WO2026027298A1 - Procédé de fabrication d'hydrocarbures aromatiques en c6-c8 à partir de véhicules en fin de vie - Google Patents

Procédé de fabrication d'hydrocarbures aromatiques en c6-c8 à partir de véhicules en fin de vie

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Publication number
WO2026027298A1
WO2026027298A1 PCT/EP2025/070797 EP2025070797W WO2026027298A1 WO 2026027298 A1 WO2026027298 A1 WO 2026027298A1 EP 2025070797 W EP2025070797 W EP 2025070797W WO 2026027298 A1 WO2026027298 A1 WO 2026027298A1
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WIPO (PCT)
Prior art keywords
feedstock
gasifier
synthesis gas
polymer
aromatic hydrocarbons
Prior art date
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Pending
Application number
PCT/EP2025/070797
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English (en)
Inventor
Andre BADER
Maximilian Vicari
Klaus Wittstock
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BASF SE
Original Assignee
BASF SE
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Application filed by BASF SE filed Critical BASF SE
Publication of WO2026027298A1 publication Critical patent/WO2026027298A1/fr
Pending legal-status Critical Current
Anticipated expiration legal-status Critical

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Classifications

    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
    • C10G1/00—Production of liquid hydrocarbon mixtures from oil-shale, oil-sand, or non-melting solid carbonaceous or similar materials, e.g. wood, coal
    • C10G1/002—Production of liquid hydrocarbon mixtures from oil-shale, oil-sand, or non-melting solid carbonaceous or similar materials, e.g. wood, coal in combination with oil conversion- or refining processes
    • C—CHEMISTRY; METALLURGY
    • C07—ORGANIC CHEMISTRY
    • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
    • C07C7/00—Purification; Separation; Use of additives
    • C07C7/04—Purification; Separation; Use of additives by distillation
    • C07C7/05—Purification; Separation; Use of additives by distillation with the aid of auxiliary compounds
    • C07C7/08—Purification; Separation; Use of additives by distillation with the aid of auxiliary compounds by extractive distillation
    • C—CHEMISTRY; METALLURGY
    • C07—ORGANIC CHEMISTRY
    • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
    • C07C7/00—Purification; Separation; Use of additives
    • C07C7/09—Purification; Separation; Use of additives by fractional condensation
    • C—CHEMISTRY; METALLURGY
    • C07—ORGANIC CHEMISTRY
    • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
    • C07C7/00—Purification; Separation; Use of additives
    • C07C7/10—Purification; Separation; Use of additives by extraction, i.e. purification or separation of liquid hydrocarbons with the aid of liquids
    • C—CHEMISTRY; METALLURGY
    • C07—ORGANIC CHEMISTRY
    • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
    • C07C7/00—Purification; Separation; Use of additives
    • C07C7/11—Purification; Separation; Use of additives by absorption, i.e. purification or separation of gaseous hydrocarbons with the aid of liquids
    • C—CHEMISTRY; METALLURGY
    • C07—ORGANIC CHEMISTRY
    • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
    • C07C7/00—Purification; Separation; Use of additives
    • C07C7/12—Purification; Separation; Use of additives by adsorption, i.e. purification or separation of hydrocarbons with the aid of solids, e.g. with ion-exchangers
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
    • C10G1/00—Production of liquid hydrocarbon mixtures from oil-shale, oil-sand, or non-melting solid carbonaceous or similar materials, e.g. wood, coal
    • C10G1/10—Production of liquid hydrocarbon mixtures from oil-shale, oil-sand, or non-melting solid carbonaceous or similar materials, e.g. wood, coal from rubber or rubber waste
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
    • C10G21/00—Refining of hydrocarbon oils, in the absence of hydrogen, by extraction with selective solvents
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
    • C10G7/00—Distillation of hydrocarbon oils
    • C10G7/08—Azeotropic or extractive distillation
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
    • C10J3/00—Production of combustible gases containing carbon monoxide from solid carbonaceous fuels
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
    • C10J3/00—Production of combustible gases containing carbon monoxide from solid carbonaceous fuels
    • C10J3/46—Gasification of granular or pulverulent flues in suspension
    • C10J3/466—Entrained flow processes
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
    • C10J3/00—Production of combustible gases containing carbon monoxide from solid carbonaceous fuels
    • C10J3/72—Other features
    • C10J3/721—Multistage gasification, e.g. plural parallel or serial gasification stages
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10K—PURIFYING OR MODIFYING THE CHEMICAL COMPOSITION OF COMBUSTIBLE GASES CONTAINING CARBON MONOXIDE
    • C10K1/00—Purifying combustible gases containing carbon monoxide
    • C10K1/04—Purifying combustible gases containing carbon monoxide by cooling to condense non-gaseous materials
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10K—PURIFYING OR MODIFYING THE CHEMICAL COMPOSITION OF COMBUSTIBLE GASES CONTAINING CARBON MONOXIDE
    • C10K1/00—Purifying combustible gases containing carbon monoxide
    • C10K1/08—Purifying combustible gases containing carbon monoxide by washing with liquids; Reviving the used wash liquors
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10K—PURIFYING OR MODIFYING THE CHEMICAL COMPOSITION OF COMBUSTIBLE GASES CONTAINING CARBON MONOXIDE
    • C10K1/00—Purifying combustible gases containing carbon monoxide
    • C10K1/08—Purifying combustible gases containing carbon monoxide by washing with liquids; Reviving the used wash liquors
    • C10K1/10—Purifying combustible gases containing carbon monoxide by washing with liquids; Reviving the used wash liquors with aqueous liquids
    • C10K1/12—Purifying combustible gases containing carbon monoxide by washing with liquids; Reviving the used wash liquors with aqueous liquids alkaline-reacting including the revival of the used wash liquors
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
    • C10J2300/00—Details of gasification processes
    • C10J2300/09—Details of the feed, e.g. feeding of spent catalyst, inert gas or halogens
    • C10J2300/0903—Feed preparation
    • C10J2300/0906—Physical processes, e.g. shredding, comminuting, chopping, sorting
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
    • C10J2300/00—Details of gasification processes
    • C10J2300/09—Details of the feed, e.g. feeding of spent catalyst, inert gas or halogens
    • C10J2300/0913—Carbonaceous raw material
    • C10J2300/0916—Biomass
    • C10J2300/092—Wood, cellulose
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
    • C10J2300/00—Details of gasification processes
    • C10J2300/09—Details of the feed, e.g. feeding of spent catalyst, inert gas or halogens
    • C10J2300/0913—Carbonaceous raw material
    • C10J2300/093—Coal
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
    • C10J2300/00—Details of gasification processes
    • C10J2300/09—Details of the feed, e.g. feeding of spent catalyst, inert gas or halogens
    • C10J2300/0913—Carbonaceous raw material
    • C10J2300/094—Char
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
    • C10J2300/00—Details of gasification processes
    • C10J2300/09—Details of the feed, e.g. feeding of spent catalyst, inert gas or halogens
    • C10J2300/0913—Carbonaceous raw material
    • C10J2300/0946—Waste, e.g. MSW, tires, glass, tar sand, peat, paper, lignite, oil shale
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
    • C10J3/00—Production of combustible gases containing carbon monoxide from solid carbonaceous fuels
    • C10J3/02—Fixed-bed gasification of lump fuel

Definitions

  • the process of the present invention relates to the manufacture of C6-C8 aromatic hydrocarbons by gasification of pre-sorted fractions from end-of-life vehicles.
  • plastic waste is converted into important base chemicals such as benzene, toluene and xylene isomers having a recycling content.
  • feedstocks can be utilized which comprise at least a portion of plastic waste from end-of life vehicles such as plastic waste comprised in automotive shredder residue (ASR).
  • ASR automotive shredder residue
  • Said base chemicals then serve as a raw material for synthesis of monomers and such monomers as building blocks in polymers of relevance for the automotive market.
  • Several polymer types of relevance for the automotive market comprise monomers which are based on C6-C8 aromatic hydrocarbons.
  • a method for producing olefins and aromatic compounds from a feedstock is disclosed in US 2014/0228606 A1.
  • a hydrocarbon feedstock is converted in the presence of a catalyst composition at a reactor temperature of 420 to 730 °C in a reactor to products of at least one of olefins and aromatic compounds within the reactor, at least some of the products being contained in a liquid product stream.
  • the catalytic composition comprises a fluidized bed catalytic cracking (FCC) catalyst and a ZSM-5 zeolite catalyst.
  • FCC fluidized bed catalytic cracking
  • ZSM-5 zeolite catalyst ZSM-5 zeolite catalyst.
  • the method disclosed in US 2014/0228606 A1 is a fluidized catalytic cracking process which is different form gasification methods in several aspects such as the reaction temperature range and residence time and the presence of specific zeolite catalyst which results in a specific product composition.
  • the main products produced by saif fluid catalytic cracking process are light gas olefins, aromatics, gasoline or naphtha, diesel, a heavier stream and coke whereas a typical gasification process produces as main products CO, H2, CO2, methane and tar.
  • step (i) providing at least one pre-sorted fraction PSE of end-of-life vehicles as first feedstock F1, wherein said at least one pre-sorted fraction PSE comprises at least one polymer which forms at least one C6-C8 aromatic hydrocarbon in step (ii), providing a second feedstock F2 and optionally a third feedstock F3, wherein at least 10 wt.-%, more preferably at least 15 wt.-% and most preferably at least 20 wt.-% of all feedstocks provided in step (i) are second feedstock F2,
  • step (ii) converting said first feedstock F1 and said second feedstock F2 provided in step (i) and said third feedstock F3 optionally provided in step (i) in a first gasifier G1 into a first raw synthesis gas RSG1 , wherein said first raw synthesis gas RSG1 comprises CO, H2, and C6-C8 aromatic hydrocarbons,
  • a chemical plant for manufacture of C6-C8 aromatic hydrocarbons from presorted fractions of end-of-life vehicles comprising a. a first gasifier G1, b. optionally a second gasifier, said optional second gasifier downstream of and fluidically connected to said first gasifier G1 , c. a gas cleaning unit GCU, said gas cleaning unit GCU downstream of and fluidically connected to said first gasifier G1 and said optional second gasifier G2, and d. an aromatic hydrocarbon extraction unit AEU, said aromatic hydrocarbon extraction unit AEU downstream of and fluidically connected to said gas cleaning unit GCU, wherein said first gasifier G1 is a fixed bed gasifier and wherein said optional second gasifier G2 is an entrained flow gasifier.
