Chemical Recycling of Thermoset Resins

Abstract

A variety of systems and methods are disclosed, including, in one embodiment, a method of performing coking on a combined feed, comprising: combining a resin feedstock with a coker feedstock comprising a T10 distillation point of about 343° C. or higher to form a combined feedstock, wherein the resin feedstock comprises a thermoset resin having a median particle size of about 5 mm or less; and exposing at least a portion of the combined feedstock to coking conditions in a coking reactor to form at least coke and a coker effluent.

1 . A method of performing coking on a combined feed, comprising:
 combining a resin feedstock with a coker feedstock comprising a T10 distillation point of about 343° C. or higher to form a combined feedstock, wherein the resin feedstock comprises a thermoset resin having a median particle size of about 5 mm or less; and   exposing at least a portion of the combined feedstock to coking conditions in a coking reactor to form at least coke and a coker effluent.   
     
     
         2 . The method of  claim 1 , further comprising reducing a particle size of the thermoset resin to the median particle size of about 5 mm or less. 
     
     
         3 . The method of  claim 1 , further comprising mixing the resin feedstock with a carrier fluid. 
     
     
         4 . The method of  claim 1 , wherein the at least a portion of the resin is combined with the coker feedstock in one or more mixing vessels, the method further comprising heating the combined feed to a temperature of about 200° C. or more in the one or more mixing vessels. 
     
     
         5 . The method of  claim 1 , wherein the resin feedstock is combined with the coker feedstock prior to introduction into the coking reactor. 
     
     
         6 . The method of  claim 1 , wherein the thermoset resin comprises a fiber-reinforced resin. 
     
     
         7 . The method of  claim 1 , wherein the thermoset resin comprises a fiberglass-reinforced resin. 
     
     
         8 . The method of  claim 1 , wherein the thermoset resin comprises a polydicyclopentadiene resin. 
     
     
         9 . The method of  claim 1 , wherein the thermoset resin is sized material from a windmill blade. 
     
     
         10 . The method of  claim 1 , wherein the coking conditions comprise exposing the combined feed to a fluidized bed of coke particles at a temperature of about 450° C. to about 650° C. 
     
     
         11 . The method of  claim 1 , wherein the coke comprises silicon in an amount of about 1000 wppm or more. 
     
     
         12 . The method of  claim 1 , wherein the coker effluent comprises cyclopentene in an amount of about 0.01 wt % to about 2 wt % and cyclopentadiene in an amount of about 0.01 wt % to about 5 wt %. 
     
     
         13 . The method of  claim 1 , wherein the coker effluent comprises cyclopentadiene in an amount of about 0.5 wt % to about 5 wt %, and the method further comprise separating at least a portion of the cyclopentadiene from the coker effluent and polymerizing the at least the portion of the cyclopentadiene to form polydicyclopentadiene. 
     
     
         14 . The method of  claim 1 , wherein the combined feedstock comprises the resin feedstock in an amount of about 1 wt % to about 25%. 
     
     
         15 . The method of  claim 1 , further comprising reducing a particle size of a material from a windmill blade to form the thermoset resin to the median particle size of about 5 mm or less, wherein the combined feedstock comprises the resin feedstock in an amount of about 1 wt % to about 25%, wherein the coke comprises silicon in an amount of about 1000 wppm to about 2 wt %. 
     
     
         16 . The method of  claim 1 , further comprising reducing a particle size of a polydicyclopentadiene resin to form the thermoset resin to the median particle size of about 5 mm or less, wherein the combined feedstock comprises the resin feedstock in an amount of about 1 wt % to about 25%, wherein the coker effluent comprises cyclopentene in an amount of about 0.01 wt % to about 2 wt % and cyclopentadiene in an amount of about 0.01 wt % to about 5 wt %. 
     
     
         17 . A petroleum coke comprising:
 a carbonaceous solid material comprising silicon in an amount of about 1000 wppm or more.   
     
     
         18 . The petroleum coke of  claim 17 , wherein the silicon is present in an amount of about 1000 wppm to about 2 wt %. 
     
     
         19 . The petroleum coke of  claim 17 , wherein the petroleum coke is produced in a delayed coker. 
     
     
         20 . The petroleum coke of  claim 17 , wherein the petroleum coke is produced in a fluidized coker. 
     
     
         21 . The petroleum coke of  claim 17 , wherein the petroleum coke is produced at least in part from coking fiberglass-reinforced thermoset resin. 
     
     
         22 . The petroleum coke of  claim 21 , wherein the fiberglass-reinforced thermoset resin comprises a polydicyclopentadiene resin.