Abstract: Methods and systems are provided for the conversion of waste plastics into various useful downstream recycle-content products. More particularly, the present system and method involves integrating a pyrolysis facility with a cracker facility by introducing at least a stream of r-pyrolysis gas into the cracker facility. In the cracker facility, the r-pyrolysis gas may be separated to form one or more recycle content products, and can enhance the operation of the facility.

Abstract: Methods and systems for separating mixed plastic waste are provided herein. The methods generally comprise separating the mixed plastic waste into a PET-enriched stream and one or more PET-depleted streams. The separating may be accomplished using the combinations of two or more density separation stages. Exemplary density separation stages include sink-float separators and centrifugal force separators. The PET-enriched and PET-depleted streams may be recovered and/or directed to downstream chemical recycling processes.

Abstract: Raw synthesis gas (syngas) compositions are provided herein. The syngas compositions are generally formed from a partial oxidation reaction with a plastic feedstock within a PDX gasifier. The raw syngas compositions may by characterized by a desirable ratio of carbon monoxide to hydrogen and/or less impurities than syngas compositions formed using other feedstocks, such as natural gas or coal.

Abstract: A chemical recycling process and facility for turning one or more waste plastics into syngas are provided. Generally, the chemical recycling process involves: (a) liquefying at least one solid waste plastic to form a liquefied waste plastic; (b) introducing at least a portion of the liquefied waste plastic into a partial oxidation (POX) gasifier; and (c) converting at least a portion of the liquefied waste plastic in the POX gasifier into a syngas composition.

Abstract: Copolyesters made from the direct esterification of terephthalic acid with diols including ethylene glycol, but which contain low diethylene glycol (DEG) content, and processes for making the copolyesters. The copolyesters are characterized by comprising 1.0 wt % or less of DEG without requiring the use of DEG-suppressing additives. The processes are characterized by features including operating at lower pressures and lower EG:TPA feed mole ratios in the first reaction zone, while simultaneously at higher temperatures than typical operation in order to lower incorporation of DEG into the final polymer.

Abstract: A method of producing synthesis gas is provided. The method includes feeding a waste plastic feedstock into a partial oxidation gasifier. The waste plastic feedstock includes one or more vitrification materials. The method also includes partially oxidizing the waste plastic within the partial oxidation gasifier to produce the synthesis gas.

Abstract: Process for preparing copolyesters by introducing TPA, EG, and CHDM at an EG:TPA molar ratio of 2.3:1 to 2.7:1 into a reaction zone; reacting TPA with EG and CHDM at a temperature of at least 250° C. and pressure of up to 40 psi to form a first esterification product; passing the first esterification product to a reaction zone; esterifying the first esterification product at a temperature of at least 250° C. and pressure of up to 20 psi to form a second esterification product, passing the second esterification product to a reaction zone; polycondensing the second esterification product in the presence of a catalyst to form a prepolymerization product; passing the prepolymerization product to one or more reaction zones; and polycondensing the prepolymerization product in the presence of the catalyst to form a copolyester comprising 1.0 wt % or less of DEG, without requiring the use of DEG-suppressing additives.

Abstract: Processes and facilities for using one or more PET-containing materials as a feedstock to a chemical recycling facility, and in particular a solvolysis facility, are provided herein. The PET-containing materials used as feedstock may comprise colored plastic-containing mixtures derived as products or co-products from plastic reclaimer facilities and/or municipal recycling facilities. Such mixtures are generally undesirable or unusable to mechanical PET recycling facilities, and typically are sent to landfills and/or incinerators. However, the processes and facilities described herein make use of the PET and other plastics present in these otherwise undesirable or unusable colored plastic-containing mixtures.

Abstract: Processes and facilities for using one or more PET-containing materials as a feedstock to a chemical recycling facility, and in particular a solvolysis facility, are provided herein. The PET-containing materials used as feedstock may comprise a quantity of PET-containing solidified purge material. The PET-containing solidified purge material may be derived from various processes and facilities, including PET reclaimer facilities, manufacturers of PET articles, and/or a polymer manufacturing facilities. For example, he purge material may be the solidified purge material from an extrusion and/or pelletization process. Such solidified purge materials are generally undesirable or unusable to mechanical PET recycling facilities, and typically are sent to landfills and/or incinerators. However, the processes and facilities described herein make use of the PET and other plastics present in these otherwise undesirable or unusable solidified purge materials.

Abstract: A chemical recycling process and facility for using one or more PET-containing materials as a feedstock to a chemical recycling facility, and in particular a solvolysis facility, are provided herein. The PET-containing materials used as feedstock may comprise PET-containing reclaimer co-products, PET-containing MRF products or co-products, sorted plastic-containing mixtures, and/or PET-containing waste plastic from a plastic article manufacturing facility. In particular, the PET-containing materials used as feedstock may comprise a quantity of PET-containing wet fines from a reclaimer facility.

Abstract: Chemical recycling facilities for processing mixed waste plastic are provided herein. Such facilities have the capability of processing mixed plastic waste streams and utilize a variety of recycling facilities, such as, for example, solvolysis facility, a pyrolysis facility, a cracker facility, a partial oxidation gasification facility, an energy recovery facility, and a solidification facility. Streams from one or more of these individual facilities may be used as feed to one or more of the other facilities, thereby maximizing recovery of valuable chemical components and minimizing unusable waste streams.