  • said second feedstock F2 is a particulate feedstock having a particle size PS and is selected from the group comprising or more preferably consisting of coal, bio char, wood and combinations thereof.
  • no catalyst composition such as a FCC catalyst and hydrogen are purposedly added into the first gasifier G1 before or during step (ii).
  • the process and the chemical plant according to the present invention is suited to fulfil recent requirements concerning the utilization and recycling targets set for end-of-life vehicles and new vehicles.
  • At least a portion of the polymers comprised in end-of-life vehicles, e.g., in the form of automotive shredder residue (ASR) which is utilized as “first feedstock F1” are converted by this process into C6-C8 aromatic hydrocarbons which can then be further converted into monomers M and optionally further converted into polymers P.
  • ASR automotive shredder residue
  • typical polymers comprised in end-of-life vehicles such as poly(azepan-2-one) (polyamide-6, PA6), poly [imino(1 ,6- dioxohexamethylene) iminohexamethylene] (polyamide-66, PA66), (T)PUs, , polyisocyanurates, polyureas, poly(ethylene terephthalate) (PET), poly(oxy-1,4-butanediyloxycarbonyl-1 ,4-phenylenecarbonyl) (PBT), and other polyesters comprising benzene-1,4-dicarboxylic acid can be used in the process according to the present invention as first feedstock F1 for a gasification from which C6-C8 aromatic hydrocarbons having a recycling content are obtained.
  • end-of-life vehicles such as poly(azepan-2-one) (polyamide-6, PA6), poly [imino(1 ,6- dioxohexamethylene) iminohexamethylene]
  • Said C6-C8 aromatic hydrocarbons having a recycling content can then be converted into monomer M such as azepan-2-one, hexanedioic acid, benzene-1,4-dicarboxylic acid, 1 ,1 '-methylenebis(4-isocyanatobenzene), 2- isocyanato-1 -methylbenzene, 3-isocyanato-1-methylbenzene, 4-isocyanato-1 -methylbenzene, 2,4-diisocyanato-1 - methylbenzene and 2,6-diisocyanato-1-methylbenzene from which alone or in combinations with further monomers M' polymers P such as poly(azepan-2-one) (polyamide-6, PA6), poly[imino(1,6-dioxohexamethylene) iminohexamethylene] (polyamide-66, PA66), (T)PUs, polyisocyanurates, polyureas, polyethylene terephthal
  • Figure 1 shows the process and chemical plant according to the present invention utilizing a first gasifier G1.
  • Figure 2 shows the process and chemical plant according to the present invention utilizing a first gasifier G1 and a washing liquid WL.
  • Figure 3 shows the process and chemical plant according to the present invention utilizing a first gasifier G1 and a second Gasifier G2.
  • Figure 4 shows the process and chemical plant according to the present invention utilizing a first gasifier G1, a second gasifier G2 and a washing liquid WL.
  • the term "about” preferably means a deviation of the thus described value of ⁇ 10 %.
  • the term “combinations thereof' is inclusive of one or more of the recited elements.
  • the term “mixture thereof” is inclusive of one or more of the recited elements.
  • fluidically connected to in respect to two or more units is defined herein that a fluid such as a particulate solid, liquids, gases, and mixtures thereof can flow from one of such unit to the other such unit and flow through and/or along such an analytical unit.
  • Two units “fluidically connected to” each other are for example connected by one or more pipes which each other or by screw conveyors or by extruders or by solids pumps.
  • “Directly” in respect to “fluidically connected” is defined as fluidically connected by a suitable means such as a pipe. Accordingly, the respective outlet of a first unit is fluidically connected by a suitable means such as a pipe with the respective inlet of a second unit wherein said second unit is downstream of said first unit.
  • “Indirectly” in respect to “fluidically connected” is defined as interrupted by e.g., an additional unit, storage tank(s), transporting a stream by for example by truck or train or in a pipeline.
  • C6-C8 aromatic hydrocarbons means benzene, toluene, 1,2-xylene, 1,3-xylene, 1,4-xylene, ethylbenzene, and styrene
  • C6-C8 aromatic hydrocarbons preferably means toluene, 1 ,2-xylene, 1,3-xylene, 1,4-xylene, and ethylbenzene.
  • Refuse-derived fuel is defined herein as a fuel produced form various types of waste such as municipal solid waste (MSW), industrial waste or commercial waste.
  • RDF consists largely of combustible components of such waste, as non-recyclable plastics (not including PVC), paper cardboard, labels, and other corrugated materials. These fractions are separated by different processing steps, such as screening, air classification, ballistic separation, separation of ferrous and non-ferrous materials, glass, stones, and other foreign materials and shredding into a uniform grain size, or also pelletized to produce a homogeneous material which can be used as a feedstock for gasification processes (Y. Yang et al., Gasification of refuse-derived fuel from municipal solid waste for energy production: a review, Environmental Chemistry Letters (2021) 19, 2127-2140 (https://doi.org/10.1007/s10311-020- 01177-5).
  • step (i) of the process according to the present invention at least one pre-sorted fraction PSE from end-of-life vehicles is provided as first feedstock F1 , wherein said at least one pre-sorted fraction PSE comprises at least one organic polymer.
  • Said first feedstock F1 comprises at least one pre-sorted fraction PSE of end-of-life vehicles, said pre-sorted fraction PSE of end-of-life vehicles formed by sorting from a non-sorted shredder residue NSR of end-of-life vehicles.
  • Said non-sorted shredder residue NSR comprises metal fragments and/or non-metallic inorganic fragments (such as glass fragments), and fragments of at least one polymer selected from the group consisting of polyolefins, polyamides, polyisocyanate polyaddition products, rubber, epoxy resins and polyolefins.
  • Said first feedstock F1 comprises plastic waste previously comprised in end-of-life vehicles, such as in the plastic waste comprised in automotive shredder residue (ASR) which has been taken from end-of-life vehicles and then presorted to increase the amount of at least one polymer therein and reduce the amount of metals and/or non-metallic inorganic fragments comprised in end-of-life vehicles.
  • ASR automotive shredder residue
  • the first feedstock F1 comprises 1 to 50 wt.-% plastic waste from end-of-life vehicles, most preferably, the first feedstock F1 comprises 5 to 30 wt.-% plastic waste from end-of-life vehicles.
  • Plastic waste comprised in end-of-life vehicles is preferably selected from the group comprising polyolefins, polyamides, polyurethanes, polyesters, and mixtures thereof.
  • the plastic waste from end-of-life vehicles comprised in the first feedstock F1 is automotive shredder residue (ASR).
  • the non-sorted shredder residue NSR may further comprise shredded electric and electronic equipment devices (WEEE - waste electric and electronic equipment) and other types of waste which are shredded.
  • Shredded electric and electronic equipment devices preferably comprises epoxy resins originating from printed circuit boards and the like comprised therein Such WEEE optionally also have been part of the end-of-life vehicles.
  • Said non-sorted shredder residue NSR is sorted to form the pre-sorted fraction PSE of end-of-life vehicles, preferably in this order, by a) optionally further reducing the size of said non-sorted shredder residue NSR and b) sorting out metal fragments and/or non-metallic inorganic fragments from said non-sorted shredder residue NSR.
  • a particularly preferred first feedstock F1 comprising pre-sorted fractions of end-of-life vehicles is pre-sorted automotive shredder residue (ASR) which is described in more detail below:
  • Automotive shredder residue is obtainable, preferably is obtained, by shredding vehicles.
  • the automotive shredder residue is obtainable by depollution of the vehicles, dismantling the vehicles, shredding the vehicles, and separating metal particles from the shredded vehicles.
  • the methods described for a) optionally further reducing the size of said metal fragments and/or non-metallic inorganic fragments and fragments of at least one polymer and b) sorting out said metal fragments and/or said non- metallic inorganic fragments in respect to automotive shredder residue (ASR) described below can also be applied to other non-sorted shredder residue NSR provided in step (i) to form at least one pre-sorted fraction PSE of end-of-life vehicles which is depleted in metal fragments and/or in non-metallic inorganic fragments by step b) compared to the non-sorted shredder residue NSR.
  • Non-metallic inorganic fragments are for example glass fragments.
  • the vehicles in automotive shredder residue are typically end-of-life vehicles (also called "ELV"), which are typically at least 15 years old.
  • the vehicles can be passenger cars, light-duty or heavy-duty trucks, motorbikes, a utility vehicle, an agricultural vehicle, or recreational vehicles.
  • the vehicle can be an electric vehicle, such as a fully electric vehicle or a hybrid electric vehicle.
  • hazardous liquids such as fuel, lubricating oil, coolants, brake fluids and batteries can be removed from the vehicles prior to shredding.
  • the dismantling of vehicles may comprise selective removal of parts, such as engines, gearboxes, tires, glass, and plastics, for being reused as spare parts for the second-hand market.
  • the dismantling may also comprise the removal of larger plastic components, such as bumpers, dashboard, fluid containers for recycling the plastics separately.
  • the ASR may comprise further waste from other sources. For examples, garbage from the last owners may remain in the trunk or interior of the vehicles.
  • the advantage of the present process is that it can handle broadly varying compositions of the ASR.
  • the shredding can be made with a vehicle shredder machine.
  • Vehicle shredder machines are manufactured in different sizes.
  • a vehicle shredder machine comprises a heavy fast-turning rotor, which may revolve in a vertical or a horizontal plane and is often equipped with swinging hammers.
