# US 2025/0145895 A1 · Catalytic pyrolysis of plastics to produce petrochemical feedstock

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- Number: US 2025/0145895 A1
- Document ID: US20250145895A1
- Status: Published application
- Kind: A1
- Application number: 18/699,248
- Filed: 2022-10-05
- Published: 2025-05-08
- Earliest claimed: 2021-10-06
- Assignees: W.R. Grace & Co.-Conn.; Universidad Del Pais Vasco
- Applicants: W.R. Grace & Co.-Conn.; Universidad Del Pais Vasco
- Inventors: Wu-Cheng CHENG; Robert Hibbard HARDING; Alessia PADOVANI; Guang YUAN; Gartzen LOPEZ ZABALBEITIA; Martin OLAZAR AURRECOECHEA
- Web page: https://patentgrep.com/patent/US20250145895A1

## CPC

- B01J 29/40: of the pentasil type, e.g. types ZSM-5, ZSM-8 or ZSM-11, as exemplified by patent documents US3702886, GB1334243 and US3709979, respectively
- B01J 35/40: characterised by dimensions, e.g. grain size (in a colloidal state B01J35/23; crystallite size B01J35/77)
- C10B 53/07: {of solid raw materials consisting} of synthetic polymeric materials, e.g. tyres (recovery or working-up of waste materials of organic macromolecular compounds or compositions based thereon by dry-heat treatment for obtaining partially depolymerised materials C08J11/10; production of liquid hydrocarbon mixtures from rubber or rubber waste C10G1/10)
- C10B 57/06: containing additives
- C10G 1/10: from rubber or rubber waste
- B01J 29/06: Crystalline aluminosilicate zeolites; Isomorphous compounds thereof
- C10G 2300/1003: Waste materials
- C10G 2400/20: C2-C4 olefins
- C10G 2400/30: Aromatics
- B01J: CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- C10B: DESTRUCTIVE DISTILLATION OF CARBONACEOUS MATERIALS FOR PRODUCTION OF GAS, COKE, TAR, OR SIMILAR MATERIALS (cracking oils C10G; underground gasification of minerals E21B43/295)
- 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

## Abstract

The present technology is generally related to the process of converting plastics to olefin and aromatics through pyrolysis, wherein the process of producing at least one or more of olefins and aromatic compounds from a plastic feedstock includes: contacting a plastic feedstock and a catalyst composition at a temperature from about 450° C. to about 650° C. in a conical spouted bed reactor and for a time period sufficient to allow at least a portion of the plastic feedstock to be converted to at least one or more olefins and aromatic compounds and wherein the catalyst composition includes greater than about 40% w/w of ZSM-5, based on the total weight of the catalyst composition.

## Claims

### Claim 1

A process of producing at least one or more of olefins and aromatic compounds from a plastic feedstock, the process comprising:
contacting a plastic feedstock and a catalyst composition at a temperature from about 450° C. to about 650° C. in a conical spouted bed reactor and for a time period sufficient to allow at least a portion of the plastic feedstock to be converted to at least one or more olefins and aromatic compounds;
wherein the catalyst composition comprises greater than about 40% w/w of ZSM-5, based on the total weight of the catalyst composition.

### Claim 2 (depends on 1)

The process of claim 1, wherein the catalyst composition comprises greater than about 45% w/w of ZSM-5, based on the total weight of the catalyst composition.

### Claim 3

(canceled)

### Claim 4 (depends on 1)

The process of claim 1, wherein the catalyst composition comprises particles having a size ranging from about 0.05 mm to about 5 mm.

### Claim 5

(canceled)

### Claim 6 (depends on 1)

The process of claim 1, wherein the catalyst composition comprises from about 5% w/w to about 15% w/w P2O5, based on the total weight of the composition.

### Claim 7 (depends on 1)

The process of claim 1, wherein the catalyst composition comprises no greater than about 40% w/w Al2O3, based on the total weight of the composition.

### Claim 8 (depends on 1)

The process of claim 1, wherein the ZSM-5 has a crystallite size of less than about 0.4 microns.

### Claim 9 (depends on 1)

The process of claim 1, wherein the catalyst composition is formed by spray drying, extrusion, or a bead forming method.

### Claim 10

(canceled)

### Claim 11 (depends on 1)

The process of claim 1, wherein the ZSM-5 is combined with an active matrix within a particle.

### Claim 12 (depends on 1)

The process of claim 1, wherein the ZSM-5 is combined with an active matrix as a separate particle.

### Claim 13 (depends on 1)

The process of claim 1, wherein the ZSM-5 is combined with one or more zeolites selected from ZSM-11, faujasite, mordenite, and beta.

### Claim at position 14

14-15. (canceled)

### Claim 16 (depends on 1)

The process of claim 1, wherein contacting the plastic feedstock and the catalyst composition is at a temperature of from about 500° C. to about 600° C.

### Claim 17 (depends on 1)

The process of claim 1, wherein the plastic feedstock comprises at least one of polyolefins, polyethylene, polypropylene, polystyrene, polyethylene terephthalate (PET), polyvinyl chloride (PVC), polyamide, polycarbonate, polyurethane, polyester, natural and synthetic rubber, tires, filled polymers, composites, plastic alloys, and plastics dissolved in a solvent.

### Claim at position 17

18-19. (canceled)

### Claim 20 (depends on 1)

The process of claim 1, wherein the at least one or more olefins is selected from ethylene, propylene, and butenes.

### Claim 21 (depends on 20)

The process of claim 20, wherein the process converts the plastic feedstock to greater than about 35 wt % of ethylene, propylene, and butenes.

### Claim 22 (depends on 20)

The process of claim 20, wherein the process converts the plastic feedstock to greater than about 20 wt % of propylene.

### Claim 23 (depends on 1)

The process of claim 1, wherein the at least one or more aromatic compounds is selected from benzene, toluene, and xylenes.

### Claim 24

(canceled)

### Claim 25 (depends on 1)

The process of claim 1, wherein the conical spouted bed reactor comprises a draft tube and a confiner.

### Claim 26 (depends on 25)

The process of claim 25, wherein the conical spouted bed reactor has a gas inlet opening of DO and a diameter of the cylindrical section of the conical spouted bed reactor of DC; the confiner has a diameter of DG; and the draft tube has a distance from the top of the draft tube and the bottom of the draft tube of HG.

### Claim 27 (depends on 26)

The process of claim 26, wherein HG is from about 3 to about 4× DO.

### Claim at position 26

28-29. (canceled)

### Claim 30 (depends on 26)

The process of claim 26, wherein DG is from about 3× DO to about 0.7 DC.

### Claim at position 28

31-32. (canceled)