rotating screws 203 of the waste material compression unit 200 may be the same.

According to various embodiments, when the waste material compression unit 200 includes a first rotating screw 203a, a second rotating screw 203b, and a third rotating screw 203c, the three rotating screws 203a, 203b, 203c Two of them may have the same rotational speed. For example, according to various embodiments, both the first rotating screw 203a and the second rotating screw 203b may have the same rotational speed, while the third rotating screw 203c It can have a smaller rotational speed compared to both the screw 203a and the second rotating screw 203b. In yet another example, according to various embodiments, both the second rotating screw 203b and the third rotating screw 203c may have the same rotational speed, while the first rotating screw 203a It can have a faster rotational speed compared to both the second rotating screw 203b and the third rotating screw 203c.

According to various embodiments, the diameter of the screw shaft of each of the at least two rotating screws 203 of the waste material compression unit 200 is continuous from the inlet 201 of the waste material compression unit 200 to the outlet 202 of the waste material compression unit 200. can be increased one after another. Accordingly, the screw shaft diameter of each successive rotating screw of the at least two rotating screws 203 of the waste material compression unit 200 may be larger than the screw shaft diameter of the corresponding previous rotating screw. For example, the diameter of the screw shaft of the first rotating screw 203a may be smaller than the diameter of the screw shaft 203b of the second rotating screw, and the screw shaft of the second rotating screw 203b may be smaller than the diameter of the screw shaft of the third rotating screw 203c. may be smaller than the diameter of the screw shaft. Therefore, due to the large screw shaft diameter of each of the at least two rotating screws 203 of the waste material compression unit 200 compared to the screw shaft diameter of the previous rotating screw, the volume of the solids transfer interval is , can be lowered from one rotating screw to the next. Therefore, the volumetric flow rate produced by each of the at least two rotating screws 203 of the waste material compression unit 200 decreases one after the other in succession from the inlet 201 of the waste material compression unit 200 to the outlet 202 of the waste material compression unit 200. Good too.
According to various embodiments, the at least two rotating screws 203 of the waste material compression unit 200 may rotate at the same or different rotational speeds, preferably at the same rotational speed.

According to various embodiments, the pitch (or pitch range) of each of the at least two rotating screws 203 of the waste material compression unit 200 is from the inlet 201 of the waste material compression unit 200 to the outlet 202 of the waste material compression unit 200. , may descend in succession from one rotating screw to another. For example, the pitch range of the first rotating screw 203a may be greater than the pitch range of the second rotating screw 203b, and the pitch range of the second rotating screw 203b may be greater than the pitch range of the third rotating screw 203c. may also be large. Thus, the pitch of each successive rotating screw of the at least two rotating screws 203 of the waste material compression unit 200 may be narrower than the pitch of the corresponding previous rotating screw. Therefore, the pitch of each of the at least two rotating screws 203 of the waste material compression unit 200 is reduced, as compared to the pitch of the previous rotating screw. The volumetric flow rate produced by each may decrease one after the other in succession from the inlet 201 of the waste material compression unit 200 to the outlet 202 of the waste material compression unit 200. According to various embodiments, the at least two rotating screws 203 of the waste material compression unit 200 can rotate at the same or different rotational speeds, preferably at the same rotational speed, have the same screw shaft diameter and the same screw blades. It can have a diameter.

According to various embodiments, at least one rotating screw of the at least two rotating screws 203 of the waste material compression unit 200 is configured such that any liquid or moisture can be drained downwardly by weight. It may be inclined with respect to the ground 9 or a horizontal plane, or may be inclined upward. The tilting of at least one of the at least two rotating screws 203 can therefore facilitate the removal of moisture from the waste plastic material. For example, as shown in FIG. 1B, the first rotating screw 203a may be vertically positioned, the second rotating screw 203b may be inclined, while the third rotating screw 203c may be located horizontally (eg, to facilitate feeding of waste plastic material to continuous heat treatment arrangement 300).

FIG. 1C shows a schematic diagram of the solid product compression unit 400 of the system 100 of FIG. 1A, according to various embodiments.

According to various embodiments, solid product compression unit 400, like waste material compression unit 200, can include at least two (or more) rotating screws. For example, solid product compression unit 400 may include at least a first rotating screw 403a and at least a second rotating screw 403b. As another example, solid product compression unit 400 may further include a third rotating screw 403c. According to various embodiments, by including a third screw 403c in the solid product compression unit 400, the solid product compression unit 400 compresses the solid product or solid material to a higher degree or compression ratio. This may provide superior prevention of air (e.g., from the atmosphere) entering the system 100 and/or superior prevention of any gases in the system 100 leaking or escaping into the atmosphere. bring. As a further example, solid product compression unit 400 may include one or more other additional rotating screws.

According to various embodiments, the at least two rotating screws 403 of the solid product compression unit 400 may be arranged in series, similar to the at least two rotating screws of the waste material compression unit 200. For example, the first rotating screw 403a of the solid product compression unit 400, the second rotating screw 403b of the solid product compression unit 400, and the third rotating screw 403c of the solid product compression unit 400 are arranged in series. You can leave it there. Accordingly, the at least two rotating screws 403 of the solid product compression unit 400 move from the inlet 401 (or the front end) of the solid product compression unit 400 to the outlet 402 (or the rear end) of the solid product compression unit 400. may be arranged one after another in order. According to various embodiments, the at least two rotating screws 403 of the solid product compression unit 400 are arranged with the end of one rotating screw in the direction of or towards the end of an adjacent subsequent rotating screw. They may line up in a line. According to various embodiments, the at least two rotating screws 403 may be in an end-to-end configuration, where the end of one rotating screw is adjacent to that of the subsequent rotating screw. Adjacent to or touching or touching an edge. According to various embodiments, the at least two rotating screws 403 may be in a spaced-apart, double-ended arrangement, in which the end of one rotating screw has a gap or gap between them. Spaced apart from the ends of adjacent trailing rotating screws by intervening spacings. According to various embodiments, the at least two rotating screws 403 of the solid product compression unit 400 may be arranged in sequence between the inlet 401 and the outlet 402 of the solid product compression unit 400. According to various embodiments, the direction of solids transfer of the solid product compression unit 400 may be from the inlet 401 of the solid product compression unit 400 to the outlet 402 of the solid product compression unit 400. Therefore, the direction of solids transfer is continuous from the rotating screw immediately adjacent to the inlet 401 of the solid product compression unit 400 to the rotating screw immediately adjacent to the outlet 402 of the solid product compression unit 400. It may be along at least two rotating screws 403 of the unit 400.

According to various embodiments, the solid product compression unit 400, similar to the waste material compression unit 200, is configured such that the volumetric flow rate produced by each of the at least two rotating screws 403 of the solid product compression unit 400 is From the inlet 401 of the compression unit 400 to the outlet 402 of the solid product compression unit 400, it may be configured to decrease successively one after the other. Therefore, the volumetric flow rate of each successive rotating screw of the at least two rotating screws 403 of the solid product compression unit 400 may be lower than the volumetric flow rate of the corresponding previous rotating screw. The volumetric flow rate produced by each of the at least two rotating screws 403 of the solid product compression unit 400 is therefore reduced compared to the volumetric flow rate for the previous rotating screw, so that the solid product is transferred to the solid product compression unit 400. The solid product may be compressed as it moves from the inlet 401 to the outlet 402. Thus, by reducing the volumetric flow rate of at least two screws arranged in series from the inlet 401 to the outlet 402 of the solid product compression unit 400, the solid product fed to the solid product compression unit 400 is , can be moved at different volumetric flow rates along different segments of the waste material compression unit 200, whereby the volumetric flow rate between the different segments is reduced from the inlet 401 to the outlet 402 of the solid product compression unit 400. Therefore, solid product with a higher volumetric flow rate from a previous segment may collide with a later segment with a lower volumetric flow rate, compressing the solid product due to the change in volumetric flow rate. According to various embodiments, the solid product in the solid product compression unit 400 is compressed to prevent air (e.g., from the atmosphere) from entering the system 100 during operation, and/or Any gas in system 100 may be compressed or compacted to prevent leaking or escaping to the atmosphere.

