Hydrothermal treatment of materials

Abstract

The present invention is directed to methods for converting feedstock comprising synthetic polymers into a product, comprising: generating a melt stream comprising the synthetic polymers under heat and pressure, and generating heated and pressurised water independently of the melt stream; injecting the heated and pressurised water from apertures of an injection device into the melt stream to form a reaction mixture, wherein the apertures are located internally of the melt stream; using a mixing device to separate and then combine components of the reaction mixture facilitating further mixing of the water and the melt stream, wherein the mixing device comprises two adjacent lattice modules in communication and each rotated at an angle relative to the other; and further treating the reaction mixture at a reaction temperature and pressure to thereby provide the product, as well as apparatus for conducting such methods.

We claim: 
     
         1 . A method for converting feedstock comprising synthetic polymers into a product, comprising:
 generating a melt stream comprising the synthetic polymers under heat and pressure, and generating heated and pressurised water independently of the melt stream;   injecting the heated and pressurised water from apertures of an injection device into the melt stream to form a reaction mixture, wherein the apertures are located internally of the melt stream;   using a mixing device to separate and then combine components of the reaction mixture facilitating further mixing of the water and the melt stream, wherein the mixing device comprises two adjacent lattice modules in communication and each rotated at an angle relative to the other; and   further treating the reaction mixture at a reaction temperature and pressure to thereby provide the product.   
     
     
         2 . (canceled) 
     
     
         3 . The method of  claim 1 , wherein the water is supercritical immediately prior to the injecting into the melt stream. 
     
     
         4 . The method of  claim 1 , wherein the heated and pressurised water is injected across;
 (i) a full or partial cross section of the melt stream; or   (ii) multiple cross sections of the melt stream, wherein at least two of the multiple cross sections are oriented at different angles relative to each other.   
     
     
         5 - 6 . (canceled) 
     
     
         7 . The method of  claim 1 , wherein the injection device comprises two injection pipes each spanning either a full or partial cross section of the melt stream, and oriented at: (i) different angles within the melt stream relative to each other; or (ii) perpendicular to each other, or, within 5°, within 10°, within 20°, within 30°, or within 40°, of perpendicular. 
     
     
         8 . (canceled) 
     
     
         9 . The method of  claim 7 , wherein either or both injection pipes comprise a sparge pipe. 
     
     
         10 - 11 . (canceled) 
     
     
         12 . The method of  claim 1 , wherein the mixing device comprises a first lattice module rotated between 20°-and 90°, 40°-and 90°, 60°-and 90°, or 80°-and 90° relative to a second adjacent lattice module. 
     
     
         13 . The method of  claim 1 , wherein the mixing device comprises a first lattice module rotated perpendicular or substantially perpendicular relative to a second adjacent lattice module. 
     
     
         14 . The method of  claim 12 , wherein the first and/or second lattice modules comprise a sequential series of adjacently positioned lattice sheets, wherein each individual lattice sheet of the series is rotated less than: 50°, 40°, 30°, 20°, 10° or 5°; relative to other adjacent lattice sheet(s) within the series, or is not rotated relative other adjacent lattice sheet(s) within the series. 
     
     
         15 . The method of  claim 14 , wherein the series comprises 2, 3, 4, 5, 6 or more individual lattice sheets rotated less than 50°, 40°, 30°, 20°, 10° or 5° relative adjacent lattice sheet(s), or not rotated relative to adjacent lattice sheet(s). 
     
     
         16 . (canceled) 
     
     
         17 . The method of  claim 14 , wherein the adjacently positioned lattice sheets are in direct contact or separated by spacer component(s). 
     
     
         18 - 27 . (canceled) 
     
     
         28 . The method of  claim 1 , wherein the melt stream comprises: polyethylene (PE), Low Density Polyethylene (LDPE), High Density Polyethylene (HDPE), Polypropylene (PP), Polyester, Poly(ethylene terephthalate) (PET), poly(lactic acid) (PLA), Poly(vinyl chloride) (PVC), Polystyrene (PS), Polyamide, Nylon, Nylon 6, Nylon 66, Acrylonitrile-Butadiene-Styrene (ABS), Poly(Ethylene vinyl alcohol) (E/VAL), Poly(Melamine formaldehyde) (MF), Poly(Phenol-formaldehyde) (PF), Epoxies, Polyacetal, (Acetal), Polyacrylates (Acrylic), Polyacrylonitrile (PAN), Polyamide-imide (PAI), Polyaryletherketone (PAEK), Polybutadiene (PBD), Polybutylene (PB), Polycarbonate (PC), Polydicyclopentadiene (PDCP), Polyketone (PK), polycondensate, Polyetheretherketone (PEEK), Polyetherimide (PEI), Polyethersulfone (PES), Polyethylenechlorinates (PEC), Polyimide (PI), Polymethylpentene (PMP), Poly(phenylene Oxide) (PPO), Polyphenylene Sulfide (PPS), Polyphthalamide (PTA), Polysulfone (PSU), Polyurethane (PU), Poly(vinylidene chloride) (PVDC), Poly(tetrafluoroethylene) (PTFE), Poly(fluoroxy alkane) (PFA), Poly(siloxanes), silicone, thermoplastic, plastic, or mixtures thereof. 
     