Abstract: A process and system for liquefying and dehalogenating a waste plastic are provided. Generally, the process comprises: (a) liquefying solid waste plastic to produce a liquefied waste plastic; (b) heating at least a portion of the molten waste plastic in a heat exchanger to thereby provide a heated liquefied waste plastic; (c) sparging a stripping gas into the heated liquefied waste plastic to produce a multi-phase mixture; and (d) disengaging a gaseous phase from a liquid phase of the multi-phase mixture to thereby provide a halogen-enriched gaseous material and a halogen-depleted liquefied waste plastic.

Abstract: Processes and facilities for using one or more PET-containing materials as a feedstock to a chemical recycling facility, and in particular a solvolysis facility, are provided herein. The PET-containing materials used as feedstock may comprise a quantity of PET-containing dry fines. The PET-containing dry fines may be derived from various processes and facilities, including PET reclaimer facilities and/or manufacturers of PET articles. For example, the dry fines may be collected from solid-liquid separators and/or dust collectors from processes that include conveying, drying, densification, centrifugation processes, and/or grinding PET-containing plastic material. Such dry fines are generally undesirable or unusable to mechanical PET recycling facilities, and typically are sent to landfills and/or incinerators. However, the processes and facilities described herein make use of the PET and other plastics present in these otherwise undesirable or unusable dry fines.

Abstract: A chemical recycling process and facility for turning one or more waste plastics into syngas are provided. Generally, the chemical recycling process involves: (a) liquefying at least one solid waste plastic to form a liquefied waste plastic; (b) introducing at least a portion of the liquefied waste plastic into a partial oxidation (POX) gasifier; and (c) converting at least a portion of the liquefied waste plastic in the POX gasifier into a syngas composition.

Abstract: Provided herein are methods of producing synthesis gas (syngas) from aplastic material. The methods generally comprise feeding a wet waste plastic and/or liquified plastic stream and molecular oxygen (O2) into a partial oxidation (POX) gasifier. The wet waste plastic generally comprises the plastic material mixed with a liquid medium and has a liquid content of at least 2 weight percent. The wet waste plastic may be in the form of a plastic-containing slurry and/or may be derived from other processes that produce plastic-containing streams. The wet waste plastic may also be combined with a quantity of coal (or pet coke) before being fed to the gasifier. A partial oxidation reaction is performed within the gasifier by reacting at least a portion of the plastic material and the molecular oxygen to form the syngas.

Abstract: Chemical recycling facilities for processing mixed waste plastic are provided herein. Such facilities have the capability of processing mixed plastic waste streams and utilize a variety of recycling facilities, such as, for example, solvolysis facility, a pyrolysis facility, a cracker facility, a partial oxidation gasification facility, an energy recovery facility, and a solidification facility. Streams from one or more of these individual facilities may be used as feed to one or more of the other facilities, thereby maximizing recovery of valuable chemical components and minimizing unusable waste streams.

Abstract: Chemical recycling facilities for processing mixed waste plastic are provided herein. Such facilities have the capability of processing mixed plastic waste streams and utilize a variety of recycling facilities, such as, for example, solvolysis facility, a pyrolysis facility, a cracker facility, a partial oxidation gasification facility, an energy recovery facility, and a solidification facility. Streams from one or more of these individual facilities may be used as feed to one or more of the other facilities, thereby maximizing recovery of valuable chemical components and minimizing unusable waste streams.

Abstract: Processes and facilities for using one or more PET-containing materials as a feedstock to a chemical recycling facility, and in particular a solvolysis facility, are provided herein. The PET-containing materials used as feedstock may comprise a quantity of PET and metal-containing reclaimer co-product. The PET and metal-containing reclaimer co-product may comprise a quantity of plastic articles, plastic flakes, and/or plastic fines, and may be derived from plastic reclaimer separation processes such as eddy current separators. Such metal-containing co-products are generally undesirable or unusable to mechanical PET recycling facilities, and typically are sent to landfills and/or incinerators. However, the processes and facilities described herein make use of the PET and other plastics present in these otherwise undesirable or unusable metal-containing co-products.

Abstract: Chemical recycling facilities for processing mixed waste plastic are provided herein. Such facilities have the capability of processing mixed plastic waste streams and utilize a variety of recycling facilities, such as, for example, solvolysis facility, a pyrolysis facility, a cracker facility, a partial oxidation gasification facility, an energy recovery facility, and a solidification facility. Streams from one or more of these individual facilities may be used as feed to one or more of the other facilities, thereby maximizing recovery of valuable chemical components and minimizing unusable waste streams.

Abstract: Processes and facilities for using one or more PET-containing materials as a feedstock to a chemical recycling facility, and in particular a solvolysis facility, are provided herein. The PET-containing materials used as feedstock may comprise a quantity of PET and PVC-containing reclaimer flake reject. The PET and PVC-containing reclaimer flake reject may be derived from various plastic reclaimer separation processes, including density separation. Such flake reject materials are generally undesirable or unusable to mechanical PET recycling facilities due to the PVC content, and typically are sent to landfills and/or incinerators. However, the processes and facilities described herein make use of the PET and other plastics present in these otherwise undesirable or unusable flake reject materials.