  • the vehicle shredder machine tears and shreds the car hulk until its parts are reduced to fragments. Then the fragments may pass through grids and leave the rotor housing.
  • the automotive shredder residue represents preferably 10 to 40 wt.-%, more preferably from 15 to 35 wt.-%, and most preferably from 20 to 30 wt.-% of the original vehicle weight.
  • the fragments are optionally further reduced in size in step a) to obtain the preferred fragment size of at least 90 wt.- % of the shredder residue fragments formed in step a) are smaller than 5 cm, preferably at least 95 wt.-% smaller than 5 cm and more preferably at least 95 wt.-% are smaller than 3 cm.
  • Optional step a) is preferably omitted in case the non-sorted shredder residue NSR has already the preferred fragment size of at least 90 wt.-% of the shredder residue fragments formed in step a) are smaller than 5 cm, preferably at least 95 wt.-% smaller than 5 cm and more preferably at least 95 wt -% are smaller than 3 cm.
  • optional step a) is selected from the group comprising or consisting of shredding, grinding, milling, sieving, classifying and combinations thereof.
  • Optional step a) may further comprise optical and/or manual sorting to remove fragments too large.
  • Such methods are known to the skilled person and can be adapted to a given non-sorted shredder residue NSR to form at least one pre-sorted fraction PSE of end-of-life vehicles which is then provided in step (i).
  • the metal fragments such as ferrous and non-ferrous metal fragments and non-metallic inorganics (“inerts”) such as glass or sand can be separated from the shredded vehicles in step b).
  • Step b) comprises at least removing metal fragments and/or glass fragments from said nonsorted shredder residue NSR.
  • Metal fragments usually but not always comprise ferrous metal fragments and nonferrous metal fragments.
  • the non-ferrous metal fragments can be separated from the shredded vehicles by eddy current separators, by density separation methods (e.g., heavy media si nk/float units), by manual sorting and combinations thereof.
  • eddy current separators exploit the principle of electromagnetic induction to create eddy currents, which in turn generate a magnetic field that repels non-ferrous metals.
  • the material is fed onto a conveyor belt or a vibrating feeder, and as the material moves along the conveyor belt, an alternating magnetic field is generated by the eddy current separator.
  • the alternating magnetic field interacts with the conductive non-ferrous metals, such as aluminum or copper, it can induce eddy currents within them due to electromagnetic induction.
  • the automotive shredder residue preferably comprises up to 15 wt.-%, more preferably up to 10 wt -%, and most preferably up to 5 wt -% of metal fragments, such as ferrous and non-ferrous metal particles.
  • metal fragments such as ferrous and non-ferrous metal particles.
  • 60 to 90 wt.- % of the vehicle weight is metal, which can be separated from the shredded vehicle.
  • Non-metallic inorganics such as glass or sand are preferably separated by density separation. Suitable methods for density separation are cyclone separation, jigging, air separation, or sink-float separation.
  • the automotive shredder residue may comprise preferably up to 15 wt.-%, more preferably up to 10 wt.-%, and most preferably up to 5 wt-% of glass fragments, e.g., broken window glass fragments.
  • the cyclone separation is usually a method used to separate materials based on their density and size using a device called a cyclone.
  • a cyclone typically consists of a cylindrical body with a conical base and an inlet and outlet at the top. The inlet may be tangentially connected to the body, which creates a swirling motion inside the cyclone. As the material spins inside the cyclone, centrifugal force can be generated which may cause the denser and larger particles to move towards the outer wall of the cyclone, while the lighter and smaller particles tend to stay closer to the center.
  • the jigging separation is a method usually used to separate materials based on their density using a device called a jig, which typically consists of a rectangular or circular container with a screen or mesh on the bottom.
  • the container can be mounted on a frame with a mechanism that causes it to move up and down.
  • the jig can be filled with water, and a pulsating flow of water is introduced from the bottom of the container. The pulsation may cause the material to move up and down in the container.
  • the denser particles may tend to settle faster and move towards the bottom of the container, while the lighter particles tend to stay near the top.
  • the air separation is often based a stream of air, e g., in an air classifier structure which typically consists of a vertical chamber with an inlet at the bottom and an outlet at the top.
  • the chamber may contain a series of vanes or blades that create a centrifugal force that separates the materials.
  • a stream of air is usually introduced from the bottom of the chamber and the air flow causes the material to move upwards and separates it based on its density.
  • the denser particles often tend to move towards the outer wall of the chamber, while the lighter particles tend to stay closer to the center.
  • the separated materials can be collected at different points of the air classifier.
  • the sink-float separation is usually based on the principle that materials with different densities will behave differently when placed in a fluid medium: Dense materials often sink while less dense materials float.
  • the fluid medium can be a heavy liquid, such as water or a specialized solution, or a finely ground powdered material.
  • the liquid is usually chosen to have a density that is between the densities of the materials to be separated.
  • the automotive shredder residue comprises fragments of various polymeric vehicle parts comprising at least one polymer selected from polyamides, polyisocyanate polyaddition products, rubber, epoxy resins and polyolefins.
  • Said fragments selected from fragments of bumpers, interior panels, dashboard, cable insulation, electrical insulation, flexible foam seating, foam insulation panels, automotive suspension bushings, electrical potting compounds, car body parts, pillar coverings, spoilers polymer parts coated with automotive paint, wheel covers, gears, bushes, cams, bearings, weatherproof coatings, interior and exterior trims, fuel systems, gear housings, headlamp retainer, engine cover, connector housings, door handles, carburetor components, exterior mirror components, windscreen wiper components, windscreen wiper protective housings, decorative grilles, cover strips, roof rails, window frames, sliding roof frames, antenna cladding covers, front and rear lights, radiator grill and body exterior parts, engine covers, cylinder head covers, intake pipes, cylinder head covers, engine covers, housings for charge air coolers, charge air cooler valves of which preferably at least one member is comprised in the sorted shredder residue SSR.
  • Contaminated vehicle components are also suited as first feedstock F1.
  • Such contaminated vehicle components are made from plastic materials and were contaminated by contaminants such as gasoline or diesel because of the yearlong physical and chemical contact between said vehicle parts and the respective contaminants.
  • Contaminated vehicle components are preferably dismantled from the respective end-of-life vehicle before shredding of said end-of-life vehicle.
  • the shredded parts of the end-of-life vehicle are defined as automotive shredder residue (ASR), the conversion of ASR into at least one pre-sorted fraction PSE of end-of-life vehicles suited a first feedstock F1 in the process according to the present invention is described above. Accordingly, such contaminated vehicle parts are preferably not comprised in automotive shredder residue (ASR). Dismantling of contaminated vehicle parts can be made by manually by humans and/or automated by robots.
  • contaminated vehicle components are combined with at least one pre-sorted fraction PSE of end-of-life vehicles to form the first feedstock F1 provided in step (i).
  • contaminated vehicle components are combined with at least one pre-sorted fraction PSE of end-of-life vehicles and shredded waste electric and electronic equipment to form the first feedstock F1 provided in step (I).
  • Polyamides which can be comprised in the at least one pre-sorted fraction PSE of end-of-life vehicles are preferably selected from the group consisting of polyamide 6 (PA6), polyamide 66 (PA66) and mixtures thereof Such polyamides may comprise fillers.
  • Polyisocyanate polyaddition products which can be comprised in the at least one pre-sorted fraction PSE of end-of- life vehicles are preferably selected from the group consisting of polyurethane (PU), thermoplastic polyurethane (TPU), polyurea, polyisocyanurate (PIR) and mixtures thereof.
  • Such polyisocyanate polyaddition products may comprise fillers.
  • Rubbers which can be comprised in the at least one pre-sorted fraction PSE of end-of-life vehicles are preferably selected from the group comprising natural rubber, styrene-butadiene rubber, butyl rubber, ethylene propylene diene monomer rubber, neoprene, nitrile rubber and silicone rubber.
  • Polyolefins which can be comprised in the at least one pre-sorted fraction PSE of end-of-life vehicles are preferably selected from the group consisting of low-density polyethylene (LDPE), high-density polyethylene (HDPE), polyethylene (PE), polypropylene (PP) and mixtures thereof.
  • LDPE low-density polyethylene
  • HDPE high-density polyethylene
  • PE polyethylene
  • PP polypropylene
  • Such polyolefins may comprise fillers.
  • the at least one pre-sorted fraction PSE of end-of-life vehicles more preferably comprises at least two different polymers of the group consisting of polyamides, polyisocyanate polyaddition products, rubber, epoxy resins and polyolefins.
  • the automotive shredder residue may comprise up to preferably 15 wt.-%, more preferably up to 10 wt.-%, and most preferably up to 5 wt.-% of wood and cardboard.
  • Such components can remain in the first feedstock F1 for the gasification process in step (iii) because they can also be converted into raw synthesis gas RSG1 comprising C6-C8 aromatic hydrocarbons.
  • the non-sorted shredder residue NSR and/or the at least one pre-sorted fraction PSE of end-of-life vehicles are/is optionally dried before step (i).
  • the first feedstock F1 is preferably pelletized before provided in step (i). More preferably, the first feedstock F1 is preferably pelletized before provided in step (i) to pellets having a particle size PS of at least 3 mm (determined by sieving with sieves having defined mesh sizes) and up to about 50 mm.
  • a second feedstock F2 is also provided in step (I) and fed into the first gasifier G1 in step (II) together with the first feedstock F1 provided in step (I).
  • Said second feedstock F2 is a particulate feedstock having a particle size PS and is preferably selected from the group comprising or more preferably consisting of coal, bio char, wood and combinations thereof.
  • a second feedstock F2 selected from the group comprising or preferably consisting of coal, bio char, wood and combinations thereof, and having a particle size PS of at least 3 mm (determined by sieving with sieves having defined mesh sizes) is more preferred for a stable operation fixed bed gasifier as first gasifier G1.
