Process for the conversion of polymers

Abstract: This invention relates to a method of cracking polymers, especially waste hydrocarbon polymers to produce products of lower molecular weight. The process comprises feeding the polymer into a processing chamber or circular-cross section which chamber also has a bed of particulate material maintained in suspension and in toroidal shape by a hot gas introduced into said chamber so that the polymer intermingles with the particulate materials of the bed and is cracked into products of lower molecular weight. The invention is useful for converting polymeric wastes into products of commercial value such as eg waxes, lubricants and monomeric olefins at the same time reducing environmental pollution.

Description: This invention relates to a process for the conversion of polymers, particularly hydrocarbon polymer waste material to obtain useful products of lower molecular weight than the starting polymer (lighter products). At the present time large amounts of polymer, particularly polyethylene, polypropylene, polystyrene, PVC and polyethylene terephthalate (hereafter ("PET") are used for packaging and other applications and after use this material becomes a waste product. Much of this waste product is collected as domestic or industrial refuse and may either be deposited in a land fill site, or, recycled by mechanical means for conversion of waste polyethylene into low grade refuse bags, or, destroyed by burning. This represents not only a potential environmental hazard but also a waste of a potentially valuable resource. WO91/13948 describes a process for retorting hydrocarbon containing feeds, which may be polymers, in 2 fluidized beds, the first being at lower temperature and having a more dilute phase than the second, and separation of at least some of the volatile products from the first step before the remainder of the feed is passed from the first to the second bed. It is an object of the present invention to provide a process for the conversion of polymers, particularly hydrocarbon polymers such as polyethylene and polypropylene, into useful products of lower molecular weight and thereby reduce environmental pollution. Accordingly, the present invention is a process for the conversion of a polymer, especially hydrocarbon polymers, into products of lower molecular weight than the starting polymer, said process comprising: a. generating in a process chamber of circular cross-section in its vertical orientation of a stream of hot gas which flows in an angular and upward direction causing (i) a bed of particulate material to be entrained in the flow of the gas and be held in suspension in a toroidal shape and (ii) the polymer introduced into said chamber in turn to intermingle with the particulate material and assume said toroidal shape thereby cracking said polymer into products of lower molecular weight, and b. recovering said products of lower molecular weight from said chamber. The polymer is suitably selected from one or more of polyethylene, polypropylene, polystyrene, PVC and PET, and is preferably a polyolefin or polystyrene. Such polymers which are used as feed are suitably waste polymers which may be discarded items of wrapping or packaging or plastics containers or off-cuts from polymer processing. Where such waste polymers are used these are suitably separated from any solid non-polymeric materials such as eg metallic components etc prior to being fed into the processing chamber. For the purposes of the present invention it is not necessary to completely remove such non-polymeric material as the processing chamber can be adapted to remove a slag of non-crackable or solid by-products from said chamber eg by a central discharge facility. The polymer is suitably introduced into the processing chamber in the form of strips, pellets, extrudates of short lengths or as a melt. Where it is introduced as strips, pellets or extrudates, these are suitably of a size of about 1-2cm 2 . The bed of particulate material suitably includes catalytic and/or non-catalytic materials such as eg an acidic and/or basic catalysts which may be a zeolite, clay or amorphous silica-alumina, silica, quartz, alumina, zirconia, incineration pellets eg sand or ceramics, and the like. The bed may also contain other materials such as eg limestone or calcium oxide which can be distributed in the bed in a manner which enables any acidic vapours such as eg HCl from halogenated polymer wastes such as eg PVC to be trapped. Where the polymer to be cracked contains significant quantities of PVC, such a polymer may be co-fed with a material capable of trapping acidic vapours such as HCl eg lime or calcium oxide. In such a process the used slag can be removed from the reaction chamber by a central discharge facility. The size of these particles is not of particular importance except that they should neither be ejected nor drop out of the reaction chamber under the reaction conditions. Thus, the bulk density of the particulate material used will have some bearing on the particle size thereof. For instance, if sand - which has a relatively high bulk density - is used, the particle size should be relatively small eg less than 500µm. The bed of material is suitably closely packed and the bed may optionally be fluidized. The processing chamber of circular-cross section in its vertical orientation is suitably of a cylindrical shape