According to various embodiments, solid product compression unit 400 may be coupled directly to termination stage 330 of continuous heat treatment arrangement 300. According to various embodiments, the inlet 401 of the solid product compression unit 400 may be connected to the pyrolysis solids outlet 332 of the termination stage 330. Accordingly, the solid product from the termination stage 330 may be fed to the solid product compression unit 400 and is transported along the solid product compression unit 400 by at least two rotating screws 403 arranged in series. It doesn't matter if it's found out. For example, the solid product is fed to the solid product compression unit 400 at a first end of the first rotating screw 403a and then to the first rotating screw 403a and then to a successive rotating screw (e.g., The solid product compression unit 400 can be moved through (or along) the solid product compression unit 400 one after the other (such as two rotating screws 403b).

According to various embodiments, the solid product compression unit 400, like the waste material compression unit 200, is such that the rotational speed of each of the at least two rotating screws 403 of the solid product compression unit 400 increases the solid product compression From the inlet 401 of the unit 400 to the outlet 402 of the solid product compression unit 400, it may be operable to descend one after the other in succession. Therefore, the rotational speed of each successive rotating screw of the at least two rotating screws 403 of the solid product compression unit 400 may be lower than the rotational speed of the corresponding previous rotating screw. For example, the second rotating screw 403b of the solid product compression unit 400 may have a rotational speed of 40% to 100%, or 55% to 98%, or 70% of the rotational speed of the first rotating screw 403a of the solid product compression unit 400. The third rotating screw 403c of the solid product compression unit 400 can have a rotational speed of ~97%, or 80-95% of the rotational speed of the first rotating screw 403a of the solid product compression unit 400. It can have a rotation speed of 35% to 97%, or 40% to 95%, or 50% to 90%, or 60 to 88%, or 70% to 85%. Thus, the rotational speed of each of the at least two rotating screws 403 of the solid product compression unit 400 is reduced compared to the rotational speed of the previous rotating screw, so that the rotational speed of each of the at least two rotating screws 403 of the solid product compression unit 400 is reduced. The volumetric flow rate produced by each of the rotating screws 403 may decrease successively from the inlet 401 of the solid product compression unit 400 to the outlet 402 of the solid product compression unit 400. According to various embodiments, at least two rotating screws 403 of solid product compression unit 400 may be of the same or different size and/or dimensions. For example, the screw shaft diameter, screw blade diameter, and pitch of at least two rotating screws 403 of solid product compression unit 400 may be the same.

According to various embodiments, if the solid product compression unit 400 includes a first rotating screw 403a, a second rotating screw 403b and a third rotating screw 403c, similar to that of the waste material compression unit 200, Two of the three rotating screws 403 may have the same rotational speed. For example, according to various embodiments, both the first rotating screw 403a and the second rotating screw 403b may have the same rotational speed, while the third rotating screw 403c It can have a smaller rotational speed compared to both the screw 403a and the second rotating screw 403b. In yet another example, according to various embodiments, the second rotating screw 403b and the third rotating screw 403c may have the same rotational speed, while the first rotating screw 403a The second rotating screw 403b and the third rotating screw 403c can both have a faster rotational speed.

According to various embodiments, the diameter of the screw shaft of each of the at least two rotating screws 403 of the solid product compression unit 400 is similar to the diameter of the screw shaft of the waste material compression unit 200 of the solid product compression unit. From the inlet 401 of the solid product compression unit 400 to the outlet 402 of the solid product compression unit 400 can be increased successively. Accordingly, the screw shaft diameter of each successive rotating screw of the at least two rotating screws 403 of the solid product compression unit 400 may be larger than the screw shaft diameter of the corresponding previous rotating screw. For example, the diameter of the screw shaft of the first rotating screw 403a may be smaller than the diameter of the screw shaft of the second rotating screw 403b, and the screw shaft of the second rotating screw 403b may be smaller than the diameter of the screw shaft of the second rotating screw 403b. The diameter of the screw shaft can be better or smaller. Therefore, due to the large diameter of the screw shaft of each of the at least two rotating screws 403 of the solid product compression unit 400 compared to the diameter of the screw shaft in the case of the previous rotating screw, there is space for solids transfer. The volume and/or volumetric flow rate may decrease from one rotating screw to the next. Therefore, the volumetric flow rate produced by each of the at least two rotating screws 403 of the solid product compression unit 400 is successively one after the other from the inlet 401 of the solid product compression unit 400 to the outlet 402 of the solid product compression unit 400. May be lowered. According to various embodiments, the at least two rotating screws 403 of the solid product compression unit 400 may rotate at the same or different rotational speeds, preferably at the same rotational speed.

According to various embodiments, the pitch (or pitch range) of each of the at least two rotating screws 403 of the solid product compression unit 400 is similar to the pitch (or pitch range) of the waste material compression unit 200. From the inlet 401 of the product compression unit 400 to the outlet 402 of the solid product compression unit 400, it can be lowered successively from one rotating screw to another. Accordingly, the pitch of each successive rotating screw of the at least two rotating screws 403 of the solid product compression unit 400 may be narrower than the pitch of the corresponding previous rotating screw. For example, the pitch range of the first rotating screw 403a may be greater than the pitch range of the second rotating screw 403b, and the pitch range of the second rotating screw 403b may be greater than the pitch range of the third rotating screw 403c. may also be large. Therefore, the pitch of each of the at least two rotating screws 403 of the solid product compression unit 400 is reduced compared to the pitch of the previous rotating screw, so that the pitch of each of the at least two rotating screws of the solid product compression unit 400 is reduced. The volumetric flow rate produced by each of the solid product compression units 403 may decrease successively from the inlet 401 of the solid product compression unit 400 to the outlet 402 of the solid product compression unit 400. According to various embodiments, the at least two rotating screws 403 of the solid product compression unit 400 can rotate at the same or different rotational speeds, preferably at the same rotational speed, have the same screw shaft diameter and the same screw The blade can have a diameter.

According to various embodiments, at least one of the at least two rotating screws 403 of the solid product compression unit 400, similar to the waste material compression unit 200, is capable of handling any solid product in the continuous heat treatment arrangement 300. and/or the liquid may also be inclined or tilted upwards with respect to the ground 9 or horizontal plane, so that the liquid may not be able to unintentionally escape from the outlet 402 of the solid product compression unit 400. It may be facing the same direction. For example, as shown in FIG. 1C, according to various embodiments, the first rotating screw 403a may be located longitudinally below the termination stage 330, and the second rotating screw 403b may be located vertically below the termination stage 330. The third rotating screw 403c, which may be located horizontally, prevents any solid product or liquid, or a combination thereof, that falls from the first rotating screw 403a from being unintentionally removed via the third rotating screw 403c. It may be inclined with respect to the ground 9 so as to be able to collect along the second rotating screw 403b while preventing.