  • at least 10 wt.-%, more preferably at least 15 wt.-% and most preferably at least 20 wt.-% of all feedstocks provided in step (I) is said second feedstock F2.
  • second feedstock F2 is a particulate feedstock having a particle size PS and is selected from the group comprising or preferably consisting of coal, bio char, wood and combinations thereof:
  • first gasifier G1 is a fixed bed gasifier
  • said content of said second feedstock F2 improves the permeability (“macro-porosity'') of the fixed bed comprising or consisting of said mixture of feedstocks F1 and F2 (or, optionally of F1 , F2 and F3)
  • gases such as the synthesis gas formed can better flow through said fixed bed.
  • the first feedstock F1 has a particle size of at least 3 mm (determined by sieving with sieves having defined mesh sizes). Such a minimum size of the first feedstock F1 is preferred for a stable operation of the first gasifier G1 which is preferably a fixed bed gasifier.
  • the upper particle size of the first feedstock F1 is about 50 mm (determined by sieving with sieves having defined mesh sizes). Thereby, a stable operation of a fixed bed gasifier as first gasifier G1 is further improved.
  • Coal is preferably selected from the group comprising or preferably consisting of meta-anthracite, anthracite, semianthracite, low volatile bituminous coal, medium volatile bituminous coal, high volatile A bituminous coal, high volatile B bituminous coal, high volatile C bituminous coal, subbituminous A coal, subbituminous B coal, subbituminous C coal, lignite A, lignite B and mixtures thereof.
  • Coal is optionally pretreated before provided in step (i).
  • the coal is pretreated by a method selected from the group comprising or preferably consisting of milling, grinding, classification, drying, pelletizing and combinations thereof, whereby optionally coal dust as a side product is formed.
  • Such pre-treatment methods are known to the skilled person and can be selected and applied for a given type of coal feedstock.
  • Said coal dust can be also subjected to the gasification process in the first gasifier G1 as an optional third feedstock F3 and/or the optional second gasifier G2 as an optional fourth feedstock F4 and thereby further increase the yield of C6-C8 aromatic hydrocarbons comprised in the raw synthesis gas RSG1 and/or the second raw synthesis gas RSG2.
  • Biochar suitable as second feedstock F2 can be made from various types of biomass (including wood), agricultural waste, crop residues, forestry waste, animal manure, and sewage sludge.
  • Said optional third feedstock F3 is selected from the group comprising or consisting of biomass, refuse-derived fuel (RDF), textiles, dried sewage sludge, pyrolysis oils made from plastic waste, pyrolysis oils made from end-of-life tires, pyrolysis oils made from biomass, heating oils, vacuum residues, preferably vacuum distillation residues, crude oil residues, heavy crude oils, extra heavy crude oils, tar sand bitumen, visbreaker bottom residues, deasphalter bottom residues, C5 asphalthene fraction, high viscous residues, fuel oils, pyrolysis gasolines, tire pyrolysis oils (TPO), waste oils, used oils, municipal solid waste (MSW), tar oils, natural gas, CO2, and mixtures thereof.
  • RDF refuse-derived fuel
  • textiles dried sewage sludge
  • pyrolysis oils made from plastic waste pyrolysis oils made from end-of-life tires
  • pyrolysis oils made from biomass heating oils, vacuum residues, preferably vacuum distillation residues
  • the optional at least one third feedstock F3 is optionally pre-treated before step (I) by a method selected from the group comprising or consisting of sorting, sieving, milling, grinding, pyrolysis, torrefaction, metal sorting and combinations thereof.
  • said first feedstock F1 is converted in step (ii) together with a second feedstock F2 which is a particulate feedstock having a particle size PS and is selected from the group comprising or preferably consisting of coal, bio char and wood wherein said particle size PS of said second feedstock F2 is at least 3 mm (determined by sieving with sieves having defined mesh sizes), most preferably the first feedstock F1 is converted in step (ii) together with a second feedstock F2 which is a particulate feedstock having a particle size PS and is selected from the group comprising or preferably consisting of coal, bio char and wood wherein said particle size PS of said second feedstock F2 is at least 3 mm (determined by sieving with sieves having defined mesh sizes) and a third feedstock F3 which comprises most preferably RDF.
  • a second feedstock F2 which is a particulate feedstock having a particle size PS and is selected from the group comprising or preferably consisting of coal, bio char and wood wherein said particle size PS
  • the yield of C6-C8 aromatic hydrocarbons separated from said first liquid residue LR1 in step (iv) is increasing, when converting said first feedstock F1 together with the second feedstock F2 or together with the second feedstock F2 and the third feedstock F3 in step (ii). Furthermore, a steadier production of raw synthesis gas RSG1 is archived by such feedstock combinations (preferably F1 + F2, more preferably F1 + F2 + F3) because fluctuating amounts and/or calorific value of the first feedstock F1 can be balanced by such feedstock combinations.
  • At least 10 wt.-% of all feedstocks provided in step (II) are second feedstock F2 More preferably, at least 15 wt.-% of all feedstocks provided in step (II) are second feedstock F2. Most preferably, at least 20 wt -% of all feedstocks provided in step (II) are second feedstock F2. The remaining portion are the first feedstock F1 and optionally also the third feedstock F3.
  • step (II) of the process according to the present invention said first feedstock F1 comprising at least one presorted fraction PSE provided in step (i) and the second feedstock F2 are converted in a first gasifier G1 into a first raw synthesis gas RSG1 , wherein said first raw synthesis gas RSG1 comprises CO, H2, C6-C8 aromatic hydrocarbons.
  • said first feedstock F1 and said second feedstock F2 and a third feedstock F3 are provided in step (i) and converted in step (ii) in a first gasifier G1 into a first raw synthesis gas RSG1, wherein said first raw synthesis gas RSG1 comprises CO, H2, C6-C8 aromatic hydrocarbons.
  • the first feedstock F1 and the second feedstock F2 can be fed into the first gasifier G1 separately or together and thereby converted into a first raw synthesis gas RSG1 , wherein said first raw synthesis gas RSG1 comprises CO, H2, 06-08 aromatic hydrocarbons.
  • first feedstock F1 and the second feedstock F2 are converted in step (ii) together with a third feedstock F3
  • all three feedstocks can be fed into the first gasifier G1 separately or together (F1 + F2 together and F3 separately or F1 + F3 together and F2 separately or F2 + F3 and F1 separately, or F1 + F2 + F3 together, "feedstock combinations”) and thereby converted into a first raw synthesis gas RSG1, wherein said first raw synthesis gas RSG1 comprises CO, H2, C6-C8 aromatic hydrocarbons.
  • feedstock combinations comprises CO, H2, C6-C8 aromatic hydrocarbons.
  • the first gasifier G1 is preferably a fixed bed gasifier which is best suited for converting at least one pre-sorted fraction PSE from end-of-life vehicles comprised in the first feedstock F1 and the second feedstock F2 by gasification into C6-C8 aromatic hydrocarbons (comprised in the raw synthesis gas RSG1). More preferably, the fixed bed first gasifier G1 is a fixed bed dry bottom gasifier or a slagging gasifier. Said gasifier types are even more suited for converting at least one pre-sorted fraction PSE from end-of-life vehicles and the second feedstock F2 by gasification into C6-C8 aromatic hydrocarbons.
  • Slagging gasifiers such as the British Gas / Lurgi gasifier (also known as “BGL” gasifier) require less steam to be fed into the gasifier than other types of fixed bed gasifiers. Thereby, a higher temperature is achieved in the combustion zone of the gasifier and the conversion of the at least one pre-sorted fraction PSE from end-of-life vehicles is further increased.
  • a fixed bed dry bottom gasifier G1 or a slagging gasifier G1 enables a higher throughput of pre-sorted fraction PSE from end-of-life vehicles comprised in the first feedstock F1 because drag out of slag which is formed therefrom during the gasification is simpler than in other types of fixed bed gasifiers G1. Thereby, the yield of desired C6-C8 aromatic hydrocarbons is increased.
  • the content of methane comprised in the raw synthesis gas RSG1 formed in the first gasifier G1 may be higher than desired.
  • side products referred herein as "condensates'' and comprising tar, particularly tar oil may also be produced in said first gasifier G1.
  • said condensates, particularly tar oil TO, produced as a side product in the first gasifier G1 are/is then used as a feedstock for a second gasifier G2 which is preferably an entrained flow gasifier.
  • Said condensates, particularly tar oil TO, are/is converted in the second gasifier G2 by a gasification process into a raw synthesis gas RSG2 which preferably comprises methane at a higher concentration than in the raw synthesis gas RSG1.
  • a raw synthesis gas RSG2 which preferably comprises methane at a higher concentration than in the raw synthesis gas RSG1.
  • the resulting combined raw synthesis gas RSG12 has a lower methane concentration than the raw synthesis gas RSG1 , which is a desired effect.
  • the yield of C6-C8 aromatic hydrocarbons formed by gasification of the first feedstock F1 comprising at least one pre-sorted fraction PSE provided in step (i) is further increased thereby, which is a particularly desired effect.
  • condensates are formed as a side product during step (ii) in said first gasifier G1 from which condensates preferably tar oil TO is separated in an optional condensate separation unit CSU.
  • Said condensates, preferably said tar oil TO is separated from said condensates are/is then fed as a feedstock into an optional second gasifier G2 which is preferably an entrained-flow gasifier and converted onside said optional second gasifier G2 into a second raw synthesis gas RSG2.
  • Said second raw synthesis gas RSG2 can be combined with the first raw synthesis gas RSG1 before cleaning said first raw synthesis gas RSG1 and said second raw synthesis gas RSG2 in step (ill).
  • gasifiers G especially entrained flow gasifiers G and plasma gasifiers G is for example provided in James G. Speight, Handbook of Gasification Technology, Scrivener Publishing and Wiley, 2020, chapter 8.4.2, pages 259 to 262.