     
         29 . The method of  claim 1 , wherein during the treatment, the water and the melt stream combined comprises: (i) at least at least 30 wt %, at least 35 wt %, at least 40 wt %, at least 45 wt %, at least 50 wt %, at least 60 wt %, at least 70 wt %, at least 80 wt %, at least 90 wt %, at least 95 wt %, or at least 98 wt % of the polymeric material; or at least at least 30 wt %, a minimum of 40 wt % of the polymeric material and up to 60 wt % of the water. 
     
     
         30 . (canceled) 
     
     
         31 . The method of  claim 1 , wherein prior to injecting the heated and pressurised water, the melt stream is at a temperature of between 200° C. and 350° C. and at a pressure of between 100 bar and 300 bar, or at a temperature of between 250° C. and 300° C. and at a pressure of between 230 bar and 280 bar. 
     
     
         32 . The method of  claim 1 , wherein the melt stream comprising the synthetic polymers under heat and pressure is generated using an extruder. 
     
     
         33 . The method of  claim 1 , wherein:
 (i) the water is at a temperature of between 300° C. and 700° C. and a pressure of 100 to 300 bar immediately prior to the injecting into the melt stream; or   (ii) the water is supercritical and at a temperature of between 500° C. and 700° C. and at a pressure of 221 to 300 bar; or   (iii) the water is supercritical and at a temperature of between 600° C. and 700° C. and at a pressure of 221 to 300 bar;   immediately prior to the injecting into the melt stream.   
     
     
         34 . The method of  claim 1 , wherein the reaction mixture enters and/or exits the mixing device:
 (i) at a temperature of between 200° C. and 550° C. and at a pressure of 100 to 300 bar, at a temperature of between 300° C. and 550° C. and at a pressure of 100 to 300 bar, at a temperature of between 350° C. and 550° C. and at a pressure of 100 to 300 bar, or at a temperature of between 400° C. and 500° C. and at a pressure of 100 to 300 bar; and/or   (ii) at a flow rate of above 2,000 kg/hr, less than 15,000 kg/hr, or between 2,000 kg/hr and 15,000 kg/hr; and/or   (iii) a viscosity of above 100 Pa·s, less than 1,000 Pa·s, or between 100 Pa·s to 1,000 Pa·s.   
     
     
         35 . The method of  claim 1 , comprising further heating of the reaction mixture after it exits the mixing device, wherein the further heating is conducted using an indirect heater located downstream of the mixing device and prior to a pressure let down device. 
     
     
         36 . (canceled) 
     
     
         37 . The method of  claim 1 , wherein said further treating the reaction mixture at a reaction temperature and pressure is: at a temperature of between 300° C. and 500° C. and at a pressure of between 100 bar and 350 bar, at a temperature of between 373° C. and 500° C. and at a pressure of between 220 bar and 350 bar, at a temperature of between 400° C. and 500° C. and at a pressure of between 220 bar and 350 bar, or at a temperature of between 420° C. and 480° C. and at a pressure of between 220 bar and 300 bar. 
     
     
         38 . The method of  claim 1 , wherein the method is performed under conditions of continuous flow. 
     
     
         39 . (canceled) 
     
     
         40 . The method of  claim 1 , wherein the injecting of the heated and pressurised water from apertures of the injection device into the melt stream is conducted while the melt stream is at a flow rate of between 1,000 kg/hr and 15,000 kg/hr and/or a viscosity of between 10 Pa·s and 1,000 Pa·s, a flow rate of between 3,000 kg/hr and 12,000 kg/hr and/or a viscosity of between 100 Pa·s and 1,000 Pa·s, a flow rate of between 5,000 kg/hr and 10,000 kg/hr, and/or a viscosity of between 400 Pa·s and 800 Pa·s. 
     
     
         41 - 62 . (canceled)