According to various embodiments, the solid product compression unit 400 may include a cooling jacket 470 around at least one of the at least two rotating screws 403 of the solid product compression unit 400. According to various embodiments, cooling jacket 470 can serve as a cooling arrangement for solid product compression unit 400. According to various embodiments, a cooling fluid (e.g., refrigerant) is circulated around and/or around the cooling jacket 470 to cool the solid product in the solid product compression unit 400 (e.g., the solid product compression unit 400 moving along and/or being compressed).

Referring to FIGS. 1B and 1C, waste material compression unit 200 and solid product compression unit 400 are similar in that they both function to compress solids; The solids to be compressed by each of compression units 400 may be different. For example, waste material compression unit 200 operates to compress waste plastic material, and solid product compression unit 400 operates to compress solid product from continuous heat treatment arrangement 300. Thus, waste material compression unit 200 and solid product compression unit 400 may be configured differently to compress different solids, even if they perform similar functions.

According to various embodiments, in the waste material compression unit 200, the second rotating screw 203b has a rotational speed of 40% to 100%, or 55% to 98%, or 70% to 70% of the rotational speed of the first rotating screw 203a. It can have a rotation speed of 97%, or 80% to 95%.

According to various embodiments, in the solid product compression unit 400, the second rotating screw 403b has a rotational speed of 40% to 100%, or 55% to 98%, or 70% of the rotational speed of the first rotating screw 403a. It can have a rotation speed of ˜97%, or 80% to 95%.

According to various embodiments, in the waste material compression unit 200, the third rotating screw 203c has a rotational speed of 35% to 97%, or 40 to 95%, or 50% to 90% of the rotational speed of the first rotating screw 203a. %, or 60% to 88%, or 70% to 85%.

According to various embodiments, in the solid product compression unit 400, the third rotating screw 403c has a rotational speed of 35% to 97%, or 40 to 95%, or 50% to 50% of the rotational speed of the first rotating screw 403a. It can have a rotation speed of 90%, or 60% to 88%, or 70% to 85%.

According to various embodiments, when the waste material compression unit 200 includes a first rotating screw 203a and a second rotating screw 203b, the shaft diameter of the first rotating screw 203a is equal to that of the second rotating screw 203b. It may be smaller than the shaft diameter. For example, the shaft diameter of the second rotating screw 203b may be 100% to 135% or 105% to 130% of the shaft diameter of the first rotating screw 203a.

According to various embodiments, when the solid product compression unit 400 includes a first rotating screw 203a, 403a and a second rotating screw 403b, the shaft diameter of the first rotating screw 403a is the same as that of the second rotating screw. It may be smaller than the shaft diameter of the screw 403b. For example, the shaft diameter of the second rotating screw 403b may be 100% to 135% or 105% to 130% of the shaft diameter of the first rotating screw 403a.

According to various embodiments, when the waste material compression unit 200 includes a first rotating screw 203a, a second rotating screw 203b, and a third rotating screw 203c, the shaft diameter of the first rotating screw 203a is: The shaft diameter of the second rotary screw 203b may be the same as the second rotary screw 203b, or it may be smaller, preferably smaller, and the shaft diameter of the second rotary screw 203b is the same as the shaft diameter of the third rotary screw 203c. It may be present, or it may be small. For example, according to various embodiments, the shaft diameter of the second rotating screw 203b, 403b may be between 100% and 135% or between 105% and 130% of the shaft diameter of the first rotating screw 203a, 403a. Often, the shaft diameter of the third rotating screw 203c, 403c may be 105% to 155% or 108% to 145% of the shaft diameter of the first rotating screw 203a, 403a.

According to various embodiments, when the solid product compression unit 400 includes a first rotating screw 403a, a second rotating screw 403b, and a third rotating screw 403c, the shaft diameter of the first rotating screw 403a is , may be the same as the second rotating screw 403b, or may be smaller, preferably smaller, and the shaft diameter of the second rotating screw 403b is the same as the shaft diameter of the third rotating screw 403c. or may be small. For example, according to various embodiments, the shaft diameter of the second rotating screw 403b may be 100% to 135% or 105% to 130% of the shaft diameter of the first rotating screw 403a, and the third The shaft diameter of the first rotating screw 403c may be 105% to 155% or 108% to 145% of the shaft diameter of the first rotating screw 403a.

According to various embodiments, when the waste material compression unit 200 includes a first rotating screw 203a, a second rotating screw 203b, and a third rotating screw 203c, the shaft diameter of the first rotating screw 203a is: It may be the same as the second rotating screw 203b, and the shaft diameter of the second rotating screw 203b may be smaller than the shaft diameter of the third rotating screw 203c.

According to various embodiments, when the solid product compression unit 400 includes a first rotating screw 403a, a second rotating screw 403b, and a third rotating screw 403c, the shaft diameter of the first rotating screw 403a is , may be the same as the second rotating screw 403b, and the shaft diameter of the second rotating screw 403b may be smaller than the shaft diameter of the third rotating screw 403c.

According to various embodiments, when the waste material compression unit 200 includes a first rotating screw 203a and a second rotating screw 203b, the first rotating screw 203a and the second rotating screw 203b have the same pitch range. It may have. For example, according to various embodiments, the first rotating screw 203a and the second rotating screw 203b can have a pitch range substantially within the range of 70 mm to 220 mm or 80 mm to 200 mm.

According to various embodiments, when the solid product compression unit 400 includes a first rotating screw 403a and a second rotating screw 403b, the first rotating screw 403a and the second rotating screw 403b have the same pitch. It may have a range. For example, according to various embodiments, the first rotating screw 403a and the second rotating screw 403b can have a pitch range substantially within the range of 70 mm to 220 mm or 80 mm to 200 mm.

According to various embodiments, when the waste material compression unit 200 includes a first rotating screw 203a, a second rotating screw 203b, and a third rotating screw 203c, the first rotating screw 203a, the second rotating screw Screw 203b and third rotating screw 203c may all have the same pitch range. For example, according to various embodiments, the first rotating screw 203a, the second rotating screw 203b, and the third rotating screw 203c have a pitch range substantially within the range of 70 mm to 220 mm or 80 mm to 200 mm. can have

According to various embodiments, when the solid product compression unit 400 includes a first rotating screw 403a, a second rotating screw 403b, and a third rotating screw 403c, the first rotating screw 403a, the second rotating screw Rotating screw 403b and third rotating screw 403c may all have the same pitch range. For example, according to various embodiments, the first rotating screw 403a, the second rotating screw 403b, and the third rotating screw 403c have a pitch range substantially within the range of 70 mm to 220 mm or 80 mm to 200 mm. can have

According to various embodiments, when the waste material compression unit 200 includes a first rotating screw 203a and a second rotating screw 203b, the pitch range of the first rotating screw 203a is equal to the pitch range of the second rotating screw 203b. It may be larger than the pitch range. For example, according to various embodiments, the pitch range of the second rotating screw 203b is substantially 70% to 100%, or 75% to 99%, or It may be within the range of 78% to 98%.

According to various embodiments, when the solid product compression unit 400 includes a first rotating screw 403a and a second rotating screw 403b, the pitch range of the first rotating screw 403a is the same as that of the second rotating screw 403b. may be larger than the pitch range of For example, according to various embodiments, the pitch range of the second rotating screw 403b is substantially 70% to 100% or 75% to 99% or 78% to 78% of the pitch range of the first rotating screw 403a. It may be within the range of 98%.

