# US 2023/0053932 A1 · Apparatus, method and catalyst for processing hydrocarbons for recycling

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- Number: US 2023/0053932 A1
- Document ID: US20230053932A1
- Status: Published application
- Kind: A1
- Application number: 17/797,364
- Filed: 2021-02-04
- Published: 2023-02-23
- Earliest claimed: 2020-02-04
- Inventors: Edward Douglas Miller
- Web page: https://patentgrep.com/patent/US20230053932A1

## CPC

- C10G 1/10: from rubber or rubber waste
- C10G 11/02: characterised by the catalyst used
- B01D 3/14: Fractional distillation {or use of a fractionation or rectification column}
- B01D 5/006: {with evaporation or distillation}
- B01J 8/0285: {Heating or cooling the reactor (for tubular reactors in furnaces B01J8/062)}
- B01J 21/066: {Zirconium or hafnium; Oxides or hydroxides thereof}
- B01J 27/053: Sulfates
- B01J 27/22: Carbides
- B01J 37/088: {Decomposition of a metal salt}
- C10G 1/002: {in combination with oil conversion- or refining processes}
- C10G 1/086: {Characterised by the catalyst used}
- B01J 27/224: Silicon carbide
- B01J 2208/0053: Controlling multiple zones along the direction of flow, e.g. pre-heating and after-cooling
- C10G 2300/1003: Waste materials
- C10G 2300/1007: Used oils
- Y02W 30/62: Plastics recycling; Rubber recycling
- C10G: CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION (cracking to hydrogen or synthesis gas C01B; cracking or pyrolysis of hydrocarbon gases to individual hydrocarbons or mixtures thereof of definite or specified constitution C07C; cracking to cokes C10B); RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
- B01D: SEPARATION (separating solids from solids by wet methods B03B, B03D; by pneumatic jigs or tables B03B; by other dry methods B07; magnetic or electrostatic separation of solid materials from solid materials or fluids, separation by high-voltage electric fields B03C; centrifuges, vortex apparatus B04; presses per se for squeezing-out liquid from liquid-containing material B30B9/02; treatment of water C02F, e.g. softening by ion-exchange C02F1/42; {arrangements of air intake cleaners in gas turbine plants F02C7/05} ; arrangements or mounting of filters in air-conditioning, air-humidification or ventilation F24F13/28)
- B01J: CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- Y02W: CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT

## Abstract

A method 10 for processing hydrocarbons for recycling includes the steps of: a) heating solid and/or liquid hydrocarbons in a chamber 16 in the absence of air, to convert at least some of the hydrocarbons into hydrocarbon gas; b) reacting the hydrocarbon gas in a reactor 20 or conduit with a catalyst 22 including a transition metal or transition metal salt, and a carbide, to break the hydrocarbon gas down into hydrocarbon products; and c) collecting the hydrocarbon products or conveying the hydrocarbon products elsewhere for use.

## Claims

### Claim 1

A method of processing hydrocarbons for recycling, without using hydrogen gas, comprising the steps of:
a) heating a mixture of solid and/or liquid hydrocarbons to remove water from the mixture, and further heating the mixture in a chamber in the absence of air, to gasify or vapourise at least some of the hydrocarbons into hydrocarbon gas;
b) in a downstream reactor or conduit connected to the chamber, reacting the hydrocarbon gas with a catalyst which includes or is prepared from a transition metal or transition metal salt, and a carbide, to reduce chain lengths of hydrocarbons in the hydrocarbon gas and produce hydrocarbon products; and
c) collecting or conveying the hydrocarbon products for use in liquid or gas form.

### Claim 2 (depends on 1)

The method as claimed in claim 1, in which the transition metal salt is independently selected from a group comprising: a zirconium salt, a metal sulphate, and zirconium sulphate.

### Claim 3 (depends on 1)

The method as claimed in claim 1, in which the carbide is independently selected from a group comprising: titanium carbide; tungsten carbide; niobium carbide; calcium carbide; molybdenum carbide; silicon carbide.

### Claim 4 (depends on 1)

The method as claimed in claim 1, in which step (a) includes:
i) heating the solid and/or liquid hydrocarbons for a period of time in a first reactor or conduit, to convert at least some lower molecular weight hydrocarbons into a first hydrocarbon gas;
heating the solid and/or liquid hydrocarbons remaining from step (i) for a longer period of time in the first reactor or conduit, or in a second reactor or conduit, to convert at least some of higher molecular weight hydrocarbons into a second hydrocarbon gas.

### Claim 5 (depends on 1)

The method as claimed in any of claim 1, in which one or both of:
the hydrocarbons in step (a) are heated to a temperature in the range 320 to 460° C.; and
the reactor or conduit in step (b) is at a temperature between about 320 to 460° C.

