Non-Thermal Plasma Based Deconstruction of Polymers
20240067792 ยท 2024-02-29
Inventors
Cpc classification
International classification
Abstract
One aspect of the present application relates to a method of decomposing a polymeric reactant. This method comprises reacting the polymeric reactant in an oxygen containing ionized gas plasma to decompose the polymeric reactant and produce oxygen-functionalized products. The reacting is carried out at a temperature of 20 to 450? C. Another aspect of the present application relates to a method of removing carbon dioxide and/or carbon monoxide from a gas mixture. This method comprises providing a gas mixture comprising carbon dioxide and/or carbon monoxide. The gas mixture is contacted with a polymeric reactant in an ionized gas plasma to remove carbon dioxide and/or carbon monoxide from the gas mixture and produce oxygen-functionalized products.
Claims
1. A method of decomposing a polymeric reactant comprising: reacting the polymeric reactant in an oxygen containing ionized gas plasma to decompose the polymeric reactant and produce oxygen-functionalized products, wherein said reacting is carried out at a temperature of 20 to 450? C.
2. The method of claim 1, wherein said reacting is carried out in an electric field.
3. The method of claim 2, wherein said reacting is carried out in a plasma reactor operating at a voltage of 10 to 20 kV.
4. The method of claim 2, wherein said reacting is carried out in a plasma reactor operating at a frequency of 5 to 10 kHz.
5. The method of claim 2, wherein said reacting is carried out for 2 to 60 minutes.
6. The method of claim 1, wherein said oxygen-functionalized products are selected from the group consisting of alcohols, carboxylic acids, esters, carbonyls other than carboxylic acids and esters, and mixtures thereof.
7. The method of claim 1 further comprising: heating the polymeric reactant prior to said reacting to a temperature sufficient to convert the polymeric reactant to a condensable vapor form but insufficient to decompose the polymeric reactant from its polymeric state.
8. The method of claim 7, wherein said heating is carried out at a temperature of 20 to 450? C.
9. The method of claim 7, wherein said heating is terminated once said reacting is initiated.
10. The method of claim 7, wherein said heating continues during said reacting.
11. The method of claim 1, wherein said oxygen containing ionized gas plasma is air.
12. The method of claim 1, wherein said oxygen containing ionized gas plasma is oxygen.
13. The method of claim 1, wherein said oxygen containing ionized gas plasma comprises carbon dioxide.
14. The method of claim 1, wherein said oxygen containing ionized gas plasma comprises carbon monoxide.
15. The method of claim 1, wherein the polymeric reactant is a polyolefin.
16. The method of claim 15, wherein the polyolefin is selected from the group consisting of polyethylene, polypropylene, polybutylene, polystyrene, and mixtures thereof
17. The method of claim 1, wherein the oxygen-functionalized products are in liquid and/or wax form.
18. The method of claim 1, wherein the ionized gas plasma comprises energetic electrons, protons, ions, radicals, molecules, and/or atoms.
19. The method of claim 1, wherein said reacting is carried out with a catalyst.
20. The method of claim 19, wherein said catalyst is a solid catalyst selected from the group consisting of zeolite catalysts, metal catalysts, metal oxides, bi-functional catalysts, and mixtures thereof.
21. A method of removing carbon dioxide and/or carbon monoxide from a gas mixture comprising: providing a gas mixture comprising carbon dioxide and/or carbon monoxide and contacting the gas mixture with a polymeric reactant in an ionized gas plasma to remove carbon dioxide and/or carbon monoxide from the gas mixture and produce oxygen-functionalized products.
22. The method of claim 21 wherein the gas mixture further comprises oxygen.
23. The method of claim 21, wherein said oxygen-functionalized products are selected from the group consisting of alcohols, carboxylic acids, esters, carbonyls other than carboxylic acids and esters, and mixtures thereof.
24. The method of claim 21, wherein said gas mixture comprises carbon dioxide.
25. The method of claim 21, wherein said gas mixture comprises carbon monoxide.
26. The method of claim 21, wherein the polymeric reactant is a polyolefin.
27. The method of claim 26, wherein the polyolefin reactant is selected from the group consisting of polyethylene, polypropylene, polybutylene, polystyrene, and mixtures thereof.