  • the temperature inside the optional entrained flow gasifier G2 preferably ranges from 1000 to 1500 °C, more preferably from 1100 to 1450 °C and most preferably from 1200 to 1400 °C.
  • the pressure inside said optional entrained flow gasifier preferably ranges from 1 to 55 bar(abs.), more preferably from 5 to 50 barfabs.) and most preferably from 20 to 45 bar(abs.).
  • a fourth feedstock F4 is converted in said optional second gasifier G2 together with said condensates, preferably said tar oil TO separated from said condensates, into raw synthesis gas RSG2.
  • Said optional fourth feedstock F4 is a feedstock which is preferably liquid or gaseous at room temperature or at an elevated temperature such as 80 °C.
  • Said optional fourth feedstock F4 is more preferably selected from the group comprising or preferably consisting of pyrolysis oils made from plastic waste, pyrolysis oils made from end-of-life tires, pyrolysis oils made from biomass, heating oils, vacuum residues, preferably vacuum distillation residues, crude oil residues, heavy crude oils, extra heavy crude oils, tar sand bitumen, visbreaker bottom residues, deasphalter bottom residues, C5 asphalthene fraction, high viscous residues, fuel oils, pyrolysis gasolines, waste oils, used oils, tar oils from other sources than the first gasifier G1 , natural gas, coal dust, CO2, and mixtures thereof.
  • Optional fourth feedstocks F4 such as bio-based oils and pyrolysis oils are preferably pre-heated and/or pressurized before fed into the optional second gasifier G2.
  • the optional fourth feedstock F4 is preferably pressurized to > 10 bar(abs.), more preferably > 20 bar(abs.) and most preferably > 40 bar(abs.) before fed into the optional second gasifier G2.
  • Suitable means for pre-heating and/or pressurizing the optional forth feedstock F4 for feeding into the optional second gasifier G2 are known in the art, comprise for example flaps and locks but also annual gaps as part of a burner such as in twin fluid atomizers, pressure nozzles and pressure atomizers, and can be adapted to a given fourth feedstock F4 and/or second gasifier G2 type by the skilled person.
  • a fourth feedstock F4 is preferred because thereby the desired constant operation conditions in said entrained flow gasifier G2 can be better maintained and the desired C6-C8 aromatic hydrocarbons and raw synthesis gas RSG2 having the desired molar ratio CO : H2 is formed.
  • the tar oil TO and the optional fourth feedstock F4 are fed into the entrained flow gasifier G2 via at least one burner whereby said at least one burner comprises one annular gap for the tar oil TO and a separate annular gap through which the optional fourth feedstock F4 is fed.
  • Steam, preferably mixed with oxygen is co-fed into the entrained flow gasifier G2 through a separate annular gap in said at least one burner.
  • a fourth feedstock F4 is preferred for a stable operation of the optional second gasifier G2 in case the amount of tar oil TO provided as a side product of the first gasifier G1 falls below a critical value.
  • said optional fourth feedstock F4 is co-fed into the optional second gasifier in case the minimum feedstock load (about 25 to 30 % of the optimum feedstock load of a given second gasifier G2) is reached or be lower because of insufficient tar oil TO supply from the first gasifier G1 .
  • Said minimum feedstock load is required for a stable operation of and synthesis gas production in said optional second gasifier G2.
  • step (iii) of the process according to the present invention said C6-C8 aromatic hydrocarbons comprised in the first raw synthesis gas RSG1 and/or the raw synthesis gas RSG2 in case an optional second gasifier G2 is also used, are removed from said first raw synthesis gas RSG1 and/or said raw synthesis gas RSG2.
  • C6-C8 aromatic hydrocarbons can be removed from the raw synthesis gas RSG1 and/or RSG2 by different gas cleaning process such as condensation, absorption (chemical absorption and/or physical separation), adsorption, filtration (e.g., membrane filtration).
  • gas cleaning process such as condensation, absorption (chemical absorption and/or physical separation), adsorption, filtration (e.g., membrane filtration).
  • the skilled person can select from such processes and adapt the selected process to a specific raw synthesis gas composition and other parameters
  • C6-C8 aromatic hydrocarbons can be condensed from raw synthesis gas by cooling down said raw synthesis gas below the boiling point of the individual components of said C6-C8 aromatic hydrocarbons. Thereby, the C6-C8 aromatic hydrocarbons become liquid and the remaining portions of the raw synthesis gas, (CO, H2 and other gases) stay in the gas phase. Thereby, C6-C8 aromatic hydrocarbons can be separated from raw synthesis gas.
  • Adsorption methods such as solid bed adsorption involve the use of specialized adsorbents, such as activated carbon, zeolites, or molecular sieves, to remove C6-C8 aromatic hydrocarbons from raw synthesis.
  • the raw synthesis gas is passed through a bed of adsorbent material, which selectively adsorbs C6-C8 aromatic hydrocarbons while allowing the clean synthesis gas to pass through.
  • the adsorbent is preferably periodically regenerated by heating or purging with an inert gas to release the captured acid gases.
  • adsorbent e.g., activated carbon, zeolites, or molecular sieves
  • the regeneration of the adsorbent material is also an important consideration, as it affects the overall cost and environmental impact of the process.
  • Membrane separation is a technology that utilizes selective permeable membranes to separate C6-C8 aromatic hydrocarbons from raw synthesis based on size, solubility, or diffusivity.
  • gases such as CO, H2, being smaller molecules, can be selectively permeated through the membrane, while the C6-C8 aromatic hydrocarbons are retained.
  • said C6-C8 aromatic hydrocarbons comprised in the first raw synthesis gas RSG1 and/or the raw synthesis gas RSG2 in case an optional second gasifier G2 is also used are separated from said first raw synthesis gas RSG1 and/or said raw synthesis gas RSG2 by a gas cleaning process GC in a gas cleaning unit GCU, wherein said first raw synthesis gas RSG1 and/or said raw synthesis gas RSG2 is contacted with at least one washing liquid WL, whereby a clean first synthesis gas CSG and a first liquid residue LR1 are formed, wherein said first liquid residue LR1 comprises C6-C8 aromatic hydrocarbons.
  • the at least one washing liquid WL separates CO2 and C6-C8 aromatic hydrocarbons comprised in the first raw synthesis gas RSG1 and/or the raw synthesis gas RSG2 therefrom, whereby C6-C8 aromatic hydrocarbons are absorbed (chemically and/or physically absorbed) by the at least one washing liquid WL.
  • further components other than CO and H2 such as sulfur oxides which may be comprised in the first raw synthesis gas RSG1 and/or the raw synthesis gas RSG2 are/is separated therefrom.
  • Preferred gas cleaning process GO with at least one washing liquid WL in the gas cleaning unit GCU comprise amine scrubbing.
  • Amine scrubbing also known as amine gas treating or gas sweetening, is a suitable gas cleaning process GO for acid gas removal and separation of C6-C8 aromatic hydrocarbons from raw synthesis gas RSG1 and/or RSG2.
  • raw synthesis gas is brought into contact with a solution of amines and/or alkanolamines, such as monoethanolamine (MEA) or diethanolamine (DEA).
  • MEA monoethanolamine
  • DEA diethanolamine
  • C6-C8 aromatic hydrocarbons comprised in the raw synthesis gas are condensed from said raw synthesis gas and thereby separated therefrom.
  • the loaded amine and/or alkanolamine solution is then regenerated by heating, releasing the captured acid gases for further processing or disposal.
  • the unipolar C6-C8 aromatic hydrocarbons are separated as a liquid phase LP1 from the more polar at least one washing liquid WL forming a liquid phase LP2 and can then be separated by standard methods for separating immiscible liquid phases from each other, e.g., by gravitation in a settler unit. Such separation methods are known to the skilled person and can applied accordingly to a given separation problem.
  • Preferred gas cleaning process GC with at least one washing liquid WL in the gas cleaning unit GCU further comprise physical solvent absorption methods such as the SelexolTM which utilizes a mixture of dimethylethers of polyethyleneglycol as washing liquid WL and the Rectisol® process which utilizes methanol as washing liquid WL.
  • physical solvent absorption methods such as the SelexolTM which utilizes a mixture of dimethylethers of polyethyleneglycol as washing liquid WL and the Rectisol® process which utilizes methanol as washing liquid WL.
  • such alcohols and/or ethers are suited as washing liquid WL in such physical solvent absorption methods.
  • Such washing liquids WL have a high affinity for C6-C8 aromatic hydrocarbons and can selectively absorb them from the first raw synthesis gas RSG1 and/or the raw synthesis gas RSG2.
  • step (a) the first raw synthesis gas RSG1 and/or the raw synthesis gas RSG2 is contacted with a washing liquid WL in step (a), at a temperature of 15 to 250 °C, to obtain a clean first synthesis gas CSG, which is depleted in C6-C8 aromatic hydrocarbons, and a first liquid residue LR1 wherein the C6-C8 aromatic hydrocarbons are dissolved
  • the first liquid residue LR1 is preferably stripped in step (b) with a stripping gas comprising at least 50 Vol.-% steam, to obtain a stripped washing liquid WL which is advantageously reused in step (a) and a loaded stripping gas comprising the aromatic compounds.
  • the aromatic compounds are separated from the loaded stripping gas in an aromatic hydrocarbon extraction unit AEU for example by condensation of the steam and/or the aromatic compounds comprised in the loaded stripping gas to obtain an immiscible composition and isolating the C6-C8 aromatic hydrocarbons therefrom.
  • the washing liquid WL comprises or consists of organic polysiloxanes, preferably organic polysiloxanes comprising aryl groups.
  • the at least one washing liquid WL is selected from the group comprising amines, alkanolamines, alcohols, ethers, organic polysiloxanes, and mixtures thereof.
  • the at least one washing liquid is selected from the group consisting of amines, alkanolamines, alcohols, ethers, organic polysiloxanes, and mixtures thereof. Most preferably, the at least one washing liquid is selected from the group consisting of monoethanolamine, diethanolamine, methanol, dimethylethers of polyethyleneglycol, organic polysiloxanes comprising aryl groups, and mixtures thereof.