### Claim 6 (depends on 1)

The method as claimed in claim 1, in which the reactor or conduit in step (b) is at a temperature between about 380 to 420° C.

### Claim 7 (depends on 1)

The method as claimed in claim 1, in which heating the hydrocarbons during step (a) provides one or more melt seals at an entrance to the chamber.

### Claim 8 (depends on 1)

The method as claimed in claim 1, in which step (c) includes at least one of:
condensing at least some of the hydrocarbon products into one or more liquid products at room temperature and atmospheric pressure; and
transferring the hydrocarbon products to a container or burning the hydrocarbon products to power a device such as a generator.

### Claim 9 (depends on 1)

The method as claimed in claim 1, in which the solid and/or liquid hydrocarbons are independently selected to include one or more of the following:
two or more different plastics or polyolefins, optionally also including one or more styrenes;
lubricating oil;
synthetic oil;
mineral oil;
engine oil.

### Claim 10 (depends on 1)

The method as claimed in claim 1, in which during heating in step (a) the hydrocarbons are mixed by at least one lobed element for evenly heating the hydrocarbon mixture.

### Claim 11

An apparatus for processing hydrocarbons for recycling without using hydrogen gas, the apparatus comprising:
a heating system including at least one heating chamber for receiving solid and/or liquid hydrocarbons, a feed system for transferring hydrocarbons into the at least one heating chamber, and heating means for removing water from the hydrocarbons and gasifying or vapourising at least some of the solid and/or liquid hydrocarbons in the at least one heating chamber into hydrocarbon gas,
at least one reactor or conduit connected to and downstream from the at least one heating chamber for receiving the hydrocarbon gas, the reactor or conduit including a catalyst which includes or is prepared from a transition metal or transition metal salt, and a carbide, for reducing chain lengths of hydrocarbons in the hydrocarbon gas and producing hydrocarbon products, and
at least one of:
a collection system, a fractional distillation system or condensing means for condensing the hydrocarbon products into liquid; and
an outlet conduit for transferring the hydrocarbon products away from the reactor or conduit.

### Claim 12 (depends on 11)

The apparatus as claimed in claim 11, further including a shredding or grinding system for mechanically breaking down solid hydrocarbons, connected to the heating system for transferring hydrocarbons to the heating system.

### Claim 13 (depends on 11)

The apparatus as claimed in claim 11, in which the heating system includes one or more feed screws for removing one or both of contaminants and moisture from the hydrocarbons before gasification.

### Claim 14 (depends on 11)

The apparatus as claimed in any of claim 11, in which the heating means includes one or both of:
one or more variable geometric elements for establishing one or more melt seals where hydrocarbons enter the heating chamber; and
one or more lobed elements for mixing the hydrocarbons during heating.

### Claim 15 (depends on 11)

The apparatus as claimed in claim 11, in which there is a first heating chamber for converting lower molecular weight hydrocarbons into hydrocarbon gas, and a second heating chamber connected to the first heating chamber for converting higher molecular weight hydrocarbons into hydrocarbon gas.

### Claim 16

(canceled)

### Claim 17

(canceled)

### Claim 18 (depends on 11)

The apparatus as claimed in claim 11, in which one or both of:
the transition metal salt is independently selected from a group comprising: a zirconium salt, a metal sulphate, and zirconium sulphate; and
the carbide is independently selected from a group comprising: titanium carbide; tungsten carbide; niobium carbide; calcium carbide; molybdenum carbide; silicon carbide.

### Claim 19 (depends on 1)

The method as claimed in claim 1, in which the catalyst is suitable for breaking down higher molecular weight hydrocarbons into lower molecular weight hydrocarbons, the catalyst comprising a transition metal or transition metal salt, and a carbide; where the ratio of transition metal or transition metal salt to carbide is from about 2:3 to 3:2.

### Claim 20

(canceled)

### Claim 21

(canceled)

### Claim 22

(canceled)

### Claim 23

A method of preparing a catalyst for use in processing hydrocarbons for recycling, the method comprising the steps of:
a) providing a transition metal or transition metal salt on one or more substrates; and
b) adding a carbide to the one or more substrates.

### Claim 24 (depends on 23)

The method as claimed in claim 23, including the step of heating or calcining the transition metal salt after step (a) and before step (b), or the step of heating or calcining the transition metal salt and carbide after step (b).

### Claim 25

(canceled)

### Claim 26 (depends on 23)

The method as claimed in claim 23, in which the transition metal salt includes zirconium sulphate prepared from zirconia or zirconium hydroxide by using sulphuric acid having a concentration in the range of 0.05 to 1 mol dm−3.

### Claim 27

(canceled)