Catalytic Depolymerisation of Polymeric Materials

Abstract

A process for converting a molten polymeric material is provided. The process includes effecting disposition of a molten polymeric material, having at least one carbon-carbon double bond, in sufficient proximity to a catalyst material within a reaction zone, to affect a reactive process that effects generation of a reaction product. The reactive process effects cleaving of at least one carbon-carbon double bond. The catalyst material includes [Fe—Cu—Mo—P]/Al2O3 prepared by binding a ferrous-copper complex to an alumina support to generate an intermediate material and reacting the intermediate material with a heteropolyacid.

What is claimed is: 
     
         1 . A process for depolymerizing polystyrene comprising disposing a quantity of liquid polystyrene in sufficient proximity to a catalyst material within a reaction zone to induce a reaction that effects generation of a reaction product. 
     
     
         2 . The process of  claim 1 , wherein said quantity of liquid polymeric material further comprises at least one second polymeric material, wherein said second polymeric material is selected from the group consisting of polyethylene, polypropylene, polyethylene terephthalate, ethylene-vinyl acetate, polyphenylene ether, polyvinyl chloride, lignin, nylon, cellulose, and mixtures thereof. 
     
     
         3 . The process of  claim 2 , wherein said at least one second polymeric material comprises waste polymeric material. 
     
     
         4 . The process of  claim 1 , wherein said reaction product is a wax or grease base stock. 
     
     
         5 . The process of  claim 4 , further comprising draining the converted wax or grease base stock into a container when said wax or grease base stock is liquid and is at a temperature above the flash point of said wax or grease base stock, respectively, wherein said reaction is conducted at a variable pressure to produce different grades of said wax and grease base stock. 
     
     
         6 . The process of  claim 1 , wherein said polystyrene is made liquid by a heated extruder. 
     
     
         7 . The process of  claim 11 , wherein said extruder is in fluid communication with said reaction zone for feeding said quantity of liquid polystyrene to said reaction zone. 
     
     
         8 . The process of  claim 1 , wherein said quantity of liquid polystyrene is molten or dissolved in a solvent. 
     
     
         9 . The process of  claim 1 , wherein said reaction product has a molecular weight less than that of said quantity of liquid polystyrene. 
     
     
         10 . A process for depolymerizing polystyrene comprising disposing a quantity of liquid polystyrene within a heated reaction zone to induce a reaction that effects generation of a reaction product. 
     
     
         11 . The process of  claim 10 , wherein said quantity of liquid polystyrene is molten or dissolved in a solvent. 
     
     
         12 . The process of  claim 10 , wherein said reaction product has a molecular weight less than that of said quantity of liquid polystyrene. 
     
     
         13 . The process of  claim 10 , wherein said quantity of liquid polymeric material further comprises at least one second polymeric material selected from the group consisting of polyethylene, polypropylene, polyethylene terephthalate, ethylene-vinyl acetate, polyphenylene ether, polyvinyl chloride, lignin, nylon, cellulose, and mixtures thereof. 
     
     
         14 . The process of  claim 13 , wherein said at least one second polymeric material comprises waste polymeric material. 
     
     
         15 . The process of  claim 14 , wherein said reaction zone temperature is between 300° C. to 600° C. 
     
     
         16 . The process of  claim 10 , wherein said reaction zone is a high-pressure reactor, wherein said reaction zone pressure is between 50 psig to 350 psig. 
     
     
         17 . The process of  claim 10 , wherein said reaction is stopped when said reaction zone reaches a predetermined pressure value. 
     
     
         18 . The process of  claim 10 , wherein said reaction product is a wax or grease base stock. 
     
     
         19 . The process of  claim 18 , further comprising draining the converted wax or grease base stock into a container when said wax or grease base stock is liquid and is at a temperature above the flash point of said wax or grease base stock, respectively, wherein said reaction is conducted at a variable pressure to produce different grades of said wax and grease base stock. 
     
     
         20 . The process of  claim 10 , wherein said polystyrene is made liquid by a heated extruder, wherein said extruder is in fluid communication with said reaction zone for feeding said quantity of liquid polystyrene to said reaction zone.