According to various embodiments, when the waste material compression unit 200 includes a first rotating screw 203a, a second rotating screw 203b, and a third rotating screw 203c, the pitch range of the first rotating screw 203a is: The pitch range of the second rotating screw 203b may be the same as or larger, preferably larger, and the pitch range of the second rotating screw 203b is the same as the pitch range of the third rotating screw 203c. It may be the same as or it may be larger. For example, according to various embodiments, the pitch range of the second rotating screw 203b is substantially 70% to 100% or 75% to 99% or 78% to 78% of the pitch range of the first rotating screw 203a. The pitch range of the third rotating screw 203c is substantially 65% to 98% or 75% to 95% or 80% of the pitch range of the first rotating screw 203a. It may be within the range of ~93%.

According to various embodiments, when the solid product compression unit 400 includes a first rotating screw 403a, a second rotating screw 403b, and a third rotating screw 403c, the pitch range of the first rotating screw 403a is , may be the same as the pitch range of the second rotating screw 403b, or may be larger, preferably larger, and the pitch range of the second rotating screw 403b is the pitch range of the third rotating screw 403c. It may be the same as the range or it may be larger. For example, according to various embodiments, the pitch range of the second rotating screw 403b is substantially 70% to 100% or 75% to 99% or 78% to 78% of the pitch range of the first rotating screw 403a. 98%, and the pitch range of the third rotating screw 203c, 403c is substantially 65% to 98% or 75% to 95% of the pitch range of the first rotating screw 403a. It may be within the range of 80% to 93%.

According to various embodiments, when the waste material compression unit 200 includes a first rotating screw 203a, a second rotating screw 203b, and a third rotating screw 203c, the pitch range of the first rotating screw 203a is: The pitch range of the second rotating screw 203b may be the same as the pitch range of the second rotating screw 203b, and the pitch range of the second rotating screw 203b may be larger than the pitch range of the third rotating screw 203c.

According to various embodiments, when the solid product compression unit 400 includes a first rotating screw 403a, a second rotating screw 403b, and a third rotating screw 403c, the pitch range of the first rotating screw 403a is , may be the same as the pitch range of the second rotating screw 403b, and the pitch range of the second rotating screw 403b may be larger than the pitch range of the third rotating screw 403c.

According to various embodiments, the solid product compression unit 400 is capable of compressing solid products in the range of substantially 1.0 to 3.0 g/cm ³ , preferably 1.4 to 2.2 g/cm ³ . The bulk density of the solid product may be reduced (or configured to be reduced) such that the solid product has a bulk density (i.e., passing along the solid product compression unit 400 and/or or compressed here). According to various embodiments, the solid product can have a compression ratio substantially ranging from 2.0 to 6.0.

According to various embodiments, the particle size (or average particle size) of the solid product exiting the solid product compression unit 400 may depend on the particle size of the sand and stones in the waste plastic material. According to various embodiments, the particle size (or average particle size) of the solid product exiting the solid product compression unit 400 can be substantially within the range of 30 nm to 500 nm.

Referring back to FIG. 1A, according to various embodiments, the system 100 is coupled to at least one pyrolysis gas outlet 326 or termination stage 330 of the last catalytic pyrolysis zone 324 (e.g., a fluid may include at least one heat exchanger unit 500 (coupled). According to various embodiments, the at least one heat exchanger unit 500 is configured such that the pyrolysis gas product is at least Passing through one heat exchanger unit 500, the pyrolysis gas products can be subjected to heat transfer treatment. For example, according to various embodiments, at least one heat exchanger unit 500 is capable of producing pyrolysis gases that are undesirable or unnecessary for subsequent processing to produce useful products or final products 701. It is possible to condense some of the long-chain carbon compounds of matter. These condensed long chain carbon compounds may be directed to the thermal to catalytic pyrolysis stage 320 for further cracking in the thermal to catalytic pyrolysis stage 320, for example by gravity, as recycled wax; or It may be washed away and returned. According to various embodiments, long chain carbon compounds can include, but are not limited to, compounds having carbon chains that are longer than the carbon chains of the desired product (eg, naphtha or diesel).

According to various embodiments, at least one heat exchanger unit 500 may be configured to minimize pressure drop in continuous heat treatment arrangement 300. According to various embodiments, at least one heat exchanger unit 500 may include any suitable type of heat exchanger unit 500. For example, according to various embodiments, at least one heat exchanger unit 500 may include a shell-and-tube heat exchanger or a dual pipe heat exchanger (e.g., a gravity dual pipe heat exchanger); These allow a cooling fluid, such as a refrigerant, having a temperature lower than that of the last catalytic pyrolysis zone 324 to flow through or through the outer pipes of the dual pipe heat exchanger, while continuous The hotter pyrolysis gas products produced from the heat treatment arrangement 300 (e.g., the melt stage and/or the thermal to catalytic pyrolysis stage 320 and/or the termination stage 330) are surrounded by an outer pipe, a dual pipe thermal It can flow through or pass through the inner pipe(s) of the exchanger. According to various embodiments, a dual pipe heat exchanger is preferred.

As shown in FIG. 1A, according to various embodiments, system 100 may include at least one gas separator unit 600 downstream of at least one heat exchanger unit 500. According to various embodiments, at least one gas separator unit 600 may be in fluid communication with at least one heat exchanger unit 500. According to various embodiments, at least one gas separator unit 600 may be produced in a continuous heat treatment arrangement 300 (e.g., melting stage 310 and/or thermal to catalytic pyrolysis stage 320 and/or termination stage 330). and may pass through the at least one heat exchanger unit 500, residual particulates or heavy hydrocarbons, or combinations thereof, from the pyrolysis gas products may be removed. The residual particulates removed by the at least one gas separator unit 600 may include solid particles, carbonized particles.

According to various embodiments, at least one gas separator unit 600 may include any suitable type of gas separator unit 600. For example, according to various embodiments, at least one gas separator unit 600 can include a cyclone separator or a drum separator, with a cyclone separator being preferred. Accordingly, pyrolysis gas products entering the cyclone separator may undergo vortex separation, according to various embodiments.

According to various embodiments, the at least one gas separator unit 600 is configured such that residual particulates and heavy hydrocarbons removed by the at least one gas separator unit 600 are removed for further melting, heating and/or pyrolysis, for example. The thermal to catalytic pyrolysis stage 320, such as the first thermal pyrolysis zone 321 of the thermal to catalytic pyrolysis stage 320, can be directed to or re-entered into the thermal to catalytic pyrolysis stage 320. It may be further coupled (e.g., fluidly coupled) to the catalytic pyrolysis stage 320.

According to various embodiments, the pyrolysis gas products are interconnected between at least one heat exchanger unit 500 and at least one gas separator unit 600 before entering at least one gas separator unit 600. and may enter or pass through other equipment, such as distillation column(s), or may be processed by the equipment described above.