  • step (iv) of the process according to the present invention said C6-C8 aromatic hydrocarbons are separated from said first liquid residue LR1 in an aromatic hydrocarbon extraction unit AEU which is downstream of the gas cleaning unit GCU and in which a C6-C8 aromatic hydrocarbon-rich stream AS is separated from said first liquid residue LR1.
  • the remaining portion of said first liquid residue LR1 leaves said aromatic hydrocarbon extraction unit AEU and is depleted in C6-C8 aromatic hydrocarbons.
  • C6-C8 aromatic hydrocarbons comprised in stream AS are preferably further separated in said aromatic hydrocarbon extraction unit AEU into a stream ASa which is enriched in benzene, a stream ASb which is enriched in toluene, a stream ASc which is enriched in C8 aromatic hydrocarbons (ethylbenzene, 1 ,2-xylene, 1 ,3-xylene, 1 ,4- xylene) and said second liquid residue LR2 which is depleted in C6-C8 aromatic hydrocarbons.
  • AEU aromatic hydrocarbon extraction unit AEU
  • the aromatic hydrocarbon extraction unit AEU can be any unit operation suitable to separate C6-C8 aromatic hydrocarbons comprised in the first liquid residue LR1 into a stream AS and a second liquid residue LR2 and/or a stream ASa, a stream ASb, a stream ASc and said second liquid residue LR2.
  • the aromatic hydrocarbon extraction unit AEU can comprise at least one selective adsorption unit operation, at least one selective absorption unit operation, at least one extractive distillation unit operation, at least one solvent extraction followed by distillation and combinations thereof.
  • Suitable solvents for extraction comprise solvents having a higher boiling point than C6-C8 aromatic hydrocarbons such as N-methylpyrrolidone and morpholine.
  • Suitable aromatic hydrocarbon extraction units AEU are commercially available, for example the Morphylane® extractive distillation process by Uhde, Sulfolan® process by Shell-UOP (using tetrahydrothiophene dioxide as extraction solvent), Arosolvan® process by Lurgi (using N-methylpyrrolidone as solvent), Morphylex® process by Krupp-Koppers (using N-formylmorpholine as solvent), Formex® process by Snamprogetti (using N-formylmorpholine as solvent), IFP process by IFP (using dimethyl sulfoxide as solvent) and Mofex® process by Leunawerke (using methylformamide as solvent).
  • the stream ASa preferably comprises at least 90 wt.-% benzene, more preferably at least 95 wt.-% benzene and most preferably at least 99 wt.-% benzene.
  • the stream ASb preferably comprises at least 90 wt.-% 1- methylbenzene, more preferably at least 95 wt.-% 1 -methylbenzene and most preferably at least 99 wt.-% 1- methylbenzene.
  • the stream ASc preferably comprises at least 90 wt.-% of xylene isomers, more preferably at least 93 wt.-% of xylene isomers.
  • Xylene isomers comprise 1,2-xylene, 1,3-xylene and 1 ,4-xlene.
  • the C6-C8 aromatic hydrocarbons comprised in the first liquid residue LR1 can also be separated therefrom in an aromatic hydrocarbon extraction unit AEU by the following steps: a) contacting the first liquid residue LR1 with a stripping gas SG, said stripping gas, preferably comprising at least 50 Vol.-% steam, to obtain a loaded stripping gas LGS, said loaded stripping gas LGS comprising C6-C8 aromatic hydrocarbons separated from said first liquid residue LR1 and a stripped washing liquid WL previously comprised in said first liquid residue LR1 and b) separating the C6-C8 aromatic hydrocarbons from the loaded stripping gas LSG formed in step a) by condensation of the C6-C8 aromatic hydrocarbons comprised in the loaded stripping gas LSG therefrom.
  • the one or both streams ASb and/or ASc are then fed into a hydroalkylation unit HAU whereby toluene and/or xylene isomers and/or ethylbenzene are converted into benzene. Accordingly, the benzene yield can be increased thereby.
  • Hydroalkylation of alkyl-substituted benzene-derivatives into benzene and corresponding hydroalkylation units HAU are known in the art and are for example described in Ullmann's Encyclopedia of Industrial Chemistry, Vol. 5, Chapter "Benzene” by H. 0. Folkins, pages 246-251, 2012 and in Industrielle organische Chemie, 3 rd Ed., K. Weissermel, H.-J. Arpe, pages 351 -352, 1988 which are both incorporated by reference herein.
  • the product PRF1 is a product as described in Reference RF1; paragraphs [1000] to [8005],
  • the process described herein is further process for the production of a product, preferably product PRF1 .
  • the converting step to obtain the product PRF1 preferably comprises one or more step(s) as described below and can be performed by conventional methods well known to a person skilled in the art.
  • the converting step preferably comprises one or more step(s) selected from: recycling, preferably depolymerizing, gasifying, pyrolyzing, and/or steam cracking; and/or purifying, preferably crystallizing, (solvent) extracting, distilling, evaporating, hydrotreating, absorbing, adsorbing and/or subjecting to ion exchanger; and/or assembling, preferably foaming, synthesizing, chemical conversion, chemically transforming, polymerizing and/or compounding; and/or forming, preferably foaming, extruding and/or molding; and/or finishing, preferably coating and/or smoothing.
  • the one or more step(s) are described in detail in Reference RF1 ; paragraphs [1000] to [8005],
  • building block comprises compounds, which are in a gaseous or liquid state under standard conditions of 0 °C and 0.1 MPa. Building blocks are typically used in chemical industry to form secondary products, which provide a higher structural complexity and/or higher molecular weight than the building block on which the secondary product is based.
  • the building block is preferably selected from the group consisting of hydrogen, carbon monoxide, carbon dioxide, ethylene oxide, ethylene glycols, syngas comprising a mixture of hydrogen and carbon monoxide, alkanes, alkenes, alkynes, and aromatic compounds.
  • the alkanes, alkenes, alkynes, and aromatic compounds comprise in particular 1 to 12 carbon atoms, respectively.
  • the term “monomer”, as used herein, comprises molecules, which can react with each other to form polymer chains by polymerization.
  • the monomer is preferably selected from the group consisting of (meth)acrylic acid, salts of (meth)acrylic acid; in particular sodium, potassium and zinc salts; (meth)acrolein and (meth)acrylates.
  • (Meth)acrylates comprising 1 to 22 carbon atoms are preferred, in particular comprising 1 to 8 carbon atoms.
  • the terms (meth)acrylic acid, (meth)acrolein or (meth)acrylate relate to acrylic acid, acrolein or acrylate and also to methacrylic acid, methacrolein or methacrylate, where applicable.
  • the monomer can be selected from hexamethylenediamine (HMD) and adipic acid.
  • the building block can further be an intermediate compound.
  • intermediate compound comprises organic reagents, which are applied for formation of compounds with higher molecular complexity.
  • the intermediate compound can be selected for example from the group consisting of phosgene, polyisocyanates and propylene oxide.
  • the polyisocyanates are in particular aromatic di- and polyisocyanates, preferably toluene diisocyanate (TDI) and/or diphenylmethane diisocyanate (MDI).
  • polymer A comprises thermoplastic, e.g., polyamide or thermoplastic polyurethane, thermoset, e.g., polyurethane, elastomer, e.g., polybutadiene, or a copolymer or a mixture thereof and is defined in more detail in paragraphs [2001] to [2007] of Reference RF1.
  • polymer composition A comprises all compositions comprising a polymer as described above and one or more additive(s), e.g., reinforcement, colorant, modifier and/or flame retardant, and is defined in more detail in paragraph [2008] of Reference RF1.
  • additive(s) e.g., reinforcement, colorant, modifier and/or flame retardant
  • polymer product A comprises any product comprising the polymer A and/or polymer composition A as described above and is defined in more detail in paragraphs [2009] and [2010] of Reference RF1.
  • the step(s) to obtain the polymer, preferably polymer A, polymer composition, preferably polymer composition A or polymer product, preferably polymer product A is/are described in more detail in paragraph [2011] of Reference RF1.
  • the term “industrial use polymer”, as used herein, comprises rheology, polycarboxylate, alkoxylated polyalkylenamine, alkoxylated polyalkylenimine, polyether-based, dye inhibition and soil release cleaning polymers defined in more detail in paragraphs [3035] to [3044] of Reference RF1 .
  • the term “industrial use surfactant”, as used herein, comprises non-ionic, anionic, and amphoteric industrial use surfactants defined in more detail in paragraphs [3008] to [3034] of Reference RF1.
  • the term “industrial use descaling compound”, as used herein, comprises non- phosphate-based builders (NPB) and phosphonates (CoP) described in more detail in paragraphs [3001] to [3005] of Reference RF1 .
  • the term “industrial use biocide”, as used herein, refers to a chemical compound that kills microorganisms or inhibits their growth or reproduction defined in more detail in paragraphs [3006] to [3007] of Reference RF1.
  • the term “industrial use solvent”, as used herein, comprises alkyl amides, alkyl lactamides, alkyl esters, lactate esters, alkyl diester, cyclic alkyl diester, cyclic carbonates, aromatic aldehydes and aromatic esters defined in more detail in paragraphs [3045] to [3055] of Reference RF1 .
  • the term “industrial use dispersant”, as used herein, comprises anionic and non-ionic industrial use dispersants defined in more detail in paragraphs [3056] to [3058] of Reference RF1.
  • composition and/or formulation thereof' with reference to the industrial use polymers, industrial use surfactants, descaling compounds and/or industrial use biocides refers to industrial use compositions and/or institutional use products and/or fabric and home care products and/or personal care products defined in more detail in paragraph [3059] of Reference RF1.
  • the converting step(s) to obtain the industrial use polymer, industrial use surfactant, descaling compound and/or industrial use biocide are defined in more detail in paragraph [3060] of Reference RF1 .
