Various processes and configuration are provided for a chemical recycling facility that can lower the carbon footprint and global warming potential of the facility. More particularly, we have discovered numerous ways for reducing the carbon footprint of the facility by: (i) recycling at least a portion of the residual heat energy from the pyrolysis effluent back upstream to the pyrolysis process and waste plastic liquification stage; (ii) recovering at least a portion of the carbon dioxide from at least a portion of the pyrolysis flue gas and/or the pyrolysis gas; (iii) feeding at least a portion of the pyrolysis gas at a cracker facility at a position downstream of a cracker furnace; (iv) using at least a portion of a demethanizer overhead stream as a fuel in a pyrolysis facility and/or a cracking facility; and (v) providing a chemical recycling facility that contains a pyrolysis facility co-located with a cracking facility. Thus, the global warming potential of the chemical recycling facility may be optimized and lowered due to the processes and configurations described herein.

Disclosed herein is a pyrolysis machine that includes a reactor tube configured to conduct pyrolysis on plastic feedstock, wherein the reactor tube is made of a steel material. The pyrolysis machine includes a plurality of ceramic band heaters located in the reactor tube configured to heat the steel material of the reactor tube. The pyrolysis machine includes a plurality of resistance coils located in the ceramic heaters configured to heat the ceramic heaters. Further, the pyrolysis machine includes a temperature sensor located in the reactor tube and a controller configured to regulate the temperature of the ceramic band heaters.

Clean, safe and efficient methods, systems, and processes for utilizing thermolysis methods to processes to convert various carpet, rug, polymeric materials and other waste sources, such as solid waste, tires, manure, auto shredder residue, glass and carbon fiber composite materials, municipal solid wastes, medical wastes, waste wood and the like into a Clean Fuel Gas and Char source are disclosed. The invention processes the carpet, rug, polymeric material to effectively shred and/or grind the waste source, such as post-consumer carpet remnants and waste, and then process using thermolysis methods to destroy and/or separate halogen and other dangerous components to provide a Clean Fuel Gas and Char source. Additional waste sources, such as solid waste, tires, manure, auto shredder residue, glass and carbon fiber composite materials, municipal solid wastes, medical wastes, waste wood and the like, are suitable for the processing of the invention disclosed.

Clean, safe and efficient methods, systems, and processes for utilizing thermolysis methods to processes to convert various e-waste sources into Clean Fuel Gas and Char source are disclosed. The invention processes e-waste sources, such as for example whole circuit boards, to effectively shred and/or grind the waste source, and then process using thermolysis methods to destroy and/or separate halogen and other dangerous components to provide a Clean Fuel Gas and Char source, along with the ability to recover precious metals and other valuable components from the Char.

A method for treating vapours generated during the pyrolysis of carbon fibre composites, such as production waste generated by the producers or composites of carbon fibre at the end of the service life thereof, includes, passing the vapours through a reactor which is at a high temperature and contains a solid material filler (solid bed), for example CSi, and optionally also a solid catalyst having an acid and/or reforming function, preferably both, for example a transition metal supported on an acid substrate, such as Ni on zeolite. Following the condensation of the vapours resulting from the treatment, an improved aqueous liquid phase, a minimum or non-existent organic fraction and a gaseous phase of increased added value are obtained.

An apparatus, system, and method for recycling glass fiber waste, particularly glass fiber embedded within a binder material. The system includes a kiln, a char separator, and a multi-stage molten salt bath having a temperature gradient. Glass fiber waste is provided to the kiln which converts the waste into glass fibers and char. At least some of the char is then separated from the glass fibers in the char separator. The glass fibers, and any remaining char, are then placed in the molten salt bath at the point having the lowest temperature. The glass fibers are then moved to the higher temperature areas within the molten salt bath. As the glass fibers pass from the low temperature to the high temperature, any remaining char is consumed, and the glass fibers are reconditioned via ionic exchange for further use. The glass fibers are then cooled for reuse.

In an embodiment, the present disclosure pertains to a method of recycling that includes applying an electromagnetic field to a composite material having carbon fiber therein, heating the composition, degrading a matrix of the composite material, and recovering the carbon fiber from the composite material. In an additional embodiment, the present disclosure pertains to a method of non-contact recycling that includes applying an electromagnetic field to a composite material having carbon fiber therein with an electromagnetic applicator via at least one of direct current or alternating current, heating the composition, degrading a matrix of the composite material, and recovering the carbon fiber from the composite material. In some embodiments, the electromagnetic field is applied in a non-contact manner. In some embodiments, the heating is locally induced heating that includes increasing the temperature inside the composite material via an inside-out method thereby initiating pyrolysis within the composite material.

Clean, safe and efficient methods, systems, and processes for utilizing thermolysis methods to processes to convert various e-waste sources into Clean Fuel Gas and Char source are disclosed. The invention processes e-waste sources, such as for example whole circuit boards, to effectively shred and/or grind the waste source, and then process using thermolysis methods to destroy and/or separate halogen and other dangerous components to provide a Clean Fuel Gas and Char source, along with the ability to recover precious metals and other valuable components from the Char.

Clean, safe and efficient methods, systems, and processes for utilizing thermolysis methods to processes to convert various carpet, rug, polymeric materials and other waste sources, such as solid waste, tires, manure, auto shredder residue, glass and carbon fiber composite materials, municipal solid wastes, medical wastes, waste wood and the like into a Clean Fuel Gas and Char source are disclosed. The invention processes the carpet, rug, polymeric material to effectively shred and/or grind the waste source, such as post-consumer carpet remnants and waste, and then process using thermolysis methods to destroy and/or separate halogen and other dangerous components to provide a Clean Fuel Gas and Char source. Additional waste sources, such as solid waste, tires, manure, auto shredder residue, glass and carbon fiber composite materials, municipal solid wastes, medical wastes, waste wood and the like, are suitable for the processing of the invention disclosed.

An extruder for processing hydrocarbon-containing material. The extruder includes a screw that is rotatably positioned in a barrel liner and a heating system positioned about at least a portion of the barrel liner that is designed to heat the hydrocarbon-containing material as the hydrocarbon-containing material moves through the barrel liner.