Resource recovery of waste organic chemicals by thermal catalytic conversion

Abstract

A process for the thermocatalytic conversion of waste organic materials (e.g., waste tires) into reusable hydrocarbons is provided. The process entails providing the feedstock and catalyst comprising AlCl to a heated, stirred reactor. An overhead portion of vaporized hydrocarbons as well as vaporized AlCl is initially removed from the reactor via a discharge port. The composition of the removed hydrocarbons will vary depending on which of three modes the process is run: low reactor pressure, partial vacuum, and high pressures. Vaporized AlCl and a certain fraction of the hydrocarbons are subsequently removed via condensation and returned to the reactor. The composition of the condensed hydrocarbon fraction is controlled based on vapor pressure. The remaining vaporized hydrocarbon is recovered for subsequent uses. A reactor discharge portion is also removed from the reactor. This portion may contain unreacted feedstock and catalyst. The reactor discharge portion is provided to a supplemental reactor in which additional vaporized hydrocarbons and additional vaporized AlCl catalyst are produced. The additional vaporized hydrocarbons and additional vaporized AlCl catalyst are removed from the supplemental reactor and provided to a recycle catalyst condenser in which the additional catalyst is condensed while the additional hydrocarbons are maintained in the vapor state. The condensed additional catalyst as well as make-up catalyst are provided to the reactor to maintain appropriate catalyst to feedstock ratios. The additional hydrocarbons are recovered for subsequent uses. Any remaining residuals contained in the supplemental reactor are subjected to solid residue treatment, which includes carbon black recovery.