  • the converting steps to obtain the industrial use composition or formulation of the industrial use polymer, industrial use surfactant, descaling compound and/or industrial use biocide are defined in more detail in paragraph [3061] of Reference RF1.
  • agrochemical composition typically relates to a composition comprising an agrochemically active ingredient and at least one agrochemical formulation auxiliary.
  • agrochemical compositions include agrochemically active ingredient and at least one agrochemical formulation auxiliary.
  • active ingredients and auxiliaries are described in more detail in Reference RF1, paragraph [4001].
  • the agrochemical composition may take the form of any customary formulation.
  • the agrochemical compositions are prepared in a known manner, e.g., described by Mollet and Grubemann, Formulation technology, Wiley VCH, Weinheim, 2001 ; or Knowles, New developments in crop protection product formulation, Agrow Reports DS243, T&F Informa, London, 2005.
  • the converting step(s) to obtain the agrochemically active ingredients and auxiliaries may be conducted in analogy to the production step(s) of their analogues that are based on petrochemicals or other precursors that are not gained by recycling processes.
  • conversion to compounds mentioned in sections “Polymer” and “Cosmetic surfactant, emollient, wax, cosmetic polymer, UV filter, further cosmetic ingredient or compositions or formulations thereof may be performed as described in these sections as well as the respective paragraphs in Reference RF1.
  • active pharmaceutical ingredients and/or intermediates thereof, as used herein, comprises substances that provide pharmacological activity or other direct effect in the diagnosis, cure, mitigation, treatment, or prevention of disease, or to affect the structure or any function of the body. Intermediates thereof are isolated products that are generated during a multi-step route of synthesis of an active pharmaceutical ingredient.
  • pharmaceutical excipients as used herein, comprises compounds or compound mixtures used in compositions for various pharmaceutical applications, which are not substantially pharmaceutically active on itself. Active pharmaceutical ingredients and/or intermediates thereof and pharmaceutical excipients are defined in more detail in paragraph [5001] of Reference RF1.
  • the converting step(s) to obtain the active pharmaceutical ingredients and/or intermediates thereof and pharmaceutical excipients may comprise one or more synthesis steps and can be performed by conventional synthesis and techniques well known to a person skilled in the art.
  • animal feed additives human food additives, dietary supplements, as used herein, comprises Vitamins, Pro-Vitamins and active metabolites thereof including intermediates and precursors, especially Vitamin A, B, E, D, K and esters thereof, like acetate, propionate, palmitate esters or alcohols thereof like retinol or salts thereof and any combinations thereof; Tetraterpenes, especially isoprenoids like carotenoids and xanthophylls including their intermediates and precursors as well as mixtures and derivates thereof, especially beta carotene, Canthaxanthin, Citranaxanthin, Astaxanthin, Zeaxanthin, Lutein, Lycopene, Apo-carotenoids, and any combinations thereof; organic acids, especially formic acid, propionic acid and salts thereof, such as sodium, calcium or ammonium salts, and any combinations thereof, such as but not limited to mixtures of formic acid and sodium formiate, propionic acid and ammonium propionate
  • the converting step(s) to obtain the animal feed additives, human food additives, dietary supplements may comprise one or more synthesis steps and can be performed by conventional synthesis and techniques well known to a person skilled in the art.
  • aroma chemical and “aroma composition” as used herein, comprise a volatile organic substance with a molecular weight between 70 and 250 g/mol comprising a functional group with a carbon skeleton of C5-C16 carbon atoms comprising linear, branched, cyclic, for example with a ring size of C5-C18, bicyclic or tricyclic aliphatic chains and but not necessarily one or more unsaturated structural elements like double bonds, triple bonds, aromatics or heteroaromatics and preferably the one or more additional functional groups are selected from alcohol, ether, ester, ketone, aldehyde, acetal, carboxylic acid, nitrile, thiol, amine
  • the aroma chemical is a terpene-based aroma chemical, for example selected from monoterpenes and monoterpenoids, sesquiterpenes and sesquiterpenoids, diterpenes, triterpenes or tetraterpenes.
  • Aroma chemicals can be combined
  • the converting step(s) to obtain the aroma chemical and aroma composition may comprise one or more synthesis steps and can be performed by conventional synthesis and techniques well known to a person skilled in the art.
  • aqueous polymer dispersion comprises aqueous composition(s) comprising dispersed polymer(s) and is defined in more detail in the section [6001] entitled “aqueous polymer dispersion” of Reference RF1.
  • the dispersed polymer(s) may be selected from acrylic emulsion polymer(s), styrene acrylic emulsion polymer(s), styrene butadiene dispersion(s), aqueous dispersion(s) comprising composite particles, acrylate alkyd hybrid dispersion(s), polyurethane(s) (including UV-curable polyurethanes) and polyurethane - poly(meth)acrylate hybrid polymer(s).
  • emulsion polymer comprises polymer(s) made by free-radical emulsion polymerization.
  • Aqueous polyurethane dispersion(s) are defined in more detail in the section [6002] entitled “Polyurethane dispersions” of Reference RF1.
  • UV-curable polyurethane(s) is/are defined in more detail in the section [6017] of Reference RF1.
  • Polyurethane - poly(meth)acrylate hybrid polymer(s) is/are defined in more detail in the section [6016] of Reference RF1.
  • polymeric dispersant comprises preferably polymer(s) comprising polyether side chain, in particular polycarboxylate ether polymer(s) and polycondensation product(s) defined in more detail in paragraph [6020] entitled “Polymeric dispersant” of Reference RF1.
  • the converting (polymerization) step(s) to obtain the aqueous polymer dispersion(s) comprising emulsion polymer(s) is/are defined in more detail in the section [6003] entitled “Emulsion polymerization” of Reference RF1.
  • the converting (polymerization) step(s) to obtain the aqueous polyurethane dispersion(s) is/are defined in more detail in the section [6014] entitled “Process for the preparation of aqueous polyurethane dispersions” and section [6017] entitled “Aqueous UV-curable polyurethane dispersions, their preparation and use and compositions containing them” of Reference RF1.
  • composition(s) and uses of aqueous polymer dispersion(s) and of polymeric dispersant(s) are defined in more detail in the following sections of Reference RF1 : section [6004] entitled “Uses of aqueous polymer dispersions”, section [6005] entitled “Binders for architectural and construction coatings”, section [6006] entitled “Binders for paper coating”, section [6007] entitled “Binders for fiber bonding”, section [6008] entitled “Adhesive polymers and adhesive compositions”, section [6015] entitled “Aqueous polyurethane dispersions suitable for use in coating compositions”, section [6016] entitled “Aqueous polyurethane - poly(meth)acrylate hybride polymer dispersions suitable for use in coating compositions”, section [6017] entitled “Aqueous UV-curable polyurethane dispersions, their preparation and use and compositions containing them”, section [6018] entitled “Inorganic binder compositions comprising polymeric dispersants and their use”
  • Polyisocyanate(s), composition(s) comprising them and their uses are defined in more detail in section [6010] entitled “Polyisocyanates” of Reference RF1.
  • Hyperbranched polyester polyol(s) and its/their uses are defined in more detail in section [6011] entitled "Organic solvent based hyperbranched polyester polyols suitable for use in coating compositions” of Reference RF1.
  • the converting step(s) to obtain the hyperbranched polyester polyols is/are defined in more detail in the section [6012] entitled “Preparation of organic solvent based hyperbranched polyester polyols” of Reference RF1.
  • Coating composition(s) comprising hyperbranched polyester polyol(s), polyisocyanate(s) and additive(s) and substrate(s) coated therewith are defined in more detail in section [6013] entitled “Organic solvent based two component coating compositions comprising hyperbranched polyester polyols and polyisocyanates” of Reference RF1 .
  • Unsaturated polyester polyol(s), solvent-based coating composition(s) comprising said unsaturated polyester polyol(s) and substrate(s) for coating with said coating composition (s) are defined in more detail in section [6018] entitled “Organic solvent-based coating composition comprising unsaturated polyester polyols” of Reference RF1 .
  • 100% curable coating composition (s) is/are defined in more detail in section [6019] of Reference RF1 .
  • Polymeric dispersant(s) for inorganic binder compositions is/are defined in more detail in section [6020] of Reference RF1.
  • the inorganic binder composition(s) comprising the polymeric dispersants and their use are defined in more detail in section [6021] of Reference RF1.
  • the converting step(s) to obtain the polymeric dispersant(s) are defined in more detail in section [6020] of Reference RF1.
  • the term “inorganic binder composition” comprising the polymeric dispersant(s), as used herein, comprises preferably in particular hydraulically setting compositions and compositions comprising calcium sulfate and is defined in more detail in section [6021] of Reference RF1 entitled “Inorganic binder compositions comprising the polymeric dispersant and their use”.
  • Specific building material formulation(s) comprising polymeric dispersant(s) or building product(s) produced by a building material formulation comprising a polymeric dispersant are disclosed in more detail in section [6021] of Reference RF1 .
  • cosmetic surfactant comprises non-ionic, anionic, cationic, and amphoteric surfactants and is defined in more detail in paragraph [7002] of Reference RF1 .
  • emollient refers to a chemical compound used for protecting, moisturizing, and/or lubricating the skin and is defined in more detail in paragraph [7003] of Reference RF1.
  • wax as used herein, comprises pearlizers and opacifiers and is defined in more detail in paragraph [7004] of Reference RF1.
  • cosmetic polymer comprises any polymer that can be used as an ingredient in a cosmetic formulation and is defined in more detail in paragraph [7005] of Reference RF1 .
  • UV filter refers to a chemical compound that blocks or absorbs ultraviolet light and is defined in more detail in paragraph [7006] of Reference RF1 .
  • further cosmetic ingredient comprises any ingredient suitable for making a cosmetic formulation.