into which the hot gas is introduced from the base thereof and the polymer to be cracked can be introduced either from the top thereof or via a side feed directly into the bed of particulate material. The hot gas is introduced into the chamber in the form of a jet stream which passes through a series of angular blades arranged in a circular shape corresponding to the internal circumference of the processing chamber at its widest internal diameter. This configuration causes the hot gas directed at the underside of the blades at an angle parallel to the axis of the chamber to be deflected by the blades and emerge into the chamber at an angle away from the axis and towards the circumference of the chamber. The continuous upward flow of the hot gas causes any particles entrained in the flow such as eg the bed of particulate material in the chamber to assume a toroidal shape. This effect is accentuated by the gravitational effect which urges the entrained particles to fall back. However, the ratio of the mass of the entrained particles and the velocity of flow of the hot gas is so selected that they enable the particles of the bed to remain in suspension and thereby assume and remain in a substantially toroidal shape. By "toroidal" shape is meant here and throughout the specification that the gases are caused to flow not only in a circular fashion forming a cylindrical doughnut shape around the widest internal circumference of the chamber with respect to the central axis of the processing chamber but also create a spiral flow of jets of hot gas around the internal circular axis of the doughnut shape so formed. The mode of entry of the hot gas is so controlled by a series of spaced baffles or blades, which suitably form an annulus at the base of the chamber, that the creation of a toroidal shape is facilitated and accentuated. The rate of flow of the hot gas into the processing chamber is so controlled that the gas acts as a support medium for a bed of particulate material which is kept afloat and in suspension above the support medium rather on the principle of a 'hovercraft'. The toroidal shape of the particulate bed and the direction of flow of the hot gas also causes the incoming polymer to assume the toroidal shape and intermingle substantially thoroughly and uniformly with the particulate material of the bed. A particularly suitable apparatus of this type which can be used in the process of the present invention is claimed and described in the published EP-A-0068853, the disclosure of which is incorporated by reference. EP-A-0068853 claims an apparatus for processing matter in a turbulent mass of particulate material, said apparatus comprising: means defining a substantially annular process region for receiving a mass of particulate material; an inlet or inlets for admitting a flow of fluid and matter to be processed to said processing region; means for directing said flow of fluid generally circumferentially of said processing region; an outlet or outlets for said flow of fluid and for processed matter; and said defining means has a profile shaped to maintain said mass of particulate material substantially in a compact turbulent band within said processing region in response to said flow of fluid in use. Advantageously, the apparatus comprises means defining a substantially annular process chamber; an inlet or inlets for admitting a flow of fluid and matter to be processed to said processing chamber; means for directing said flow of fluid generally circumferentially of said processing chamber to cause said matter to be processed to circulate around said processing chamber for processing; an outlet or inlets for said flow of fluid and for processing matter; and said defining means is radially inwardly enlarged in a region between its axial limits. Preferably the defining means include a structure defining a radially inner wall of said processing chamber and defining a waist in said radially inner wall, especially with the structure having two frusto-conical sections which are inverted relative to one another to define said waist. In the apparatus the inlet or inlets may comprise an annular inlet opening to said processing chamber for said flow of fluid, said inlet opening being disposed at a base of said processing chamber, and the directing means may comprise a plurality of overlapping vanes arranged in said inlet opening. Preferably the inlet or inlets comprise an annular inlet opening to said processing chamber for said matter to be processed, especially with the inlet opening for said matter to be processed provided in said structure at said waist. Preferably the said outlet or outlets comprise an annular outlet opening at an upper axial end of said processing chamber. In particular as described in EP-A-0068853 the furnace comprises a generally tubular housing arranged with its axis vertical. A central structure within the housing co-operates with it to define an annular processing chamber and a fluid flow path passing through the chamber. The flow path has a lower section for supplying a mixture of gas and combustion air in EP-A-0068853 generally upwardly into the annular chamber, and an upper section for carrying exhaust fluid away from an upper region of the chamber. The lower section of the flow path is defined by a funnel-shaped portion of the housing and a conical portion of the central structure, both of which widen towards the