Depolymerization processes, apparatuses and catalysts for use in connection therewith

Abstract

The present disclosure generally relates to processes, apparatuses and custom catalysts designed to depolymerize a polymer. In one embodiment, the present invention relates to a de-polymerizing apparatus, catalysts and reaction schemes to obtain useful monomers including fuel products by “in situ” reactions using coupled electromagnetic induction.

1 . A method of depolymerizing polymers, the method comprising the steps of:
 (i) providing one or more polymer starting materials, or feed materials;   (ii) providing a reactor to depolymerize the one or more polymer starting materials, or feed materials, into one or more monomers;   (iii) heating the one or more polymer starting materials, or feed materials, at a rate of from about 1° C./second to about 1000° C./second; and   (iv) providing an electromagnetic induction field to facilitate the depolymerization of the one or more polymer starting materials, or feed materials, into their constituent monomers,   wherein the method utilizes one or more catalysts that permit in situ reactions to yield one or more functional monomers.   
     
     
         2 . The method according to  claim 1 , wherein the in situ reaction involves at least one catalytic composition supported on at least one solid substrate. 
     
     
         3 . The method according to  claim 1 , wherein the method further comprises the step of:
 (v) selectively harvesting at least one of the monomers produced by the method or converting at least one of the monomers into one or more stable value added products.   
     
     
         4 . The method according to  claim 1 , wherein the reactor is provided with an electromagnetic source to inductively couple with the mixing device and heat one or more polymer starting materials, or feed materials, to a desired temperature. 
     
     
         5 . The method according to  claim 1 , wherein the reactor is provided with a plasma device in combination with an electromagnetic source to inductively couple with the mixing device and heat the one or more polymer starting materials, or feed materials to a desired temperature. 
     
     
         6 . The method according to  claim 1 , wherein the one or more catalysts sites are alkaline in nature, acidic in nature, or a combination thereof. 
     
     
         7 . The method according to  claim 1 , wherein the one or more catalysts are applied on one or more solid supports by an additive deposition process. 
     
     
         8 . The method according to  claim 1 , wherein the one or more catalysts are synthesized on one or more solid supports by thermo-chemical processes. 
     
     
         9 . The method according to  claim 1 , wherein the one or more catalysts are nanoscale catalysts. 
     
     
         10 . The method according to  claim 9 , wherein the one or more nanoscale catalysts enhance the depolymerization process and perform additional chemical transformations to yield and/or obtain functional chemicals. 
     
     
         11 . The method according to  claim 1 , wherein the one or more monomers produced by the method according to  claim 1  are the basic components which were used to form the one or more polymer starting materials, or feed materials. 
     
     
         12 . The method according to  claim 1 , wherein the method further comprises the step of: reacting one or more of the monomers to yield one or more functional chemicals. 
     
     
         13 . The method according to  claim 1 , wherein the heating rate in Step (iii) is about 50° C./second to about 500° C./second. 
     
     
         14 . The method according to  claim 1 , wherein the heating rate in Step (iii) is about 100° C./second to about 200° C./second. 
     
     
         15 . The method according to  claim 1 , wherein the heating rate in Step (iii) is about 200° C./second. 
     
     
         16 . A method of depolymerizing polymers, the method comprising the steps of:
 (a) providing one or more polymer starting materials, or feed materials;   (b) providing a reactor to depolymerize the one or more polymer starting materials, or feed materials, into one or more monomers;   (c) heating the one or more polymer starting materials, or feed materials, at a rate of from about 10° C./second to about 1000° C./second;   (d) providing an electromagnetic induction field to facilitate the depolymerization of the one or more polymer starting materials, or feed materials, into their constituent monomers; and   (e) selectively harvesting at least one of the monomers produced by the method or converting at least one of the monomers into one or more stable value added products,   wherein the method utilizes one or more catalysts that permit in situ reactions to yield one or more functional monomers.   
     
     
         17 . A method of depolymerizing polymers, the method comprising the steps of:
 (I) providing a polymer starting material, or feed material;   (II) providing a reactor to depolymerize the polymer starting material, or feed material, into a constituent monomer;   (III) heating the one or more polymer starting materials, or feed materials, at a rate of from about 10° C./second to about 1000° C./second; and   (IV) providing an electromagnetic induction field to facilitate the depolymerization of the material, or feed material into its constituent monomer,   wherein the method achieves a yield of constituent monomer of at least about 80 weight percent based on the extractable weight percent value contained in the polymer starting material, or feed material, subjected to depolymerization.