  • composition and/or formulation thereof with reference to the cosmetic surfactant, emollient, wax, cosmetic polymer, UV filter and/or further cosmetic ingredient refers to personal care and/or cosmetic compositions or formulations defined in more detail in paragraph [7007] of Reference RF1.
  • the converting step(s) to obtain the cosmetic surfactant, emollient, wax, cosmetic polymer, UV filter or further cosmetic ingredient is/are defined in more detail in paragraph [7008] of Reference RF1.
  • the present invention is further illustrated by the following set of embodiments and combinations of embodiments resulting from the dependencies and back-references as indicated.
  • every embodiment in this range is meant to be explicitly disclosed for the skilled person, i.e. the wording of this term is to be understood by the skilled person as being synonymous to "The method of any of embodiments 1, 2 and 3".
  • the following set of embodiments represents a suitably structured part of the general description directed to preferred aspects of the present invention, and thus, suitably supports the claims of the present invention.
  • step (i) providing at least one pre-sorted fraction PSE of end-of-life vehicles as first feedstock F1, wherein said at least one pre-sorted fraction PSE comprises at least one polymer which forms at least one C6-C8 aromatic hydrocarbon in step (ii), providing a second feedstock F2 and optionally a third feedstock F3, wherein at least 10 wt.-%, more preferably at least 15 wt.-% and most preferably at least 20 wt.-% of all feedstocks provided in step (I) are second feedstock F2,
  • step (ii) converting said first feedstock F1 and said second feedstock F2 provided in step (I) and said third feedstock F3 optionally provided in step (i) in a first gasifier G1 into a first raw synthesis gas RSG1, wherein said first raw synthesis gas RSG1 comprises CO, H2, and C6-C8 aromatic hydrocarbons,
  • step Hi. is selected from the group comprising or consisting of magnetic separation, separation by eddy current, density separation, manual sorting, and combinations thereof.
  • said second feedstock F2 is a particulate feedstock having a particle size PS and is selected from the group comprising or preferably consisting of coal, bio char, wood and combinations thereof.
  • the second feedstock F2 is selected from the group comprising or preferably consisting of meta-anthracite, anthracite, semianthracite, low volatile bituminous coal, medium volatile bituminous coal, high volatile A bituminous coal, high volatile B bituminous coal, high volatile C bituminous coal, subbituminous A coal, subbituminous B coal, subbituminous C coal, lignite A, lignite B and mixtures thereof.
  • the second feedstock F2 is selected from the group consisting of low volatile bituminous coal, medium volatile bituminous coal, high volatile A bituminous coal, high volatile B bituminous coal, high volatile C bituminous coal, subbituminous A coal, subbituminous B coal, subbituminous C coal, lignite A, lignite B and mixtures thereof.
  • a third feedstock F3 is provided in step (i) and wherein said third feedstock F3 is selected from the group comprising or consisting of biomass, refuse-derived fuel (RDF), textiles, dried sewage sludge, pyrolysis oils made from plastic waste, pyrolysis oils made from end-of-life tires, pyrolysis oils made from biomass, heating oils, vacuum residues, preferably vacuum distillation residues, crude oil residues, heavy crude oils, extra heavy crude oils, tar sand bitumen, visbreaker bottom residues, deasphalter bottom residues, C5 asphalthene fraction, high viscous residues, fuel oils, pyrolysis gasolines, tire pyrolysis oils (TPO), waste oils, used oils, municipal solid waste (MSW), tar oils, natural gas, CO2, and mixtures thereof.
  • RDF refuse-derived fuel
  • textiles dried sewage sludge
  • pyrolysis oils made from plastic waste pyrolysis oils made from end-of-life tires
  • the third feedstock is selected from the group consisting of biomass, refuse-derived fuel (RDF), pyrolysis oils made from plastic waste, pyrolysis oils made from end-of- life tires, pyrolysis oils made from biomass, municipal solid waste (MSW), CO2, and mixtures thereof.
  • RDF refuse-derived fuel
  • MSW municipal solid waste
  • said at least one washing liquid WL is selected from the group comprising or preferably consisting of alcohols, ethers, amines, alkanolamines, organic polysiloxanes, and mixtures thereof.
  • said at least one washing liquid WL is selected from the group consisting of methanol, methylethers of polyethyleneglycol, monoethanolamine, diethanolamine, organic polysiloxanes comprising aryl groups, and mixtures thereof.
  • the product PRF1 is selected from: i) building block or monomer; or ii) polymer, preferably polymer A, polymer composition, preferably polymer composition A, or polymer product, preferably polymer product A; or ill) cleaning polymer, cleaning surfactant, descaling compound, cleaning biocide or composition or formulation thereof; or iv) agrochemical composition, agrochemical formulation auxiliary or agrochemically active ingredient; or v) active pharmaceutical ingredient or intermediate thereof, pharmaceutical excipient, animal feed additive, human food additive, dietary supplements, aroma chemical or aroma composition; or vi) aqueous polymer dispersion, preferably polyurethane or polyurethane - poly (meth)acrylate hybrid polymer dispersion, emulsion, binder for paper and fiber coatings, UV-curable acrylic polymer for hot melts and coatings polyisocyanates, hyperbranched polyester polyol, polymeric dispersant for inorganic binder compositions, unsaturated polyester polyo
  • Chemical plant for manufacture of C6-C8 aromatic hydrocarbons from pre-sorted fractions of end-of-life vehicles comprising a. a first gasifier G1, b optionally a second gasifier, said optional second gasifier downstream of and fluidically connected to said first gasifier G1, c. a gas cleaning unit GCU, said gas cleaning unit GCU downstream of and fluidically connected to said first gasifier G1 and said optional second gasifier G2, and d an aromatic hydrocarbon extraction unit AEU, said aromatic hydrocarbon extraction unit AEU downstream of and fluidically connected to said gas cleaning unit GCU, wherein said first gasifier G1 is a fixed bed gasifier and wherein said optional second gasifier G2 is an entrained flow gasifier.
  • a feedstock composition consisting of 50 wt.-% first feedstock F1 (pre-sorted fraction PSE of end-of-life vehicles, pelletized), 20 wt.-% second feedstock F2 (coal) and 30 wt.-% of feedstock F3 (RDF) are provided in step (i).
  • the feedstock composition is converted in a first gasifier G1 (fixed-bed gasifier) into a first raw synthesis gas RSG1 , wherein said first raw synthesis gas RSG1 comprises 14 Vol.-% CO, 30 Vol.-% H2, and 26 g C6-C8 aromatic hydrocarbons per m 3 of first raw synthesis gas RSG1.
  • C6-C8 aromatic hydrocarbons are removed from said first raw synthesis gas RSG1 by a gas cleaning process GC in a gas cleaning unit GCU with a washing liquid WL (methanol), whereby a clean first synthesis gas CSG1 and a first liquid residue LR1 are formed.
  • the first liquid residue LR1 after a liquid phase comprising methanol was separated therefrom, comprises 86.2 wt.-% benzene.
  • C6-C8 aromatic hydrocarbons comprised in the first liquid residue LR1 are separated by extractive distillation in an aromatic hydrocarbon extraction unit AEU.

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Abstract

La présente invention concerne un procédé de fabrication d'hydrocarbures aromatiques en C6-C8 à partir de fractions pré-triées provenant de véhicules en fin de vie (première charge de départ) à l'aide d'au moins un gazéificateur. Ladite première charge de départ F1 et une seconde charge de départ sont converties dans au moins un gazéificateur en un premier gaz de synthèse brut RSG1, ledit premier gaz de synthèse brut RSG1 comprenant CO, H2 et des hydrocarbures aromatiques en C6-C8. Ensuite, lesdits hydrocarbures aromatiques en C6-C8 sont éliminés dudit premier gaz de synthèse brut RSG1 par un processus de nettoyage de gaz GC dans une unité de nettoyage de gaz GCU, un premier gaz de synthèse propre CSG1 et un premier résidu liquide LR1 étant ainsi formés. Ensuite, un flux aromatique AS et un second flux liquide LR2 sont éliminés dudit premier résidu liquide LR1 dans une unité d'extraction d'hydrocarbures aromatiques AEU, ledit flux aromatique AS étant enrichi en hydrocarbures aromatiques en C6-C8 et ledit second flux liquide LR2 étant appauvri en hydrocarbures aromatiques en C6-C8.
PCT/EP2025/070797 2024-07-31 2025-07-21 Procédé de fabrication d'hydrocarbures aromatiques en c6-c8 à partir de véhicules en fin de vie Pending WO2026027298A1 (fr)

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Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20140228606A1 (en) 2013-02-12 2014-08-14 Saudi Basic Industries Corporation Conversion of plastics to olefin and aromatic products with product recycle
WO2018208144A1 (fr) 2017-05-12 2018-11-15 Stichting Energieonderzoek Centrum Nederland Élimination de composés aromatiques monocycliques (btex) contenus dans un gaz

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20140228606A1 (en) 2013-02-12 2014-08-14 Saudi Basic Industries Corporation Conversion of plastics to olefin and aromatic products with product recycle
WO2018208144A1 (fr) 2017-05-12 2018-11-15 Stichting Energieonderzoek Centrum Nederland Élimination de composés aromatiques monocycliques (btex) contenus dans un gaz

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"Industrielle organische Chemie", 1988, pages: 351 - 352
"Ullmann's Encyclopedia of Industrial Chemistry", 2012, BENZENE, pages: 246 - 251
JAMES G. SPEIGHT: "Handbook of Gasification Technology", 2020, WILEY, pages: 259 - 262
MOLLETGRUBEMANN: "Formulation technology", 2001, WILEY VCH
Y. YANG ET AL.: "Gasification of refuse-derived fuel from municipal solid waste for energy production: a review", ENVIRONMENTAL CHEMISTRY LETTERS, vol. 19, 2021, pages 2127 - 2140, XP038170384, Retrieved from the Internet <URL:https://doi.org/10.1007/s10311-020-01177-5> DOI: 10.1007/s10311-020-01177-5

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