28. The method of claim 21, wherein the oxygen-functionalized products are in liquid and/or wax form.
29. The method of claim 21 wherein said contacting is carried out in an electric field.
30. The method of claim 29, wherein said contacting is carried out in a plasma reactor operating at a voltage of 10 to 20 kV.
31. The method of claim 29, wherein said contacting is carried out in a plasma reactor operating at a frequency of 5 to 10 kHz.
32. The method of claim 29, wherein said contacting is carried out for 2 to 60 minutes.
33. The method of claim 21, wherein the ionized gas plasma comprises energetic electrons, protons, ions, radicals, molecules, and/or atoms.
34. The method of claim 21, wherein said contacting is carried out with a catalyst.
35. The method of claim 34, wherein said catalyst is a solid catalyst selected from the group consisting of zeolite catalysts, metal catalysts, metal oxides, bi-functional catalysts, and mixtures thereof.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
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DETAILED DESCRIPTION
[0041] One aspect of the present application relates to a method of decomposing a polymeric reactant. This method comprises reacting the polymeric reactant in an oxygen containing ionized gas plasma to decompose the polymeric reactant and produce oxygen-functionalized products. The reacting is carried out at a temperature of 20 to 450? C.
[0042] The polymeric reactant can be decomposed with or without preheating. Based on reactor configuration, preheating can be accomplished by any suitable means, including but not limited to, heating the polymeric reactant in a container (e.g., reactor) using any suitable external heat source to a sufficient temperature to melt the polymeric reactants. The container may be equipped with an agitator or stirring device. The polymer can be preheated until it melts and is then fed into the plasma reactor using an extruder, an auger, or gravity flow under pressurized or non-pressurized conditions. Additionally, the feed gas can also be preheated prior to entering plasma reactors to achieve dielectric breakdown under milder conditions inside the plasma reactor.
[0043] Plasma, which is often referred to as the fourth state of matter, are ionized gases having at least one electron that is not bound to an atom or molecule. In recent years, plasmas have become of significant interest to researchers in fields such as organic and polymer chemistry, fuel conversion, hydrogen production, environmental chemistry, biology, and medicine, among others. This interest, in part, is because plasmas offer several advantages over traditional chemical processes. For example, plasmas can generate much higher temperatures and energy densities than conventional chemical technologies; plasmas are able to produce very high concentrations of energetic and chemically active species; and plasma systems can operate far from thermodynamic equilibrium, providing extremely high concentrations of chemically active species while having a bulk temperature as low as room temperature. Many details concerning the generation and applications of plasmas are described in ALEXANDER FRIDMAN, PLASMA CHEMISTRY (Cambridge University Press, 2012), which is hereby incorporated by reference in its entirety.
[0044] Plasmas are generated by ionizing gases using any of the variety of ionization sources and may be characterized as either thermal or non-thermal, depending upon the ionization source and the extent of ionization. Thermal and non-thermal plasmas can also be characterized by the temperature of their components. Thermal plasmas are in a state of thermal equilibrium, which means that the temperature of the free electrons, ions, and heavy neutral atoms are approximately the same. Non-thermal plasmas, also referred to as low-temperature plasmas or cold plasmas, are far from a state of thermal equilibrium; the temperature of the free electrons is much greater than the temperature of the ions and heavy neutral atoms within the plasma. The reactive species and excited molecules and atoms are generated by energetic electrons rather than by high temperature. As used herein, non-thermal plasma or low-temperature plasma refers to plasma that is produced by a process that does not involve the use or generation of substantial heat; the temperature of the fluid used to generate the plasma (e.g., ambient air) is not substantially increased during the process of generating plasma. Non-thermal plasma (NTP) technology is also referred to as dielectric barrier discharge, dielectric barrier corona discharge, silent discharge plasma, high energy corona, electron beam plasma corona destruction, electro-catalytic oxidation, and capillary discharge.
