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Patent 2202941 Summary

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(12) Patent Application: (11) CA 2202941
(54) English Title: DEPOLYMERIZATION
(54) French Title: DEPOLYMERISATION
Status: Dead
Bibliographic Data
(51) International Patent Classification (IPC):
  • C07C 4/22 (2006.01)
  • C08J 11/10 (2006.01)
  • C08J 11/20 (2006.01)
  • C10G 1/00 (2006.01)
  • C10G 1/10 (2006.01)
(72) Inventors :
  • KRZYWICKI, ANDRZEJ Z. (Canada)
  • OBALLA, MIKE C. (Canada)
  • WONG, WILLIAM (Canada)
  • WONG, CHI (Canada)
(73) Owners :
  • NOVA CHEMICALS LTD. (Canada)
(71) Applicants :
  • NOVA CHEMICALS LTD. (Canada)
(74) Agent:
(74) Associate agent:
(45) Issued:
(22) Filed Date: 1997-04-17
(41) Open to Public Inspection: 1998-10-17
Examination requested: 2002-02-27
Availability of licence: N/A
(25) Language of filing: English

Patent Cooperation Treaty (PCT): No

(30) Application Priority Data: None

Abstracts

English Abstract



Thermoplastic waste may be depolymerized by heating the
thermoplastic to a temperature from about 623°K to 773°K at a low
pressure for a time of at least 30 minutes in the presence of a catalyst.
Optionally the depolymerization may be conducted in the presence of
hydrogen and in the presence of other hydrocarbon streams. The product
is suitable to go into a petroleum refinery product stream or into a
petrochemical plant as feedstock, e.g. a naphtha steam cracker for the
production of ethylene and coproducts. The invention provides a method
to "recycle" plastics to valuable feedstocks.


French Abstract

Les déchets thermoplastiques peuvent être dépolymérisés par chauffage à une température allant d'environ 623 à 773 degrés K à basse pression pendant au moins 30 minutes en présence d'un catalyseur. La dépolymérisation peut au choix être effectuée en présence d'hydrogène et de courants d'hydrocarbures. Le produit peut être utilisé dans un courant de produits de raffinerie de pétrole ou dans une usine pétrochimique comme matière première, p. ex., vapocraquage du naphta pour la production d'éthylène et de coproduits. L'invention fournit une méthode pour «recycler» les plastiques en matières premières de valeur.

Claims

Note: Claims are shown in the official language in which they were submitted.


The embodiments of the invention in which an exclusive property or
privilege is claimed are defined as follows:


1. A process to recover hydrocarbons from waste thermoplastic
material comprising:
(i) heating clean particulate thermoplastic waste material comprising at
least 85 weight % of one or more polymers selected from the group
consisting of:
(A) polymers comprising from 85 to 100 weight % of ethylene
and from 0 to 15 weight % of one or more C4-12 alpha olefins,
(B) polymers comprising 55 weight % of ethylene and up to 45
weight % of vinyl acetate;
(C) polymers comprising from 50 to 80 weight % of propylene
and from 50 to 30 weight % of ethylene;
(D) polymers comprising from 100 to 50 weight % of one or more
C8-12 vinyl aromatic monomers which are unsubstituted or
substituted by a C1-4 alkyl radical and from 0 to 50 weight %
of one or more monomers selected from the group
consisting of C1-4 alkyl esters of C3-6 ethylenically
unsaturated carboxylic acids; and maleic anhydride; and
(E) polyesters selected from the group consisting of
polyethylene terephthalate, polybutylene terephthalate and
polyethylene naphthenate, and
up to 15 weight % of one or more polymers selected from the group
consisting of:




(F) polymers comprising from 100 to 50 weight % of one or more
C8-12 vinyl aromatic monomers which are unsubstituted or
substituted by a C1-4 alkyl radical and from 0 to 50 weight %
of one or more monomers selected from the group
consisting of C1-4 alkyl esters of C3-6 ethylenically
unsaturated carboxylic acids; and maleic anhydride which
have been grafted on to up to 20 weight % of one or more
rubbers selected from the group consisting of:
(1) polymers comprising from 40 to 60 weight % of one or
more C8-12 vinyl aromatic monomers which are
unsubstituted or substituted by a C1-4 alkyl radical,
and from 60 to 40 weight % of one or more C4-6
conjugated diolefins;
(2) polymers comprising co- or homopolymers of one or
more C4-6 conjugated diolefins; and
(3) polymers comprising one or more C4-8 alkyl esters of
acrylic or methacrylic acid, and
(G) polyvinyl chloride,
in a non-oxidizing atmosphere to produce a melt;
(ii) contacting in a reactor said melt with one or more catalysts selected
from the group consisting of natural zeolites, synthetic zeolites,
bauxite, the residue produced by the removal of aluminum from
bauxite, alkali oxides, alkaline metal earth oxides, aluminum
phosphates, transition metal oxides, and mixtures thereof to
provide a weight ratio of said melt to said one or more catalysts of
21

from 100:1 to 5:1 at a pressure from 10 to 507 kPa under a
non-oxidizing atmosphere at a temperature from 623°K to 773°K for a
period of time from 10 minutes to 180 minutes and a conversion of
at least 20%;
(iii) removing from said reactor a gaseous stream comprising hydrogen
and one or more C1-4 saturated and unsaturated hydrocarbons; a
liquid stream comprising one or more members selected from the
group consisting of C4-12 saturated and unsaturated hydrocarbons;
and removing as a bottom stream paraffin wax and a stream of
unreacted thermoplastic.