annular chamber. Consequently, the flow cross-section, which is circular at the narrower end of the housing portion, is annular in the vicinity of the annular processing chamber. This annular flow cross-section is arranged to decrease in area towards the chamber. Within the narrower end of the housing portion, there is a burner. In EP-A-0068853 combustion air is supplied through the narrower end of the housing portion in use and, mingling with gas from the burner, flows upwardly to the annular processing chamber. As a result of the decreasing section of the flow path, the velocity of the fluid speeds up as it approaches this chamber. Entry of the fluid into the chamber is effected through an annular inlet opening which is co-extensive with the region of the flow path at the upper end of its lower section. A plurality of vanes are disposed in the inlet opening to impart rotational motion to the fluid flow entering the chamber so that the fluid circulates about the axis of the chamber as it rises. These vanes form part of a circular disc which rests in the upper end of the housing portion and supports the central structure inside the housing, being mounted between the conical portion and the remainder of the central structure. The vanes lie around the periphery of the disc and are simply angled away from the remainder of the disc about generally radially extending lines in the plane of the disc. Each vane spans the inlet opening in the radial direction, and the vanes are equispaced about the opening so that the supply of fluid to the chamber is substantially evenly distributed around it. The chamber itself is defined between a cylindrical portion of the housing and a waisted portion of the central structure. By virtue of the waist in said portion of the structure, the chamber is radially inwardly enlarged in a region between its axial ends. Accordingly, the vertical component of the fluid flow passing through the chamber is subject first to a decrease and then to an increase in velocity during the passage of the fluid The combined effects of the inclined vanes in the inlet opening and the waist in the central structure on the fluid travelling along the path results in a highly turbulent swirling flow in the chamber. At the upper end of this chamber, there is an annular outlet opening which is co-extensive with the region of the flow path at the lower end of its upper section. This upper section of the flow path is provided by an inverted funnel shaped portion of the housing and a further conical portion of the central structure. The facing surfaces of the housing portion and the conical portion of the central structure are substantially parallel and converge away from the chamber. Thus, these members define an annular region in the flow path of decreasing cross sectional area in which the velocity of the fluid increases as the flow departs from the chamber. One or more inlet openings to the chamber are also provided in the wall of the cylindrical housing portion. A chute, from for example a hopper, leads to the or each inlet to supply firstly refractory particles and subsequently in EP-A-0068853 perlite to the chamber. The use of the apparatus is described in EP-A-0068853 with respect to perlite as the matter to be processed rather than the polymers used in the process of the present invention. Operation of the apparatus is as follows: A rising flow of heated fluid is generated within the lower section of the flow path by supplying combustion air through the narrower end of the housing portion, supplying gas to the burner, and initiating combustion in the vicinity of the burner. The velocity of the fluid increases as it approaches the chamber. On encountering the vanes, the heated fluid is deflected into the chamber and caused to rotate about the chamber's axis whilst still rising. The fluid swirls around the chamber in a turbulent fashion and then exhausts from the chamber through the annular outlet opening. Particulate material is injected into the chamber by way of the chute or chutes and, under the influence of fluid in the chamber, becomes a turbulent mass heated by the fluid. The turbulent mass assumes the form of a compact toroidal band within which the particles circulate. Complex flows occur within this band under the combined effects of gravity, centrifugal action and gaseous flow, and the particles circulate both around the axis of the chamber and to and fro within the band. Although the theory behind the motion of the turbulent mass has not yet been fully developed, it is believed that the circulation occuring within the turbulent mass has a first component flow and in some instances, but not all, also a second component flow. The first component flow is in the close vicinity of the wall of the cylindrical housing portion. Particles are lifted up against this wall by the rising flow of gas, and in the upper regions of the turbulent mass, tumble inwardly remaining close to the wall. At the same time, the particles are displaced circumferentially by the rotational movement of the fluid in the chamber. The particles which circulate according to the second component flow follow a path which is directed inwardly and upwardly from the inlet opening with the entering fluid. As they reach the innermost edge of the turbulent mass, centrifugal forces take over and urge them generally outwardly again. The particles move outwardly, and also