[0045] The initial generation of free electrons may vary depending upon the ionization source. With respect to both thermal and non-thermal ionization sources, electrons may be generated at the surface of the cathode due to a potential applied across the electrode. In addition, thermal plasma ionization sources may also generate electrons at the surface of a cathode as a result of the high temperature of the cathode (thermionic emissions) or high electric fields near the surface of the cathode (field emissions). The energy from these free electrons may be transferred to additional plasma components, providing energy for additional ionization, excitation, dissociation, etc. For non-thermal plasmas, the ionization process typically occurs by direct ionization through electron impact. Direct ionization occurs when an electron of high energy interacts with a valence electron of a neutral atom or molecule. If the energy of the electron is greater than the ionization potential of the valence electron, the valence electron escapes the electron cloud of the atom or molecule and becomes a free electron.
[0046] Although thermal plasmas are capable of delivering extremely high powers, they have several drawbacks. For example, thermal plasmas do not allow for adjusting the amount of ionization, they operate at extremely high temperatures requiring high input energy, they lack efficiency, and may have electrode erosion problems. Non-thermal plasma ionization sources have alleviated some of these problems. Exemplary ionization sources for non-thermal plasmas include glow discharges, floating electrode dielectric barrier discharges (FE DBD), and gilding arc discharges among others. In contrast to thermal plasmas, non-thermal plasmas provide for high selectivity, high energy efficiencies, and low operating temperatures. In many non-thermal plasma systems, electron temperatures are at about 10,000 K while the bulk gas temperature may be as cool as room temperature.
[0047] Dielectric barrier discharge (DBD) may be performed using an alternating current at a frequency of from about 0.5 kHz to about 500 kHz between a high voltage electrode and a ground electrode. In addition, one or more dielectric barriers are placed between the electrodes. DBDs have been employed for over a century and have been used for the generation of ozone in the purification of water, polymer treatment (to promote wettability, printability, adhesion), and for pollution control. DBDs prevent arc formation by limiting the current between the electrodes. Different plasma electricity sources and other reactor types can also be used, including DC, AC, radio frequency or nanosecond pulsed plasma, corona glow discharge plasma, microwave plasma, and controlled arc discharge plasma.
[0048] Several materials can be utilized for the dielectric barrier. These include, but are not limited to, glass, quartz, polymer layers, and ceramics. The clearance between the discharge gaps is typically between about 0.1 mm and several centimeters. The required voltage applied to the high voltage electrode varies depending upon the pressure and the clearance between discharge gaps. For a DBD at atmospheric pressure and a few millimeters between the gaps, the breakdown voltage required to generate a plasma is about 10 kV. The breakdown voltage varies depending on the fluid supplied, the gap between the electrodes, and the dielectric strength of the dielectric layer.
[0049] In one embodiment, the ionized gas plasma comprises energetic electrons, protons, ions, radicals, molecules, and/or atoms.