2. The process according to claim 1, wherein the pressure is from 76
to 304 kPa.

3. The process according to claim 2, wherein the temperature is from
663°K to 723°K.

4. The process according to claim 3, wherein the time of contact
between said melt and said catalyst is from 20 minutes to 90 minutes.


5. The process according to claim 4, wherein said non-oxidizing
atmosphere is selected from the group consisting of hydrogen, helium,

nitrogen, argon and mixtures thereof.
22

6. The process according to claim 5, wherein said catalyst together
with a binder is in the form of particles or pellets having a size from 0.1 to
10 mm.

7. The process according to claim 6, which is continuous, wherein
said reactor is a cracking column; and further comprising step (iv)
recycling said stream of unreacted thermoplastic.

8. The process according to claim 6, wherein said process is a batch
process carried out in a stirred tank reactor and said thermoplastic and
said catalyst are subject to shear after said thermoplastic has been heated
to a temperature of 623°K.

9. The process according to claim 7, wherein said thermoplastic is at
least 85 weight % of a polymer comprising from 85 to 100 weight % of
ethylene and from 0 to 15 weight % of one or more C4-12 alpha olefins.


10. The process according to claim 8, wherein said thermoplastic is at
least 85 weight % of a polymer comprising from 85 to 100 weight % of
ethylene and from 0 to 15 weight % of one or more C4-12 alpha olefins.


11. The process according to claim 7, wherein in step (i) said
thermoplastic waste is in the form of pellets having a size from 0.1 to
10 mm.
23


12. The process according to claim 7, wherein in step (i) said
thermoplastic waste is shredded to a particle size less than 5 cm.

13. The process according to claim 11, wherein said catalyst comprises
aluminum phosphate.


14. The process according to claim 12, wherein said catalyst comprises
aluminum phosphate.


15. The process according to claim 11, wherein said catalyst comprises
a transition metal oxide.


16. The process according to claim 12, wherein said catalyst comprises
a transition metal oxide.

17. The process according to claim 11, wherein said catalyst comprises
an alkali or alkaline earth metal oxide.


18. The process according to claim 12, wherein said catalyst comprises
an alkali or alkaline earth metal oxide.


19. The process according to claim 11, wherein said catalyst comprises
bauxite.

24


20. The process according to claim 12, wherein said catalyst comprises
bauxite.


21. The process according to claim 11, wherein said catalyst comprises
the residue produced by the removal of aluminum from bauxite.


22. The process according to claim 12, wherein said catalyst comprises
the residue produced by the removal of aluminum from bauxite.


23. The process according to claim 11, wherein said catalyst comprises
an intermediate pore size zeolite.


24. The process according to claim 12, wherein said catalyst comprises
an intermediate pore size zeolite.


25. The process according to claim 23, wherein said catalyst comprises
an intermediate pore size zeolite which has entrained or has been ion
exchanged with from 0.1 to 10 weight % of a metal selected from the
group consisting of platinum, palladium, and nickel.


26. The process according to claim 24, wherein said catalyst comprises
an intermediate pore size zeolite which has entrained or has been ion
exchanged with from 0.1 to 10 weight % of a metal selected from the
group consisting of platinum, palladium, and nickel.



27. The process according to claim 11, wherein said catalyst comprises
a mixture of an alkali or alkaline earth metal oxide and one or more
intermediate pore size zeolites.

28. The process according to claim 12, wherein said catalyst comprises
a mixture of an alkali or alkaline earth metal oxide and one or more
intermediate pore size zeolites.


29. The process according to claim 11, wherein said plastic is
coprocessed with one or more members selected from the group
consisting of vacuum gas oils, pyrolysis fuel oil, and with waste or
contaminated solvent from a solution polymerization process.


30. The process according to claim 12, wherein said plastic is
coprocessed with one or more members selected from the group
consisting of vacuum gas oils, pyrolysis fuel oil, and with waste or
contaminated solvent from a solution polymerization process.


31. The process according to claim 11, further comprising dissolving
said paraffin wax in light oil or naphtha and feeding the resulting stream to
a cracker.


32. The process according to claim 12, further comprising dissolving
said paraffin wax in light oil or naphtha and feeding the resulting stream to
a cracker.