circumferentially, until they meet and merge with the particles in the first component flow. At this point, gravity dominates and the particles drop to the bottom of the bed for the recirculation. Observation of the mass during testing suggests that this is what occurs within it, although the precise paths of the particles have not been determined. It is thought that by appropriate adjustment of the velocity of the fluid flowing into the chamber and the positioning of the vanes, the circulation of particles within the chamber can be modified so that the first component flow predominates and the second disappears almost altogether. Then, the particles would flow up and outside of the mass, circumferentially and downwardly in the upper region of the mass to its inner area, and finally outwardly and circumferentially to repeat the cycle. In any event, the motion of the particle in the toroidal band causes very thorough mixing and a uniform distribution of heat throughout the band. Once the circulating mass has acquired a sufficiently high temperature, perlite in EP-A-0068853 is supplied to the chamber by way of the chute or chutes. The perlite drops into the turbulent band and is held embedded there by gravity acting on it, whilst it mixes with the particles and is heated. On heating, the perlite expands and becomes increasingly influenced by the rising flow of fluid passing through the chamber due to change in density. As a result, the perlite has a tendency to migrate generally upwardly to the top of the turbulent mass with the fluid flow. Here, it is located towards the axial centre of the chamber where the vertical velocity of the fluid is starting to increase. The perlite becomes entrained in the fluid and is lifted towards the annular outlet at an increasing rate, being expelled from the chamber with the exhaust fumes. The apparatus has two significant advantages. Firstly, the high degree of turbulence within the particulate mass and the circulation of the particles throughout the chamber in the circumferential direction gives rise to a uniform temperature distribution within the mass and a very efficient transfer of heat between the particles, fluid and the perlite. Secondly, the fully expanded perlite separates naturally and automatically both from the circulating mass and from matter yet to be fully processed. A further and preferred apparatus from that already discussed of different construction, but with the same principle of operation features a housing containing a central structure, and defining with this structure an annular process chamber through which a fluid flow path extends vertically. As before, the central structure is waisted, providing a radially inwardly enlarged region in the chamber between its axial limits. An annular inlet opening for fluid is situated at the base of the chamber and contains a plurality of overlapping vanes. Also, the chamber constricts upwardly towards an annular outlet opening for exhaust fluid and expanded perlite. Lower portions of the housing and central structure respectively, together define a lower section of the flow path. This lower section of the flow path is generally annular and decreases in cross-section as it approaches the chamber. Combustion air is supplied into the lower region of this flow path section where a burner burns the air with the gas to generate a heated flow of fluid rising into the chamber. On entering the chamber, the heated fluid is deflected circumferentially by the vanes, and within the chamber it swirls and becomes turbulent by virtue of the waist in the central structure. This apparatus differs from the preceding one chiefly in the arrangement by which particulate material and perlite are supplied to the processing chamber, and additionally in the design of the support structure for the vanes and the exhaust section of the flow path. In this case, the furnace features a continuous annular inlet opening for the particulate material and, later, the perlite, which is situated in the central structure at its waist. Particulate material and perlite are supplied to this opening by way of a chute, and a distribution arrangement located internally of the central structure. More especially, the central structure is divided into two separate parts in the present instance. These comprise a lower part which includes the lower portion of the structure, and an upper part. Both parts are supported by and fixed relative to the housing. The lower part includes a support for a rotatable disc and a motor, the motor being operable to rotate the disc. The disc has a central bump, and its periphery coincides with the upper edge of the substantially frustoconical outer wall of the lower part. A portion of the wall serves as the lower portion of the radially inner wall of the chamber below the waist. The upper part of the central structure serves to support the chute above the bump in the disc, and has a frustoconical wall providing the upper portion of the radially inner wall of the chamber above the waist. In use, the disc is set into motion by the motor, and particulate material is supplied into the chute. The particles drop onto the bump and are flung outwardly towards the periphery of the disc. From the disc periphery, the particles fall downwardly over the wall in a thin curtain into the chamber. Thus, the particles are uniformly distributed around the chamber. Heated fluid is driven