As shown in FIG. 1A, according to various embodiments, system 100 can include at least one product separation and purification unit 700. According to various embodiments, at least one product separation and purification unit 700 may be located downstream of at least one gas separator unit 600. According to various embodiments, at least one product separation and purification unit 700 may be coupled or fluidly coupled to at least one gas separator unit 600. According to various embodiments, the at least one product separation and purification unit 700 converts pyrolysis gas products into hydrocarbons in the C2-C34 range, such as, but not limited to, hydrocarbons suitable for petrochemical processes or fuels. One or more hydrocarbon products or end products 701 (e.g., desired hydrocarbon products or end products), including hydrocarbons having carbon atoms (e.g., naphtha, diesel, or other hydrocarbons, etc.) 701) can be separated and purified. According to various embodiments, pyrolysis gas products from at least one gas separator unit 600 may be received or entered into at least one product separation and purification unit 700 for separation and purification. You may.

According to various embodiments, a method of converting waste plastic materials into useful products is provided. The method can include any one or more of the steps described herein and any corresponding features described herein.

According to various embodiments, the method can include introducing waste plastic material into the system 100.

According to various embodiments, the method can include compressing waste plastic material to form a compressed waste plastic feed, eg, via waste material compression unit 200. According to various embodiments, the method can include compressing the waste plastic material via the waste material compression unit 200 with a compression ratio substantially in the range of 2.0 to 5.0. . According to various embodiments, compression of the waste plastic material via the waste material compression unit 200 results in a compressed waste plastic feed output from the waste material compression unit 200 that is substantially between 2% and 16% by weight, preferably Air may be removed so that the air (eg, oxygen) content can be in the range of 5% to 10% by weight. According to various embodiments, compression of the waste plastic material via the waste material compression unit 200 results in a compressed waste plastic feed output from the waste material compression unit 200 that is substantially between 2% and 16% by weight, preferably Moisture may be removed so that it can have a moisture content in the range of 5% to 10% by weight.

According to various embodiments, if the waste material compaction unit 200 of the system 100 includes at least one moisture release port, the method includes , releasing moisture from the waste material compaction unit 200 or from the system 100. For example, if moisture release is desired (e.g., if moisture increases above a moisture volume threshold in the following area(s)), multiple moisture release ports may be provided along the waste material compaction unit 200 of the system 100. provided and distributed, the method includes selectively operating or opening any one or a combination of the moisture release ports of the plurality of moisture release ports. The waste material compaction unit 200 may include venting moisture from the area(s) of the waste material compaction unit 200 that are directly coupled (e.g., fluidly connected) to open moisture discharge port(s).

According to various embodiments, the compression of waste plastic material by the waste material compression unit 200 is substantially between 80°C and 170°C, or between 90°C and 140°C, or between 90°C and 160°C, or between 110°C and 120°C. or at a temperature within the range of 130°C to 150°C, or 120°C to 155°C. According to various embodiments, the compaction of the waste plastic material by the waste material compaction unit 200 is substantially between 100 kPa and 190 kPa, preferably between 100 kPa and 150 kPa, or more preferably between 100 kPa and 110 kPa (or between 0 bar gauge pressure and 0.9 bar gauge pressure). Gauge pressure, preferably 0 bar gauge pressure to 0.5 bar gauge pressure, more preferably 0 bar gauge pressure to 0.1 bar gauge pressure, or 1 bar to 1.9 bar, preferably 1 bar to 1.5 bar, or more preferably 1 bar to 1 .1 bar). According to various embodiments, the compaction of waste plastic material by the waste material compaction unit 200 may occur over a period of time ( For example, during the holding time). For example, according to various embodiments, the waste plastic material is disposed of for substantially 30 seconds to 120 seconds (or 0.5 minutes to 2.0 minutes), preferably 60 seconds to 78 seconds (or 1.0 minutes to 1.3 minutes) (e.g., holding time) by the waste material compression unit 200.

According to various embodiments, the method includes heating the compressed waste plastic feed at a temperature equal to or greater than the melting point of the compressed waste plastic feed, e.g., via melting stage 310. The method may include melting the feed to form a molten mixture. According to various embodiments, the temperature is substantially between 110°C and 350°C, or between 110°C and 160°C, or between 120°C and 140°C, between 200°C and 350°C, or between 240°C and 320°C, or between 250°C It is within the range of ~300℃. According to various embodiments, melting the compressed waste plastic feed by the melting stage 310 has a flow rate of the compressed waste plastic feed or melt mixture along the melting stage 310, or the dimensions of the melting stage 310, or the melting stage 310. Depending on or based on the reactor, it can be for a period of time (eg, holding time). For example, according to various embodiments, the melting of the compacted waste plastic feed through the melting stage 310 may be performed for substantially 10 seconds to 120 seconds, or 18 seconds to 90 seconds (i.e., 0.16 minutes to 2 minutes, .3 minutes to 1.5 minutes) or 48 seconds to 90 seconds, preferably 48 seconds to 72 seconds (i.e. 0.8 minutes to 1.5 minutes or 0.8 minutes to 1.2 minutes). (e.g., retention time).

According to various embodiments, the method includes a thermal to Feed the catalyst at one or more of the various catalyst feed points (e.g., catalyst feed ports) 32 of the pyrolysis stage 320 to separate the thermal pyrolysis process and the catalytic pyrolysis process in the thermal to catalytic pyrolysis stage 320. The method may include a step of varying the ratio of .

According to various embodiments, if the melt stage 310 of the system 100 includes at least one auxiliary catalyst feed point (e.g., a auxiliary catalyst feed port), the method may include a catalyst feed point located downstream of the melt stage 310. (e.g., catalyst feed ports) 32 (e.g., one of the at least one auxiliary catalyst feed points in the melt stage 310 of the system 100 with respect to the type or composition and/or amount of catalyst fed at one or more of the or multiple catalysts of the same or different type or composition and/or the same or different amounts.

According to various embodiments, the thermal pyrolysis process comprises converting or converting or converting or converting waste plastic materials into a catalytic pyrolysis process by interacting with a catalyst and converting the waste plastic material into a catalytic pyrolysis process. The process may be carried out at a temperature or temperature range suitable for decomposition or destruction. According to various embodiments, the thermal pyrolysis process comprises substantially between 130°C and 380°C, or between 130°C and 370°C, or between 130°C and 280°C, or between 150°C and 250°C, or between 300°C and It may be carried out or carried out at a temperature or temperature range within the range of 380°C, or 310°C to 360°C, or 320°C to 350°C.

According to various embodiments, the catalytic pyrolysis process comprises substantially 250°C to 440°C, or 250°C to 370°C, or 270°C to 320°C, or 300°C to 440°C, or 320°C to 420°C. ℃, or at a temperature or temperature range within the range of 350°C to 400°C.

According to various embodiments, the method includes heating the pyrolysis solid residue for conversion to a solid product in a termination stage 330. According to various embodiments, the method includes: (i) breaking any residual C--H bonds in the pyrolysis solid residue; (ii) removing any hydrogen from the pyrolysis solid residue; and/or (iii) heating the pyrolyzed solid residue via termination step 330 to a temperature suitable for any one or a combination of drying the pyrolyzed solid residue. can. According to various embodiments, the heating of the pyrolyzed solid residue in termination step 330 is at a temperature of at least substantially 350°C, preferably at least substantially 400°C, more preferably at least or about 410°C. can be performed or performed. According to various embodiments, the method can control the flow rate of pyrolyzed solid residue along termination stage 330, or the amount of pyrolyzed solid residue, or the amount of solid product produced, or the dimensions of termination stage 330. , or depending on the reactor having the termination stage 330, may include heating the pyrolysis solid residue through the termination stage 330 for a period of time (e.g., a hold time). For example, the heating of the pyrolyzed solid residue by termination step 330 may range from substantially 18 seconds to 210 seconds (i.e., 0.3 minutes to 3.5 minutes), or from 42 seconds to 180 seconds (i.e., 0.7 minutes to 3 minutes). 0 minutes) or for a period (eg, hold time) of 84 seconds to 144 seconds (ie, 1.4 minutes to 2.4 minutes). According to various embodiments, the method provides a method in which the solid product (i.e., produced in the final step 330) is substantially within the range of 5% to 35% by weight, preferably 10% to 30% by weight. and a solids content in the range of substantially 60% to 95%, preferably 70% to 90%, more preferably at least 90% by weight. Step 330 can include heating the pyrolyzed solid residue to remove moisture (ie, from the pyrolyzed solid residue).