26

33. The process according to claim 11, further comprising feeding said
liquid stream comprising one or more saturated C4-12 hydrocarbons to a
gasoline refiner.

34. The process according to claim 12, further comprising feeding said
liquid stream comprising one or more saturated C4-12 hydrocarbons to a
gasoline refiner.


35. The process according to claim 11, further comprising feeding said
liquid stream to a naphtha steam cracker to produce ethylene and
coproducts.


36. The process according to claim 12, further comprising feeding said
liquid stream to a naphtha steam cracker to produce ethylene and
coproducts.
27

Description

Note: Descriptions are shown in the official language in which they were submitted.


' CA 02202941 1997-04-17


Depolv,., e ri,alion
FIELD OF THE INVENTION
The present invention relates to the treatment of waste
thermoplastic material and more particularly the recovery of hydrocarbon
streams from waste thermoplastic. More particularly the present invention
relates to the "depolymerization" of waste thermoplastic material,
optionally in the presence of vacuum distillates or pyrolysis fuel oil (PFO).
BACKGROUND OF THE INVENTION
The article "Wasfe plastic yields high-quality fuel O;/n in Science
News, Vol.144, page 134 teaches that waste thermoplastic may be
converted into a hydrocarbon stream similar to a light crude oil by heating
a mixture of zeolite catalysts, tetralin (i.e. tetrahydronaphthalene) and
waste thermoplastic in a sand bath and then feeding the mixture to a
"tubing-bomb" and heating to 693~K (420~C) in the presence of hydrogen
for about an hour. The present invention does not contemplate the use of
a "sand bed" nor does it require the use of tetralin.
United States patent 5,364,995, issued November 15,1994,
assigned to BP Chemicals Limited teaches producing waxes from
thermoplastic material by feeding the thermoplastic to a fluidized bed of
infusible material such as quartz sand, silica, ceramics, carbon black and
aluminosilicates and the like, together with a fluidizing gas free of
molecular oxygen such as nitrogen or refinery fuel gas and maintaining the
bed at a temperature of above 573~K (300~C) and below 963~K (690~C).
As noted above the present invention does not contemplate the presence



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of an infusible material, nor does the reaction take place in a fluidized bed
reactor.
United States patent 4,851,601, issued July 25,1989, assigned to
Mobil Oil Corporation teaches a two stage process for cracking
thermoplastics to produce an oil. In the first step the thermoplastic is
thermally cracked at a temperature of at least 633~K (360~C), preferably in
the presence of particulate porous material to a vaporous overhead
stream which is then contacted with an acidic intermediate pore size
zeolite at an elevated temperature of at least 523~K (250~C) to produce a
hydrocarbon oil having a low pour point. The present invention does not
contemplate such a two stage reaction.
The present invention seeks to provide a simple direct reaction in
the absence of an inert particulate material to depolymerize waste

thermoplastic to one or more hydrocarbon streams which are useful per se
or may be further refined.
SUMMARY OF THE INVENTION
The present invention provides a process to recover hydrocarbons
from waste thermoplastic material comprising:
(i) heating clean particulate thermoplastic waste material comprising at
least 85 weight % of one or more polymers selected from the group
consisting of:
(A) polymers comprising from 85 to 100 weight % of ethylene
and from 0 to 15 weight % of one or more C4 12 alpha olefins,
(B) polymers comprising 55 weight % of ethylene and up to 45
weight % of vinyl acetate;


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(C) polymers comprising from 50 to 80 weight % of propylene
and from 50 to 30 weight % of ethylene;
(D) polymers comprising from 100 to 50 weight % of one or more
C8 12 vinyl aromatic monomers which are unsubstituted or
substituted by a C14 alkyl radical and from 0 to 50 weight %
of one or more monomers selected from the group
consisting of C14 alkyl esters of C3-6 ethylenically
unsaturated carboxylic acids; and maleic anhydride; and
(E) polyesters selected from the group consisting of
polyethylene terephthalate, polybutylene terephthalate and
polyethylene naphthenate, and
up to 15 weight % of one or more polymers selected from the group

consisting of:

(F) polymers comprising from 100 to 50 weight % of one or more
C8 12 vinyl aromatic monomers which are unsubstituted or
substituted by a C14 alkyl radical and from 0 to 50 weight %
of one or more monomers selected from the group
consisting of C14 alkyl esters of C3-6 ethylenically
unsaturated carboxylic acids; and maleic anhydride which
have been grafted on to up to 20 weight % of one or more
rubbers selected from the group consisting of:
(1 ) polymers comprising from 40 to 60 weight % of one or
more C8 12 vinyl aromatic monomers which are
unsubstituted or substituted by a C14 alkyl radical,



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and from 60 to 40 weight % of one or more C4-6
conjugated diolefins;
(2) polymers comprising co- or homopolymers of one or
more C4-6 conjugated diolefins; and
(3) polymers comprising one or more C4-8 alkyl esters of
acrylic or methacrylic acid, and