upwardly into the chamber, and the particles form a heated turbulent toroidal mass behaving in the manner described above. Then, the perlite is injected into the chamber by way of the chute and rotating disc. Like the particulate material, the perlite falls as a thin curtain into the chamber and is evenly distributed around the chamber. This promotes particularly efficient mixing of the perlite with the turbulent mass. The vane structure of the apparatus serves to deflect fluid entering the chamber in a circumferential direction. The vane structure comprises an inner ring forming part of the lower part of the central structure, and an outer ring forming part of the housing. The two rings face one another and have regularly spaced slots in their opposed faces. The slots are arranged in corresponding pairs, one in each ring and are inclined in relation to the plane surfaces of these rings. A respective vane is fitted into each corresponding pair of slots. The vanes thus overlap to a significant extent and define narrow flow passages between one side of the vane structure and the other. This promotes a clean flow in the fluid entering the chamber. Such controlled flow assists in supporting the turbulent toroidal mass above the vanes and in inhibiting particles from falling through the vanes into the lower section of the flow path. The exhaust section of the flow path is arranged as follows: At the upper end of the chamber, the flow path is directed radially into a scroll shaped upper portion of the housing, which is hollow. The expanded perlite leaving the chamber is flung outwardly into this housing portion and flows round it to an outlet at its outer-most end. The swirling motion of the fluid and expanded perlite leaving the chamber assists in carrying the particles to the outlet. The swirling motion of the fluid and expanded perlite leaving the chamber assists in carrying the particles to the outlet. This embodiment of the apparatus is particularly advantageous for a number of reasons. Each opening into and out of the chamber embraces its full circumference so that the supply of fluid and other matter into the chamber and the exhaust of products from the chamber occurs uniformally over its entire operational extent. Efficient processing is a natural consequence of this. Another advantage lies in the construction and arrangement of the vanes as mentioned above. An alternative form of apparatus comprises an outer housing. The housing defines a combustion chamber and a heating chamber. Within the chamber, there is a processing chamber formed by a shallow, roughly cylindrical, hollow body. The housing is arranged to contact the body at top and bottom, but so that a helical flow path, leading from the combustion chamber, is provided between the housing and the circumferential wall of the body. The path leads to an inlet opening in the wall. Gas and combustion air are supplied in use to the chamber where combustion takes place, and the fluid then circulates around the circumference of the body before entering the processing chamber. The exterior of the body is thus heated and, to promote an even temperature along the wall, a plurality of annular ribs are provided. The body and ribs are formed mainly from a material such as cast iron or ceramic. The hot gas enters the processing chamber in a generally tangential manner through the inlet and, thereafter, initially tends to flow the interior of the wall round the chamber. The fluid is then exhausted from the chamber through the outlet formed in the top of the body in its axial direction. An additional inlet extends into the chamber through the top of the body and the adjacent wall of the housing. This inlet serves initially for supplying particulate material and subsequently for injecting perlite into the chamber. The inlet is arranged radially inwardly of the wall so as to direct the particulate material and the perlite tangentially of the chamber. In operation, heated fluid is caused to flow round the exterior and then the interior of the wall before being exhausted through the outlet. Particulate material is supplied into the chamber and, under the influence of the fluid flow, hugs the inside of the wall and is caused to flow in a turbulent manner about the annular exterior region of the processing chamber. The fluid rotating about the axis of the chamber causes this turbulent mass to rotate and to be urged continually outwards against the wall and the mass, therefore, forms a compact toroidal band. This band is heated both by the transfer of heat through the wall and by the heat of the fluid circulating within the chamber. When perlite is added to the chamber, it is flung forcefully outwards against and into the turbulent band and is heated therein. As the perlite expands, it tends to work its way towards the inner edge of the band and it becomes entrained in the flow of fluid passing to the outlet. The fluid and expanded perlite are exhausted from the chamber together. Various modifications can also be made in the construction of the apparatus. For example, instead of forming the waist in the central structure in the manner described above by arranging two frustoconical wall positions of this structure in inverted relation and thereby defining a precisely angled corner in the processing chamber, the waist may be defined by a radially inwardly curved wall portion of the central structure. Also, it