Process for hydrothermal liquefaction of a purcontaining waste feedstock

Abstract

A process (PHP) for hydrothermal liquefaction of a PUR-containing waste feedstock (WFT) is disclosed, the process comprising the steps of providing (PPF) the PUR-containing waste feedstock (WFT), the PUR-containing waste feedstock (WFT) comprising polyurethane, wherein at least 30% by weight of said polyurethane is polyether polyol-based polyurethane, subjecting the PUR-containing waste feedstock (WFT) to hydrothermal liquefaction (HTL) to obtain a HTL output stream (OPS), separating (SEP) polyether polyol (PEP) from the HTL output stream (OPS). Also, a system for decomposing PUR-containing waste feedstock is disclosed.

1 . A process for hydrothermal liquefaction of a PUR-containing waste feedstock, the process comprising the steps of
 providing the PUR-containing waste feedstock, the PUR-containing waste feedstock comprising polyurethane, wherein at least 30% by weight of said polyurethane is polyether polyol-based polyurethane,   subjecting the PUR-containing waste feedstock to hydrothermal liquefaction to obtain an HTL output stream,   separating polyether polyol from the HTL output stream.   
     
     
         2 . The process according to  claim 1 , wherein the PUR-containing waste feedstock comprises polyurethane in an amount of at least 50% by weight of the dry matter of the PUR-containing waste feedstock. 
     
     
         3 . The process according to  claim 1 , wherein the PUR-containing waste feedstock comprises non-polyurethane components in an amount of no more than 20% by weight of the dry matter of the PUR-containing waste feedstock. 
     
     
         4 . The process according to  claim 1 , wherein the PUR-containing waste feedstock comprises polyurethane obtained from the group consisting of foam cushions, insulation material, packaging material, footwear, and any combination thereof. 
     
     
         5 . The process according to  claim 1 , wherein the PUR-containing waste feedstock comprises polyurethane obtained from the group consisting of flexible foam polyurethane, rigid foam polyurethane, rigid non-foam polyurethane, flexible non-foam polyurethane. 
     
     
         6 . The process according to  claim 1 , wherein at least 50% by weight of said polyurethane is polyether polyol-based polyurethane. 
     
     
         7 . The process according to  claim 1 , wherein said polyurethane is comprises polyurethane based on non-polyether polyols. 
     
     
         8 . The process according to  claim 1 , wherein the polyurethane is made using isocyanates selected from the group consisting of aromatic and/or aliphatic diisocyanates including, methylene diphenyl diisocyanate (MDI), toluene diisocyanate (TDI), oligomeric diphenylmethane diisocyanate (OMDI), polymeric diphenylmethane diisocyanate (PMDI), 1,4-butane diisocyanate (BDI), 1,6-hexamethylene diisocyanate (HMDI), isophorone diisocyanate (IPDI), cyclohexane diisocyanate (CHDI), trimethyl hexamethylenediisocyante (TMDI), 4,4′-diisocyanato dicyclohexylmethane, and any combination thereof. 
     
     
         9 . The process according to  claim 1 , wherein the PUR containing waste feedstock comprises water in an amount at least 65% by weight of the PUR containing waste feedstock when subjected to the hydrothermal liquefaction. 
     
     
         10 . The process according to  claim 1 , wherein the PUR-containing waste feedstock has an average particle size of no more than 10 cm. 
     
     
         11 . The process according to  claim 1 , wherein the step of hydrothermal liquefaction comprises subjecting the PUR containing waste feedstock to a temperature of at least 150 degrees Celsius. 
     
     
         12 . The process according to  claim 1 , wherein the step of hydrothermal liquefaction comprises subjecting the PUR containing waste feedstock to a pressure of at least 5 bar. 
     
     
         13 . The process according to  claim 1 , wherein the step of hydrothermal liquefaction has a processing time of at least 5 minutes. 
     
     
         14 . The process according to  claim 1 , wherein the method further comprises adding an additive, a reagent, a catalyst, or any combination thereof. 
     
     
         15 . The process according to  claim 1 , wherein the hydrothermal liquefaction is operated in continuous mode. 
     
     
         16 . The process according to  claim 1 , wherein the separation step comprises separating the HTL output stream into a polyether polyol containing phase and an aqueous phase. 
     
     
         17 . The process according to  claim 1 , wherein the polyether polyol is separated from the HTL output stream by physical separation. 
     
     
         18 . The process according to  claim 1 , wherein the separation step further comprises separating isocyanate or its components from the HTL output stream. 
     
     
         19 . The process according to  claim 1 , wherein a water stream is obtained from the HTL output stream and wherein at least part of said water stream is mixed with said PUR containing waste feedstock prior to hydrothermal liquefaction. 
     
     
         20 . A system for decomposing PUR-containing waste feedstock, the system comprising
 at least one inlet for receiving PUR-containing waste feedstock,   at least one hydrothermal liquefaction unit comprising a HTL inlet and a HTL outlet, the HTL inlet being arranged to receive PUR-containing waste feedstock from said inlet, the HTL outlet being arranged to output a HTL output stream,   at least one separation unit arranged to separate polyether polyol from the HTL output stream.