(G) polyvinylchloride,
in a non-oxidizing atmosphere to produce a melt;
(ii) contacting in a reactor said melt with one or more catalysts selected
from the group consisting of natural zeolites, synthetic zeolites,
bauxite, the residue produced by the removal of aluminum from
bauxite, alkali oxides, alkaline metal earth oxides, aluminum
phosphates, transition metal oxides, and mixtures thereof to

provide a weight ratio of said melt to said one or more catalysts of
from 100:1 to 5:1 at a pressure from 10 to 507 kPa (0.1 to 5
atmospheres) under a non-oxidizing atmosphere at a temperature
from 623~K to 773~K (350 to 500~ C) for a period of time from
10 minutes to 180 minutes and a conversion of at least 20%; and
(iii) removing from said reactor a gaseous stream comprising hydrogen
and one or more C14, preferably C13, saturated and unsaturated
hydrocarbons; a liquid stream comprising one or more members
selected from the group consisting of C4 12 saturated and
unsaturated hydrocarbons; and removing as a bottom stream
paraffin wax and a stream of unreacted thermoplastic.



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The process of the present invention may be useful with other
polymers which may contain acrylonitrile or methacrylonitrile (e.g. styrene
acrylonitrile (SAN) or styrene methacrylonitrile type products), sulphur (e.g.
rubbers or rubber containing products) or PVC which tend to poison
catalysts and in particular zeolite catalysts. Such polymers may be used
in accordance with the present invention if there is a pretreatment to


remove nitrogen N, S, and halides (e.g. chlorides) or to reduce the amount
of such polymer in the feed to less than about 15 weight %, preferably less
than about 10 weight %.
DETAILED DESCRIPTION
There are a number of waste thermoplastics which may be used in
the process of the present invention. These thermoplastics need not be

sorted and may be commingled in the process of the present invention.

The thermoplastics may be selected from the group consisting of
polyolefins such as polyethylene and polypropylene; styrenic polymers
such as polystyrene, styrene acrylics. The thermoplastic may be
predominantly (i.e. at least 50 weight %) polyethylene.
The polyolefins may comprise homopolymers of ethylene and
copolymers comprising from 85 to 100 weight % of ethylene and from 0 up
to 15 weight % of one or more C4 12, preferably C4 10 olefins, preferably
alpha olefins. Suitable alpha olefin copolymers include 1-butene,
1-pentene, 1-hexene, 1-octene and 1-decene. The alpha olefin
comonomer may also be an isomer such a methyl pentene monomer.
However, the polyolefin could also include other alpha olefin monomers
such as C2 8 ethylenically unsaturated carboxylic acids such as


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methacrylic acid, acrylic acid and itaconic acid, preferably acrylic acid and
methacrylic acid and C14 alkyl esters of such acids. Such polymers also
include metal salts of the resulting polymer such as sodium, potassium
and calcium salts (e.g. SURLYNTM type materials). The copolymer could
be a vinyl ester of a lower C14, preferably C2 carboxylic acid such as vinyl
acetate. In the case of ethylene vinyl acetate copolymers, the vinyl
o acetate may be present in amounts of greater than 15 weight % up to 45
weight % of the polymer. The polymer could be obtained from the
manufacturing process such as low molecular weight (Mw less than about
4,000) fractions obtained in some processes to produce polyolefins,
sometimes referred to as polymer "grease" or off specification polymer.
The waste thermoplastic may be polypropylene. Generally, such
polymers comprise from 50 to 80 weight % of propylene and from 50 to 30

weight % of one or more copolymerisable comonomers. The comonomer
may be an alpha olefin such as ethylene. However, the comonomer may
be a conjugated diolefin such as butadiene, hexadiene, dicyclopentadiene,
and ethylidene norbornene (ENB).
The copolymer may be a styrenic polymer. The styrenic polymer
may be a homopolymer of a C8 ,2 vinyl aromatic monomer which are
unsubstituted or substituted by a C14 alkyl radical such as styrene, alpha
methylstyrene, p-tert-butyl styrene, preferably styrene. The styrenic
polymer may be a copolymer of one or more C8 ,2 vinyl aromatic
monomers and one or more monomers selected from the group consisting
of C1 8, preferably C14 alkyl esters of a C3-6 ethylenically unsaturated
carboxylic acid; and maleic anhydride. Suitable esters include methyl