should be noted that where the waist is defined by frustoconical wall portions of the central structure, the cone angles of each may be either the same or different. Alternative arrangements for the vanes of the two furnaces described above are also possible. In these two embodiments, each vane is inclined only about a radially extending line. However, each vane may be lifted at its outer edge as well so that it is inclined both in the generally circumferential direction of the annular inlet opening for fluid and in the generally radial direction. This would result in a change in the particle flows within the turbulent toroidal mass but would still generate a high degree of mixing of the particles. A further modification resides in the provision of an additional outlet at or adjacent the lower end of the annular process chamber in the above furnaces. For example, the cylindrical portion of the housing may be somewhat enlarged relative to the wider end of the housing portion and a substantially annular opening may be created at the lower outer edge of the processing chamber. Any relatively heavy matter or particles in the circulating band of particulate material will have a tendency to gravitate to this region and will consequently drop from the chamber. Such arrangements are advantageous for separating relatively heavy particles of processed or waste matter from the toroidal band in a manner which does not block the annular inlet opening to the processing chamber. Consequently, these arrangements may be useful, for example, in instances where the or some of the processed matter is too heavy to be easily extracted from the processing chamber by entrainment in the exhaust flow of gas or where the supply of the matter to be processed is contaminated. In EP-A-0068853, the apparatus described also acts on the 'hovercraft' principle and uses a momentum of exchange between a gas stream (the hot gas) and a mass (the polymer). By inverting the flow of the gas stream and by channelling the gas stream through a series of blades, the resultant linear jets of gas act as a support medium for a shallow bed (50-75mm in depth) of particles which can be floated over the gas stream. The blades convert the pressure head in the gas stream into a velocity head and, by suitable blade design, forces can be exerted on the bed causing it to lift and be transported horizontally. This exchange of energy is one of the fundamental differences between a fluidzed bed reactor and the apparatus of EP-A-0068853, the so called "TORBED®" reactor, in which a toroidal bed of particulate material is achieved. In the case of the TORBED®, the momentum of the gas stream, which is normally the product of mass flow and its velocity, for a given bed may be supported either by a low velocity gas stream with a high mass flowrate, or, by a higher velocity gas stream with a correspondingly low mass flowrate. The ability to control the momentum of the hot gas as described above enables the use of particulate bed materials having large-size range distributions. Thus the shape of the particulate bed material being processed need not be spheroidal; they may be flakes, rings, extrudates or of other irregular shapes. In the TORBED®, the blades are formed into an annulus at the base of the process chamber thereby enabling maximum exposure of all the material in the particulate bed to the area in which the velocity of the gases are at a maximum. The hot gas is preferably inert under the reaction conditions to the polymer being cracked or the low molecuolar weight products produced thereby. Examples of gases that may be used include hydrogen, nitrogen, steam, carbon monoxide, carbon dioxide, other flue gases (which may comprise ethane, propane and mixtures thereof and which may be the by-products of the polymer cracking reaction or of steam/catalytic cracking of naphthenes, paraffins etc) which are substantially free of oxygen. Of these, nitrogen is preferred. The heating for the gas to generate a hot gas may be provided by burners located suitably beneath the annular baffles/blades at the base of the processing chamber. The hot gas may be a mixture of gases and combusted air eg from combustion of hydrocarbon mixtures. The polymer is suitably cracked at a temperature in the range from 300-600°C. Within this range, a temperature of 300-450°C is suitably used if the particulate bed used contains a catalyst. In the absence of any catalytic material in the particulate bed, the temperature used is preferably higher and can be up to 600°C. The residence time of the polymer in the processing chamber is suitably very short and is preferably of the order of less than 20 seconds, most preferably from 1-3 seconds in order to generate the desired products of lower molecular weight from the polymer. The process of the present invention can be carried out by a batch process or by a continuous process. It is preferable to use a reactor in which the slag or inactive beds or other particulate contaminants in the polymer being cracked are withdrawn through a central discharge facility at the base of the reactor whereas the exit gases containing the desired products of lower molecular weight are recovered from the top of the reactor. The process of the present invention enables the polymers to be cracked into products of relatively lower molecular weight than the starting materials. These products of lower