According to various embodiments, the melting of the compressed waste plastic feed, the thermal pyrolysis process and/or the catalytic pyrolysis process, and the heating of the pyrolysis solid residue in termination stage 330 may be performed at the same pressure. . According to various embodiments, the pressure is substantially between 100 kPa and 110 kPa, or between 120 kPa and 180 kPa, or between 140 kPa and 160 kPa (0 bar gauge pressure to 0.1 bar gauge pressure, or 0.2 bar gauge pressure to 0.8 bar gauge pressure). or 0.4 bar gauge pressure to 0.6 bar gauge pressure, or 1 bar to 1.1 bar, or 1.2 bar to 1.8 bar, or 1.4 bar to 1.6 bar).

According to various embodiments, the method can include removing solid product from termination stage 330.

According to various embodiments, the removal of solid product from termination stage 330 prevents the solid product that builds up (or remains) in termination stage 330 from unintentionally flooding or leaking out of termination stage 330. Instead, the pyrolysis solids outlet 332 of the termination stage 330 is blocked to prevent solid products from building up in the termination stage 330 to prevent gas leakage from the termination stage 330 via the pyrolysis solids outlet 332. It may include waiting and/or allowing the increase.

According to various embodiments, removing solid products from termination stage 330 can include continuously removing solid products from termination stage 330.

According to various embodiments, the method includes adjusting the proportions of the thermal to catalytic pyrolysis process within the thermal to catalytic pyrolysis stage 320 to achieve the desired final product output from the system 100. Monitoring properties of the final product 701 output from the system 100 (i.e., obtained from the at least one product separation and purification unit 700) to determine whether the final product 701 is necessary to produce the product 701. can. For example, according to various embodiments, the final product 701 in the form of one or more hydrocarbon products obtained from the at least one product separation and purification unit 700 is the final product initially produced from the system 100. It can be the first sample or the first iteration of the object 701. The property monitored may be or include the specific gravity of such final product 701 initially produced from the system 100, and/or any other suitable property(s). be able to. According to various embodiments, the desired properties are determined based on the monitored or determined property(s) (e.g., specific gravity) of such final product(s) 701 initially produced from the system 100. It may be determined whether to add catalyst to at least one intermediate variable zone 322 and/or the last catalytic pyrolysis zone 324 to obtain a final product 701 of . Therefore, determining the necessary adjustment of the proportions of thermal and catalytic pyrolysis processes can be based on iterative processing until the desired end product 701 is achieved.

For example, upon startup of system 100 or at the beginning of the method, catalyst may be fed to one of the catalyst feed points of system 100 (the "initial catalyst feed point"). According to various embodiments, the initial catalyst feed point can be optional, such as the feed port 32b of the last catalytic pyrolysis zone 324. The characteristic(s) of the final product 701 initially produced from the system 100, which may be a first sample or first iteration of the final product 701, then Product 701 may be monitored to determine whether it has the same property(s) (eg, specific gravity, etc.) as desired final product 701. Otherwise, the point(s) at which the catalyst is fed into the system 100 may be adjusted to correspondingly change the final product 701 output from the system 100. The point(s) at which the catalyst is fed may be adjusted until the corresponding end product 701 output from the system 100 matches the desired end product 701. If longer catalytic cracking times for the waste plastic material are required to produce the desired final product 701, the catalyst may be added to the system 100 earlier (e.g., during the melting stage 310). Nearer catalyst feed point 32). According to various embodiments, the adjusted point(s) at which catalyst is fed into system 100 may include or be different from the initial catalyst feed point.

According to various embodiments, adjusting the ratio of the thermal pyrolysis process and the catalytic pyrolysis process can include adjusting the retention time of the thermal pyrolysis process and/or the retention time of the catalytic pyrolysis process. .

According to various embodiments, determining the ratio or adjustment of the required thermal and catalytic pyrolysis processes may be based on the composition of the waste plastic material and/or the type of catalyst used.

According to various embodiments, the method can include withdrawing pyrolysis gas products from continuous heat treatment arrangement 300. In particular, according to various embodiments, the method includes withdrawing pyrolysis gas products from the thermal to catalytic pyrolysis stage 320 of the system 100 and/or the termination stage 330 of the continuous heat treatment arrangement 300. I can do it.

According to various embodiments, the method can include condensing (eg, some) long chain carbon compounds from the pyrolysis gas products by at least one heat exchanger unit 500. According to various embodiments, the condensation of long chain carbon compounds in the pyrolysis gas products by the at least one heat exchanger unit 500 occurs after withdrawing the pyrolysis gas products from the thermal to catalytic pyrolysis stage 320. May be done. According to various embodiments, the method can include returning or recycling the condensed long chain carbon compounds to the thermal to catalytic pyrolysis stage 320. For example, the condensed long chain carbon may be directed to the thermal to catalytic pyrolysis stage 320, eg, by gravity, as recycled wax, or may be flowed back.

According to various embodiments, the method can include removing particulates or heavy hydrocarbons, or a combination thereof, from the pyrolysis gas products, e.g., by at least one gas separator unit 600. . According to various embodiments, the removal of particulates or heavy hydrocarbons, or a combination thereof, from the pyrolysis gas products by at least one gas separator unit 600 passes to at least one heat exchanger unit 500. may be performed on the pyrolysis gas products after the According to various embodiments, the method includes returning or recycling particulates and/or heavy hydrocarbons removed by the at least one gas separator unit 600 to the thermal to catalytic pyrolysis stage 320. can be included. For example, the removed particulates and/or heavy hydrocarbons may be directed to a thermal to catalytic pyrolysis stage 320 after the pyrolysis gas products have been processed by at least one gas separator unit 600. Or it may be re-entered. According to various embodiments, the method processes the particulates and/or heavy hydrocarbons that are returned to the thermal to catalytic pyrolysis stage 320 (e.g., melts them and/or undergoes a pyrolysis process). , and/or heating them).

According to various embodiments, prior to entering at least one gas separator unit 600, the pyrolysis gas products are interconnected between at least one heat exchanger unit 500 and at least one gas separator unit 600. may enter or pass through or be processed by other equipment, such as a distillation column with which it is fluidly connected.

According to various embodiments, the method transfers pyrolysis gas products from at least one gas separator unit 600 to one or more hydrocarbon products or end products 701, such as a petrochemical process or fuel. The process may include separating and refining hydrocarbons having carbon atoms in the range of C2 to C34, such as hydrocarbons suitable for use in, for example, naphtha, diesel or other hydrocarbons. Accordingly, after the pyrolysis gas products have been processed by the at least one gas separator unit 600, the processed pyrolysis gas products are converted into one or more final products 701 (e.g. at least one product separation and purification unit for separating and refining hydrocarbons having carbon atoms in the range of C2 to C34, such as hydrocarbon waters, such as naphtha, diesel or other hydrocarbons, suitable for petrochemical processes or fuels; 700.