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methacrylate, ethyl methacrylate, methyl acrylate, ethyl acrylate, butyl
acrylate and ethylhexyl acrylate. Typically the copolymers will comprise at
least 50 weight % of the vinyl aromatic monomer and the balance of one
or more comonomers. For the vinyl aromatic (meth)acrylate ester
polymers the (meth)acrylate monomer may be present in amounts of from
about 15 to about 50 weight %. For the copolymers containing maleic


lo anhydride, the anhydride is present in amounts typically from about 5 to
25, preferably 5 to about 15 weight %.
The thermoplastic may be a polyester such as polyethylene
terephthalate (PET), polybuylene terephthalate (PBT), or polyethylene
naphthenate.
Typically the plastic is introduced into the reactor, which may be a

cracking column, as a particulate. The plastic may be shredded to a

particle size of less than 5 cm. In a preferred embodiment the plastic may
be pelletized. Typically the pellets could have a size from 0.1 to 10,
preferably about 5 mm. Generally, the pelletizing would be used to make
it easier to feed the thermoplastic into the first stage of the process - the
melting stage - by suitable means such as a conveyor.
In the process of the present invention the thermoplastic waste is

melted typically at temperatures from about 623~K to 773~K (350~C to

500~C), preferably from 663~K to 723~K (390 to 450~C).
In a further embodiment of the invention the thermoplastic is fed to
the reactor together with one or more members selected from the group
consisting of vacuum gas oils (VGO), pyrolysis fuel oil (PFO), and waste
or contaminated solvent from a solution polymerization process (e.g. the




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solvent from a solution polyethylene process which contains polymer
grease). VGO typically boils in the true boiling range of 61 3~K to 81 3~K
(340~C to 540~C), while PFO boils in the range of 473~K to 81 3~K (200~C
to 540~C). Generally these oils comprise a C20 to C100 fraction having a
high aromatic content. The waste solvent from a solution polymerization
process would generally comprise a C5 to C80 stream.


The melt is then directly contacted with one or more catalysts
selected from the group consisting of natural zeolites, synthetic zeolites,
bauxite, the residue produced by the removal of aluminum from bauxite,
alkali oxides, alkaline metal earth oxides, aluminum phosphates, transition
metal oxides, and mixtures thereof to provide a weight ratio of said
polymer melt to said catalysts of from 100:1 to 5:1, preferably from 80:1 to

20:1. Generally the catalyst is used together with a binder in the form of

pellets having a particle size from 0.1 to 10 mm.
Suitable alkali oxides include sodium and potassium oxide.
Suitable alkaline earth metal oxides include calcium oxide. Suitable
transition metal oxides include oxides of iron, copper, titanium, vanadium,
chromium, nickel, zirconium, ruthenium, and palladium.
A good discussion of zeolites is contained in The Kirk Othmer
Encyclopedia of Chemical Technology, in the third edition, volume 15,
pages 638-668, and in the fourth edition, volume 16, pages 888-925.
Zeolites are based on a framework of Al04 and SiO4 tetrahedra linked
together by shared oxygen atoms having the empirical formula
M2/nO~AI2O3~ySiO2 wH2O in which y is 2 or greater, n is the valence of the
cation M (typically an alkali or alkaline earth metal (e.g. Na, K, Ca and


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Mg), and w is the water contained in the voids within the zeolite.
Structurally zeolites are based on a crystal unit cell having a smallest unit
of structure of the formula Mx/n[(AlO2)x(SiO2)y].wH2O in which n is the
valence of the cation M, x and y are the total number of tetrahedra in the
unit cell and w is the water entrained in the zeolite. Generally the ratio y/x
may range from 1 to 100. The entrained water (w) may range from about
10 to 275. Natural zeolites include chabazite (in the structural unit formula
M is Ca, x is 4, y is 8 and w is 13), mordenite (in the structural unit formula
M is Na, x is 8, y is 40 and w is 24), erionite (in the structural unit formula
M may be Ca, Mg, Na2, or K2, x is 9, y is 27 and w is 27), faujasite (in the
structural unit formula M may be Ca, Mg, Na2, K2, x is 59, y is 133 and w is
235), clinoptilolite (in the structural unit formula M is Na2, x is 6, y is 30 and
w is 24). Synthetic zeolites generally have the same unit cell structure

except that the cation may in some instances be replaced by a complex of
an alkali metal, typically Na and tetramethyl ammonium (TMA) or the
cation may be a tetrapropylammonium (TPA). Synthetic zeolites include
zeolite A (in the structural unit formula M is Na2, x is 12, y is 12 and w is
27), zeolite X (in the structural unit formula M is Na2, x is 86, y is 106 and
w is 264), zeolite Y (in the structural unit formula M is Na2, x is 56, y is 136and w is 250), zeolite L (in the structural unit formula M is K2, x is 9, y is 27
and w is 22), zeolite omega (in the structural unit formula M is
Na68TMA1.6, x is 8, y is 28 and w is 21) and other zeolites wherein in the
structural unit formula M is Na2 or TPA2, x is 3, y is 93 and w is 16.
Preferred zeolites have an intermediate pore size typically from about 5 to
10 angstroms (having a constrainf index of 1 to 12 as described in U.S.