molecular weight volatilize and/or are entrained in the gases exiting the processing chamber. The products of lower molecular weight comprise one or more of waxes, lubricating oils, paraffinic hydrocarbons, naphthenes and other monomers. The desired products can be recovered from the gases exiting the chamber eg by condensation. If desired, some of the products may be further treated to improve the value thereof. For instance, the paraffinic and naphthenic hydrocarbons resulting from the polymer cracking process may be steam cracked further to produce lower olefins. The present invention is further illustrated with reference to the following Examples: EXAMPLE 1: A TORBED® T400 reactor (with a 400 cm diameter chamber with each blade ca. 5-7cm long) supplied by Davy Mckee Ltd and having a configuration described in EP-A-0 068 853, was provided with a side burner and air blower, a side exit port and a batch feed hopper. The reactor contained a resident bed of fused alumina (750g anti-bumping granules, ex BDH Ltd) which was caused to circulate toroidally about the axis of the chamber. The bed was heated to 350 °C using propane as the fuel gas. Samples of polyethylene particles (37.8g linear low density polyethylene, MW 106,000, ex BP Chemicals SNC, Lavera) were fed into the reactor batchwise by the feed hopper at the top of the reactor and introduced into the circulating alumina granules. After a contact time of 1-2 seconds in the reactor, an aerosol spray type mist entrained in the gases exiting the reactor was collected, condensed and found to contain a waxy product. This waxy product on analysis by gas chromatography was found to contain a mixture of hydrocarbons, mainly having 30 to 40 carbon atoms. EXAMPLE 2: The above process was repeated but now using a heated nitrogen feed fed at the rate of 200 cm 3 /hr (NTP). The particulate bed was that of zirconia pellets (2 Kg, 2-5 mm diameter, ex Brown & Tawse Ltd) and the same polyethylene grade as above(6 Kg) was fed via a screw feeder at the rate of 6 Kg/hr. The reactor was run at a temperature of 500°C. The resultant product was a wax which was collected via a water scrubber and analysis of the wax by HPLC showed it to contain a broad range of hydrocarbons containing 25-120 carbon atoms with a predominating amount of these having 40-80 carbon atoms.

Claims: A process for the conversion of a polymer, especially hydrocarbon polymers, into products of lower molecular weight than the starting polymer, said process comprising introducing polymer into a processing chamber and supporting it therein with gas which flows in an upward direction to crack the polymer into products of lower molecular weight and recovering said products characterized by comprising: a. generating in a processing chamber of circular cross-section in its vertical orientation a stream of hot gas which flows in an angular and upward direction causing (i) a bed of particulate material to be entrained in the flow of the gas and held in suspension in a toroidal shape around the widest internal circumference of the chamber and (ii) the polymer introduced into said chamber in turn to intermingle with the particulate material and assume said toroidal shape thereby cracking said polymer into products of lower molecular weight, and b. recovering said products of lower molecular weight from said chamber. A process according to Claim 1 wherein the polymer is introduced into the reactor as strips, pellets, extrudates or as a melt. A process according to Claim 1 or 2 wherein the polymer is selected from polyethylene, polypropylene, polystyrene, PVC or polyethylene terephthalate. A process according to any one of the preceding Claims wherein the polymer is a waste polymer. A process according to any one of the preceding Claims wherein the polymer is cracked in a reactor in which hot gas is introduced into the processing chamber from its base via a jet stream which passes through a series of angular blades arranged in a circular shape corresponding to the internal circumference of the processing chamber, and the polymer is introduced from the top of the chamber or via a side feed directly into the bed of particulate materials, and exit gases containing the products of lower molecular weight are recovered from the top of the reactor. A process according to any one of the preceding Claims wherein the bed of particulate material comprises catalytic materials, non-catalytic materials or mixtures thereof. A process according to any one of the preceding Claims wherein the bed of particulate material comprises one or more of a zeolite, clay or amorphous silica-alumina, silica, quartz, alumina, zirconia, incineration pellets and calcium oxide. A process according to any one of the preceding Claims wherein the hot gas is selected from hydrogen, nitrogen, steam, carbon dioxide, carbon monoxide, flue gases and mixtures thereof which are substantially free of oxygen. A process according to any one of the preceding Claims wherein the polymer is cracked at a temperature in the range from 300-600°C. A process according to any one of the preceding Claims wherein the residence time of the polymer in the processing chamber is less than 10 seconds.

Inventors: ATKINS MARTIN PHILIP, KIDD DAVID ARTHUR, ATKINS, MARTIN PHILIP, KIDD, DAVID ARTHUR
Applicants: TORFTECH LTD, TORFTECH LIMITED
Application year: 1993
Main classification: C10G1
IPC codes: C10G1, C08F8, C08J11