Some examples of operation of systems and methods according to various embodiments are described below by reference to Examples (A) and (B).

The examples described below (i.e., Examples (A) and (B)) were performed in a pilot system (or test system or experimental system) constructed in accordance with the system 100 of various embodiments. The melting stage, thermal to catalytic pyrolysis stage and termination stage of this pilot system can be carried out in a multi-zone reactor. According to various embodiments, the total length of the reactor can be 16 m, thereby providing a first end of the reactor (e.g., in the melt stage) to a first catalyst feed port (e.g., in the melt stage). The length from the first end of the reactor to the second catalyst feed port may be 6 m, and the length from the first end of the reactor to the second catalyst feed port may be 6 m. The length from the end of 1 to the third catalyst feed port may be 9 m.

Example (A):
The feed used for the pilot system is 50% by weight of '7% PVC, 55% PE, 31% PP, 4% PS and 3% others', 20-30% moisture and 20-30% sand and stone. It can include a mixture of waste plastics, including 30% by weight. The feed may be compressed in a compression stage (eg, a waste material compression unit) at a temperature of about 115°C (or, in another example, about 140°C). The compressed feed may be introduced into the reactor at a first end of the reactor, where the melting step is at a temperature of about 130°C (or in another example, about 300°C). to form a molten mixture. The molten mixture may then be transferred to a thermal to catalytic pyrolysis stage, where the thermal pyrolysis is performed initially at a temperature of about 270°C (or in another example, about 330°C) and then Catalyst is added through the second catalyst feed port (ie 6 m from the first end of the reactor). After adding the catalyst, the thermal pyrolysis process can be converted to a catalytic pyrolysis process at a temperature of about 330° C. (or in another example, about 400° C.) in a thermal to catalytic pyrolysis step. . The pyrolysis gas products produced in the reactor are withdrawn from the reactor in the termination stage and put into a double pipe heat exchanger to condense the long chain carbon compounds in the pyrolysis gas products, and then passed through a cyclone separator. to remove particulates or heavy hydrocarbons in the pyrolysis gas products. The pyrolyzed solid residue produced in the reactor can be transferred to a termination stage, which is operated at 350°C (or in another example, about 410°C) to remove the pyrolyzed solid residue. destroy any residual carbon-hydrogen (C-H) bonds in the pyrolysis solid residue, remove any hydrogen from the pyrolysis solid residue, and/or dry the pyrolysis solid residue to produce a solid product (or production). The solid product can be removed by a solid product compression unit, whereby the rotational speed of the second screw of the solid product compression unit can be about 90% of the rotational speed of the first screw, and the solid product can be removed by a solid product compression unit. The rotational speed of the third screw of the product compression unit may be approximately 80% of the rotational speed of the first screw. The diesel selectivity of the pyrolysis gas product may be 50.10% and the naphtha selectivity of the pyrolysis gas product may be 7.40%. The bulk density of the solid product can be 1.91 g/ ^cm3 .

Example (B):
Example (B) is Example (A) using the same feed, except that catalyst can be added via the first catalyst feed port (i.e. 3 m from the first end of the reactor). It can be operated under the same conditions. The diesel selectivity of the pyrolysis gas product may be 7.40% and the naphtha selectivity of the pyrolysis gas product may be 57.40%. The bulk density of the solid product can be 1.97 g/ ^cm3 .

By comparing Example (A) and Example (B), it can be observed that feeding the catalyst at different catalyst feed ports can result in different product selectivities. Thus, individual catalyst feed ports feed catalyst into the system based on the desired product (i.e., desired end product) or the characteristics or composition of the waste plastic material or feed introduced into the system. may be selected for. Accordingly, various types of waste plastic materials may be converted into useful products by using the present system and methods according to various embodiments.

Various embodiments provide systems and methods for converting waste plastic materials into useful products. In various embodiments, the present systems and methods can include selectively varying points along the system, wherein the catalyst is provided at various points (i.e., stages) along the system, and the catalyst is at least It is added via two catalyst feed ports and/or at least one auxiliary catalyst feed port. Therefore, the catalyst can be selectively added only at certain points in the system, in which case the system can optimally perform its function without wasting catalyst.

Additionally, in various embodiments, the systems and methods provide a versatile and efficient pyrolysis process. In various embodiments, a wide variety of raw materials can be used in the present systems and methods. For example, in various embodiments, adulterated raw materials can be used in the present systems and methods to achieve desired results. In various embodiments, the system and method may be easy to control and safe to operate to obtain the desired end product.

Although the invention has been particularly shown and described with reference to specific embodiments thereof, various changes in form and detail may be made without departing from the scope of the invention, which is defined by the appended claims. It should be understood by those skilled in the art that , modifications and variations may be made. The scope of the invention is, therefore, indicated by the appended claims, and, accordingly, all changes that come within the meaning and range of equivalency of the claims are intended to be embraced.

Claims (34)