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patent 4,016,218). Synthetic zeolites are prepared by gel process
(sodium silicate and alumina) or a clay process (kaolin) which form a
matrix to which a zeolite is added. Some commercially available synthetic
zeolites are described in U.S. patent 4,851,601). The zeolites may
undergo ion exchange to entrain a catalytic metal or may be made acidic
by ion exchange with ammonium ions and subsequent deammoniation
(see the Kirk Othmer reference above). A hydrogenation metal
component such as platinum, palladium, nickel or other transition metals
such as group Vlll metals may be present in (e.g. entrained within the
pores) or exchanged or impregnated into the zeolite in amounts from 0.1
to 10 weight %.
Combinations of catalysts may be used in accordance with the
present invention. One useful combination is a mixture of one or more

alkali or alkaline earth metal oxides and one or more zeolites. Preferably
the zeolites are selected from the group consisting of one or more
intermediate pore size zeolites (as noted above). The catalyst may be
mixed in the sense of being commingled or it may be mixed in the sense
of being a layered bed of two or more catalysts.
The thermoplastic is contacted with the above noted catalysts for a
period of time from 10 to 180, preferably from 20 to 90 minutes. The
reaction may take place under pressure or under a partial vacuum. The
pressure in the reactor may be from 10 to 507, preferably from 76 to 304
kPa (0.1 to 5, preferably from 0.75 to 3 atmospheres). The melt is under a
non-oxidizing atmosphere preferably selected from the group consisting of
hydrogen, helium, nitrogen, argon and mixtures thereof.


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The process of the present invention may be a batch or continuous
process, preferably batch. If the process is operated continuously the
reactor is preferably a cracker, most preferably a cracking column. If the
process is a batch process the reactor is preferably a stirred tank reactor
(STR). In an STR the thermoplastic is subjected to shear, typically by a
turbine or "paddle" stirrer. The thermoplastic should be heated to


lo temperatures of at least about 523~K (250~C), preferably greater than

623~K (350~C). The agitation rate may be low, about 200 rpm (typically at
lower temperatures) or may be high, greater than 500 rpm, preferably
greater than about 700 rpm at the higher temperatures.
The residence time in the reactor is such to provide at least a 20%
conversion of thermoplastic and if present one or more members selected

from the group consisting of vacuum gas oils, pyrolysis fuel oil and waste

solvent from a solution or bulk polymerization. Preferably in a continuous
process the per pass conversion should be in the range from 50 to 90%.
The thermoplastic and if present one or more members selected
from the group consisting of vacuum gas oils, pyrolysis fuel oil and waste
solvent from a solution or bulk polymerization, in the reactor (cracking
column) under the above noted conditions produces three product
30 streams. There is a gaseous overhead stream comprising hydrogen and
C14, preferably C13, saturated and unsaturated hydrocarbons. There is a
liquid stream taken off at an intermediate level within the reactor which
comprises C412, preferably C48, saturated and unsaturated hydrocarbons.
Finally, there is a bottom stream comprising a paraffin wax and a stream
of unreacted thermoplastic polymer. The unreacted thermoplastic polymer




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is typically fed back into the reactor, preferably after blending with fresh
thermoplastic.
The catalyst is not consumed during the reaction but will have to be
regenerated periodically depending upon the conditions in the reactor.
Additionally, there may be some coke generated during the reaction which
will have to be removed when the reactor is shut down.


In an optional embodiment the melt of the thermoplastic may be

subjected to shear, typically by a turbine or "paddle stirrer". The polymer
should be heated to temperatures of at least about 523~K (250~C),
preferably greater than 623~K (350~C). The agitation rate may be low,
about 200 rpm (typically at lower temperatures) or may be high, greater
than 500 rpm, preferably greater than about 700 rpm, at the higher

temperatures.

The paraffin stream may be further processed for example by
dissolving it in a light oil or naphtha and feeding the resulting stream to a
naphtha cracker. The liquid stream may be fed to a gasoline refiner, or
blended with gas oil and feeding the resulting stream to a steam cracker
or separated into various streams or components through distillation. The
liquid stream may be fed to a naphtha (steam) cracker for the production
of ethylene and coproducts.
As noted above, care should be used when practicing the present
invention with polymers which contain nitrogen, sulphur or halides (e.g.
polyvinyl chloride) unless treated to remove the nitrogen, sulphur or
halides. It may not be practical to remove nitrogen from acrylonitrile
polymers such as styrene acrylonitrile (SAN) or styrene methacrylonitrile




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CA 02202941 1997-04-17


polymers or impact modified polymers such as acrylonitrile butadiene
styrene (ABS) polymers (typically for copolymers of the vinyl aromatic
monomer and one or more nitriles, the nitrile monomer may be present in
amounts from about 15 to 45 weight %). If present in commingled
thermoplastic waste such polymers should be present in amounts not
greater than about 15 weight %, preferably not greater than 10 weight %,
o of the plastic to be treated. However, impact modified styrenic polymers
such as the styrenic polymers identified in group (C) modified with rubber
that does not contain sulphur may be suitable for treatment in accordance
with the present invention. Such polymers would be the polymers of group
(C) noted above which have been grafted to up to 20 weight % of a
rubbery phase selected from the group consisting of:

(i) polymers comprising from 40 to 60 weight % of one or more
~0
C8 12 vinyl aromatic monomers which are unsubstituted or
substituted by a C14 alkyl radical, and from 60 to 40 weight
% of one or more C4-6 conjugated diolefins;
(ii) polymers comprising co- or homopolymers of one or more
C4-6 conjugated diolefins; and
(iii) polymers comprising one or more C4-8 alkyl esters of acrylic
or methacrylic acid.
The rubber may be a copolymer comprising from about 40 to 60
weight % of one or more C6 8 vinyl aromatic monomers which are
unsubstituted or substituted by a C14 alkyl radical and from 60 to 40
weight % of one or more C4-6 conjugated diolefins. Suitable vinyl aromatic
monomers have been listed above. Suitable conjugated diolefins include




tVjm/spec/9129can.doc 1 4

- CA 02202941 1997-04-17


butadiene and isoprene. The rubber may be a homopolymer of one or
more C4-6 conjugated diolefin monomers. Suitable diolefin monomers
have been listed above. Preferred diolefin rubbers are homopolymers of
butadiene rubber. The polymer may have a stereo configuration such as
high cis rubber having over 90, most preferably over 95%, of the polymer
in the cis configuration or medium cis rubbers having about 50 to 65,
o preferably from about 50 to 60%, of the polymer in the cis configuration.
The rubber may be a rubbery acrylate comprising one or more C4-8 alkyl
esters of acrylic or methacrylic acid. Preferred esters are butyl and
ethylhexyl acrylate.
The broad aspects of the present invention have been disclosed
above. Following the above teaching, specific combinations of time,

temperature, catalyst, and feedstock may be determined by non-inventive

testing.
The present invention will now be illustrated by the following non-
limiting examples in which, unless otherwise specified, parts is parts by
weight and % is weight %
Example 1
The experiments were conducted in a batch catalytic cracking unit
(BCCU) consisting of a two liter high pressure autoclave designed to
operate at temperatures up to 773~K (500~C); at a pressure of up to
35,000 kPa (about 5,000 psi) at 773~K (500~C). The autoclave had a
removable top through which a stirrer shaft extended. In operation the
stirrer was driven by an electric motor. The reactor was heated by two
high temperature electric heaters. At the bottom of the reactor was an




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CA 02202941 1997-04-17


inlet line for hydrogen. (Although the hydrogen could be replaced by an
inert gas such as nitrogen or if the valve is kept closed no gas would be
introduced into the reactor.) The hydrogen pressure was controlled by a
pressure controller at the exit of a knock-out drum also having a valve in
the bottom, up-stream of the upper outlet of the reactor. The reactor had
two outlets. An outlet in the top of the reactor permitted gaseous products
to be drawn off. A valve in the bottom of the reactor permitted liquid
products to be drawn off.
The catalyst was conditioned overnight in a vacuum oven at 353~K
(80~C) under a reduced pressure of 6.5 kPa (28 inches of mercury (torr)).
The conditioned catalyst was then placed in a desiccator and allowed to
cool to room temperature. The reactor was loaded with about 1500 g of

polymer. First, about 30 grams of polymer was placed in the reactor and

then the catalyst was added in an amount to provide a weight ratio of
catalyst to total polymer of 0.05. Then the remainder of polymer was fed
to the reactor (in an amount not to exceed a total volume of polymer of
1500 cc).
The reactor was then pressurized to 6990 kPa (1000 psig) with
nitrogen to check for leaks and then purged with nitrogen. The reactor

was heated at a rate to provide a temperature increase of 100~K (100~C)
per hour for the first four hours and a rate to provide a temperature
increase of 50~K (50~C) per hour for the last hour to provide a final
operating temperature of 773~K (500~C). During the heat-up cycle the
hydrogen pressure was set and the flow rate of about 2500 cc/min is
maintained through out the reaction. The stirrer started at a low speed of


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CA 02202941 1997-04-17


about 200 rpm when the temperature reaches 523~K (250~C) and the rate
is increased to about 800 rpm when the temperature is 633~K (360~C).
The run time is recorded when the reactor reaches the desired reaction
temperature (773~K (500~C)). At the end of the reaction heaters are
turned off. The hydrogen flow is maintained to prevent the hydrogen inlet
from becoming plugged with the waxy residue from the polymer. The


knock-out drum is separated from the reactor and depressurized and the
contents emptied into a sampling bottle and weighed. The waxy residue
from the polymer is scooped out of the reactor when cool and solidified
and weighed. The recovered streams from the reaction were then
analyzed for their components.
A series of screening runs were conducted initially with virgin high

density polyethylene resin and repeated with recycled high density

polyethylene resin obtained from Montreal and Toronto to determine a
useful combination of residence time, reaction pressure, and temperature.
These were found to be 45 minutes, 345 kPa (50 psig) and 678~K
(405~C), respectively.
A sample of commingled plastics obtained from the Edmonton
Recycling Society typically comprising: 60% Polyethylene (PE); 15%