A system for converting waste plastic materials into useful products, the system comprising:
a melting stage for melting compressed waste plastic feed produced from waste plastic material to form a molten mixture;
a thermal to catalytic pyrolysis stage downstream of the melting stage for subjecting the molten mixture to a thermal pyrolysis process followed by a catalytic pyrolysis process to produce pyrolysis gas products and pyrolysis solid residues; at least two catalyst feed points distributed along the thermal to catalytic pyrolysis stage, and the ratio between the thermal and catalytic pyrolysis processes varies within the thermal to catalytic pyrolysis stage; at various points along the thermal to catalytic pyrolysis stage in such a way as to a thermal to catalytic pyrolysis stage operable to selectively feed a catalyst through a plurality of pyrolysis solid residues downstream of the thermal to catalytic pyrolysis stage for conversion to solid products; A system comprising a continuous heat treatment arrangement having a termination stage for heating. a waste material compression unit upstream of the continuous heat treatment arrangement, operative to compress waste plastic material to remove air and moisture to produce a compressed waste plastic feed for feeding into the continuous heat treatment arrangement; 2. The system of claim 1, further comprising a waste material compaction unit capable of being compressed. The thermal to catalytic pyrolysis step
an initial thermal pyrolysis zone for heating the molten mixture received from the melting stage at or above the pyrolysis temperature of the molten mixture;
one or more intermediate variable zones, each intermediate variable zone having a catalyst feed port at the beginning of the intermediate variable zone, the catalyst feed port along the thermal to catalytic pyrolysis stage; one or more intermediate variable zones serving as one of at least two catalyst feed points; and a final catalyst feed of at least two catalyst feed points along the thermal to catalytic pyrolysis stage for receiving catalyst. a last catalytic pyrolysis zone with a catalyst feed port at the beginning of the last catalytic pyrolysis zone serving as a point;
The catalyst is provided at various points along the thermal to catalytic pyrolysis stage, at one or more intermediate variable zone catalyst feed ports, or at the end, to convert a thermal pyrolysis process to a catalytic pyrolysis process. 3. The system of claim 1 or 2, fed from a catalyst feed port of the catalytic pyrolysis zone. System according to any one of claims 1 to 3, wherein the melting stage comprises at least one auxiliary catalyst feed point for feeding catalyst in the melting stage. The continuous heat treatment arrangement comprises at least one pyrolysis gas outlet for discharging pyrolysis gas products, the at least one pyrolysis gas outlet being a thermal to catalytic pyrolysis stage or a termination stage, or both. 5. The system of claim 3 or claim 4, wherein the at least one pyrolysis gas outlet in both last catalytic pyrolysis zones comprises a vacuum pump. 6. The system of claim 5, further comprising at least one heat exchanger unit coupled to at least one pyrolysis gas outlet for condensing long chain carbon compounds in the pyrolysis gas product. 7. Further comprising at least one gas separator unit downstream of the at least one heat exchanger unit for removing residual particulates or heavy hydrocarbons, or a combination thereof, from the pyrolysis gas products. System described. System according to any one of claims 1 to 7, wherein the termination stage comprises at least one solid product outlet for removing solid product. System according to any one of claims 1 to 8, wherein the continuous heat treatment arrangement comprises a reactor comprising any one or a combination of a melting stage, a thermal to catalytic pyrolysis stage or a termination stage. . 10. The system of claim 9, wherein the reactor is tilted with a rate of rise per horizontal distance of 1:250 to 1:20. The waste material compression unit comprises at least two rotating screws arranged in series from the inlet of the waste material compression unit to the outlet of the waste material compression unit, the direction of solids transfer being from the inlet of the waste material compression unit. System according to any one of claims 2 to 10, in combination with claim 2, up to the outlet of the waste material compression unit. The volumetric flow rate produced by each of the at least two rotating screws of the waste material compression unit is successively reduced from the inlet of the waste material compression unit to the outlet of the waste material compression unit to compress the waste plastic material into waste plastics. 12. The system of claim 11, compressing into a feed. further comprising at least one solid product compression unit for compressing a solid product output from a termination stage of the continuous heat treatment arrangement, the solid product compression unit being downstream of the termination stage of the continuous heat treatment arrangement. , a system according to any one of claims 1 to 12. The solid product compression unit comprises at least two rotating screws arranged in series from the inlet of the solid product compression unit to the outlet of the solid product compression unit, and the direction of solids transfer is directed to the solid product compression unit. 14. The system of claim 13, from the inlet of the unit to the outlet of the solid product compression unit. The volumetric flow rate produced by each of the at least two rotating screws of the solid product compression unit is successively reduced one after the other from the inlet of the solid product compression unit to the outlet of the solid product compression unit to compress the solid product. 15. The system of claim 14, wherein the system compresses. 16. The method according to claim 14 or 15, wherein the rotational speed of each of the at least two rotating screws of the solid product compression unit decreases successively one after the other from the inlet of the solid product compression unit to the outlet of the solid product compression unit. System described. System according to any one of claims 14 to 16, wherein the solid product compression unit further comprises at least three rotating screws. A method of converting waste plastic materials into useful products, the method comprising:
introducing a compressed waste plastic feed produced from waste plastic material into a melting stage of a continuous heat treatment arrangement of a system for converting waste plastic materials into useful products, the melting stage comprising compressed waste plastic feed; melting to form a molten mixture;
Catalyst is selectively fed by any one or more of the at least two catalyst feed points of the thermal to catalytic pyrolysis stage of the continuous heat treatment arrangement of the system to varying the proportions of a pyrolysis process and a catalytic pyrolysis process, the thermal to catalytic pyrolysis stage being downstream of the melting stage to produce pyrolysis gas products and pyrolysis solid residues; subjecting the molten mixture to a thermal pyrolysis process, followed by a catalytic pyrolysis process, and removing solid products from a termination stage of a continuous heat treatment arrangement of the system, the termination stage being a thermal pyrolysis process; A method downstream of a catalytic pyrolysis stage, the method comprising heating a pyrolysis solid residue to convert it to a solid product. To determine whether adjustment of the proportions of thermal and catalytic pyrolysis processes within the thermal to catalytic pyrolysis stage is necessary to produce the desired end product output from the system. , monitoring at least one property of the final product output from the system; 19. The method of claim 18, further comprising selectively feeding the catalyst through one or more of the following: 20. The method of claim 18 or claim 19, further comprising feeding the catalyst through at least one auxiliary catalyst feed point in the melting stage of the continuous heat treatment arrangement of the system. 21. The method of any one of claims 18 to 20, further comprising withdrawing pyrolysis gas products from the continuous heat treatment arrangement via at least one pyrolysis gas outlet of the continuous heat treatment arrangement. condensing long-chain carbon compounds from the pyrolysis gas product by at least one heat exchanger unit connected to at least one pyrolysis gas outlet; and converting the long-chain carbon compounds into a thermal to catalytic pyrolysis step. 22. The method of claim 21, further comprising the step of reverting to . removing residual particulates or heavy hydrocarbons, or a combination thereof, from the pyrolysis gas product by at least one gas separator unit downstream of the at least one heat exchanger unit; and residual particulates or heavy carbonization. 23. The method of claim 22, further comprising returning hydrogen, or a combination thereof, to the thermal to catalytic pyrolysis stage. further comprising compressing the waste plastic material through a waste material compression unit, the waste material compression unit being upstream of a continuous heat treatment arrangement of the system for converting waste plastic material into a useful product. The method according to any one of items 18 to 23. removing a solid product from a terminal stage of a continuous heat treatment arrangement of the system through a solid product compression unit, the solid product compression unit comprising: a solid product compression unit; at least two rotating screws arranged in series, the direction of solids transfer being from the inlet of the solid product compression unit to the outlet of the solid product compression unit; A method according to any one of claims 18 to 24. The volumetric flow rate produced by each of the at least two rotating screws of the solid product compression unit is successively reduced from the inlet of the solid product compression unit to the outlet of the solid product compression unit to compress the solid product. 26. The method of claim 25, comprising compressing. 26. The rotational speed of each of the at least two rotating screws of the solid product compression unit decreases successively one after the other from the inlet of the solid product compression unit to the outlet of the solid product compression unit. Method. A solids compression unit comprising at least two rotating screws arranged in series from an inlet of the solids compression unit to an outlet of the solids compression unit, wherein the at least two rotating screws are connected to the inlet of the solids compression unit. A solids compression unit, wherein the at least two rotating screws are cooperatively operable to compress the solid material upon moving the solid material from the solid material to the outlet of the solids compression unit. As the solid material is moved from the inlet of the solids compression unit to the outlet of the solids compression unit, at least two rotating screws of the solids compression unit are operated in concert to compress the solid material. Solids compression unit according to claim 28, wherein the volumetric flow rate produced by each decreases one after the other in succession from the inlet of the solids compression unit to the outlet of the solids compression unit. Solids according to claim 28 or 29, wherein the rotational speed of each of the at least two rotating screws of the solids compression unit decreases successively one after the other from the inlet of the solids compression unit to the outlet of the solids compression unit. material compression unit. 30. The diameter of the screw shaft of each of the at least two rotating screws of the solids compression unit increases successively one after the other from the inlet of the solids compression unit to the outlet of the solids compression unit. solids compression unit. The pitch range of each of the at least two rotating screws of the solids compression unit decreases successively from one rotating screw to another from the inlet of the solids compression unit to the outlet of the solids compression unit. A solids compression unit according to claim 28 or 29. Solids compression unit according to any one of claims 28 to 32, further comprising at least three rotating screws. Solids compression unit according to any one of claims 28 to 33, further comprising a cooling jacket around the at least one rotating screw.

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