Polystyrene(PS); 10% Polyvinyl chloride (PVC); 5% Polypropylene (PP);
5% Polyethylene terephthalate (PET); and 5% others, shredded into 5-
10 mm flakes, was washed and dried (overnight at 353~K (80~C)). The
sample was treated under the above conditions with aluminum phosphate
gel as the catalyst. The results of the analysis of the recovered streams is
set forth in table 1 below.


tVjm/spec/91 29can.doc 17

CA 02202941 1997-04-17



Table 1
Component Wt. % Component Wt. %
Cl to C3 1.44 Benzene 0.023
Isobutane Non-aromatic C7's1.21
n-Butane 0.267
Isobutene/1-Butene<0.002 Toluene 4.38
t-2-Butene 0.109
c-2-Butene 0.087 Non-aromatic C8's4.11
1 o 1,2-Butadiene <0.002
1,3-Butadiene 1.30 Ethyl Benzene 0.58
1-Butyne <0.002 m,p-Xylene 0.200
2-Butyne <0.002 o-Xylene 0.08
Total C4's 1.77 Styrene 2.63
Total Aromatic C8's 3.49
Pentanes 4.41
Pentenes 0.80 Non-aromatic C9's18.5
Pentadienes 0.054
Isoprene 0.013 Propylbenzene 0.194
Cyclopentane 0.008 m,p-Ethyl Toluene0.190
Cyclopentene <0.002 o-Ethyl Toluene 0.56
Cyclopentadiene 0.003 Other Aromatic C9's 1.85
2 o Other C5's 0.213 Total Aromatic C9's 2.80
Total C5's 5.5
Dicyclopentadiene 0.066
1-Hexene 0.148 Indene <0.002
t-2-Hexene 0.140 Naphthalene 0.077
c-2-Hexene 0.08
Cyclohexane 0.08 C9+ by difference 48.3
Cyclohexene 0.029
Other C6's 7.8
Total Non-aromatic C6's 8.3


The results of the experiment show that commingled plastic can be
catalytically converted to streams suitable for refining and use in the
petrochemical business to produce a mixture of products such as naphtha,
jet fuel, diesel fuel and gas oil.




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' CA 02202941 1997-04-17


Example 2
The above experiment was then repeated with an intermediate pore
size zeolite without the use of hydrogen and it was found that although
there was a change in the ratio of gas to liquid components in the product
streams (i.e. the gas went from 20.33 weight % to 18.33 weight % and the
liquids went from 79.67 weight % to 81.67 weight %) the resulting product
stream could still be used as a feed stock in petrochemical operations.




tVjm/spec/9129can.doc 1 9

Representative Drawing

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Administrative Status

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Administrative Status

Title Date
Forecasted Issue Date Unavailable
(22) Filed 1997-04-17
(41) Open to Public Inspection 1998-10-17
Examination Requested 2002-02-27
Dead Application 2004-04-19

Abandonment History

Abandonment Date Reason Reinstatement Date
2003-04-17 FAILURE TO PAY APPLICATION MAINTENANCE FEE

Payment History

Fee Type Anniversary Year Due Date Amount Paid Paid Date
Registration of a document - section 124 $100.00 1997-04-17
Application Fee $300.00 1997-04-17
Maintenance Fee - Application - New Act 2 1999-04-19 $100.00 1999-02-12
Maintenance Fee - Application - New Act 3 2000-04-17 $100.00 2000-02-07
Maintenance Fee - Application - New Act 4 2001-04-17 $100.00 2001-02-23
Request for Examination $400.00 2002-02-27
Maintenance Fee - Application - New Act 5 2002-04-17 $150.00 2002-03-05
Owners on Record

Note: Records showing the ownership history in alphabetical order.

Current Owners on Record
NOVA CHEMICALS LTD.
Past Owners on Record
KRZYWICKI, ANDRZEJ Z.
OBALLA, MIKE C.
WONG, CHI
WONG, WILLIAM
Past Owners that do not appear in the "Owners on Record" listing will appear in other documentation within the application.
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Document
Description 
Date
(yyyy-mm-dd) 
Number of pages   Size of Image (KB) 
Cover Page 1998-10-27 1 36
Abstract 1997-04-17 1 16
Description 1997-04-17 18 647
Claims 1997-04-17 8 204
Assignment 1997-04-17 5 189
Prosecution-Amendment 2002-02-27 3 85