[0050] In one embodiment, the polymeric reactant is heated prior to reacting to a temperature sufficient to convert the polymeric reactant to a condensable vapor form, but insufficient to decompose the polymeric reactant from its polymeric state.
[0051] The heating of the polymeric reactant is carried out at a temperature of 20 to 450? C., or any temperature or range of temperatures therein. In certain embodiments, the polymeric reactant is heated to 20-50, 20-100, 20-150, 20-200, 20-250, 20-300, 20-350, 20-400, 20-450, 40-50, 40-100, 40-150, 40-200, 40-250, 40-300, 40-350, 40-400, 40-450, 60-100, 60-150, 60-200, 60-250, 60-300, 60-350, 60-400, 60-450, 80-100, 80-150, 80-200, 80-250, 80-300, 80-350, 80-400, 80-450, 100-150, 100-200, 100-250, 100-300, 100-350, 100-400, 100-450, 120-150, 120-200, 120-250, 120-300, 120-350, 120-400, 120-450, 140-150, 140-200, 140-250, 140-300, 140-350, 140-400, 140-450, 160-200, 160-250, 160-300, 160-350, 160-400, 160-450, 180-200, 180-250, 180-300, 180-350, 180-400, 180-450, 200-250, 200-300, 200-350, 200-400, 200-450, 220-250, 220-300, 220-350, 220-400, 220-450, 240-250, 240-300, 240-350, 240-400, 240-450, 260-300, 260-350, 260-400, 260-450, 280-300, 280-350, 280-400, 280-450, 300-310, 300-320, 300-330, 300-340, 300-350, 300-360, 300-370, 300-380, 300-390, 300-400, 300-410, 300-420, 300-430, 300-440, 300-450, 310-320, 310-330, 310-340, 310-350, 310-360, 310-370, 310-380, 310-390, 310-400, 310-410, 310-420, 310-430, 310-440, 310-450, 320-330, 320-340, 320-350, 320-360, 320-370, 320-380, 320-390, 320-400, 320-410, 320-420, 320-430, 320-440, 320-450, 330-340, 330-350, 330-360, 330-370, 330-380, 330-390, 330-400, 330-410, 330-420, 330-430, 330-440, 330-450, 340-350, 340-360, 340-370, 340-380, 340-390, 340-400, 340-410, 340-420, 340-430, 340-440, 340-450, 350-360, 350-370, 350-380, 350-390, 350-400, 350-410, 350-420, 350-430, 350-440, 350-450, 360-370, 360-380, 360-390, 360-400, 360-410, 360-420, 360-430, 360-440, 360-450, 370-380, 370-390, 370-400, 370-410, 370-420, 370-430, 370-440, 370-450, 380-390, 380-400, 380-410, 380-420, 380-430, 380-440, 380-450, 390-400, 390-410, 390-420, 390-430, 390-440, 390-450, 400-410, 400-420, 400-430, 400-440, 400-450, 410-420, 410-430, 410-440, 410-450, 420-430, 420-440, 420-450, 430-440, 430-450, 440-450, 345-355? C.
[0052] In one embodiment, the reacting of the polymeric reactant is carried out in an electric field. In another embodiment, the reacting of the polymeric reactant can be carried out in a plasma reactor operating at a voltage of 10.0 to 20.0 kV (e.g., 10.0-10.5, 10.0-11.0, 10.0-11.5, 10.0-12.0, 10.0-12.5, 10.0-13.0, 10.0-13.5, 10.0-14.0, 10.0-14.5, 10.0-15.0, 10.0-15.5, 10.0-16.0, 10.0-16.5, 10.0-17.0, 10.0-17.5, 10.0-18.0, 10.0-18.5, 10.0-19.0, 10.0-19.5, 10.0-20.0, 10.5-11.0, 10.5-11.5, 10.5-12.0, 10.5-12.5, 10.5-13.0, 10.5-13.5, 10.5-14.0, 10.5-14.5, 10.5-15.0, 10.5-15.5, 10.5-16.0, 10.5-16.5, 10.5-17.0, 10.5-17.5, 10.5-18.0, 10.5-18.5, 10.5-19.0, 10.5-19.5, 10.5-20.0, 11.0-11.5, 11.0-12.0, 11.0-12.5, 11.0-13.0, 11.0-13.5, 11.0-14.0, 11.0-14.5, 11.0-15.0, 11.0-15.5, 11.0-16.0, 11.0-16.5, 11.0-17.0, 11.0-17.5, 11.0-18.0, 11.0-18.5, 11.0-19.0, 11.0-19.5, 11.0-20.0, 11.5-12.0, 11.5-12.5, 11.5-13.0, 11.5-13.5, 11.5-14.0, 11.5-14.5, 11.5-15.0, 11.5-15.5, 11.5-16.0, 11.5-16.5, 11.5-17.0, 11.5-17.5, 11.5-18.0, 11.5-18.5, 11.5-19.0, 11.5-19.5, 11.5-20.0, 12.0-12.5, 12.0-13.0, 12.0-13.5, 12.0-14.0, 12.0-14.5, 12.0-15.0, 12.0-15.5, 12.0-16.0, 12.0-16.5, 12.0-17.0, 12.0-17.5, 12.0-18.0, 12.0-18.5, 12.0-19.0, 12.0-19.5, 12.0-20.0, 12.5-13.0, 12.5-13.5, 12.5-14.0, 12.5-14.5, 12.5-15.0, 12.5-15.5, 12.5-16.0, 12.5-16.5, 12.5-17.0, 12.5-17.5, 12.5-18.0, 12.5-18.5, 12.5-19.0, 12.5-19.5, 12.5-20.0, 13.0-13.5, 13.0-14.0, 13.0-14.5, 13.0-15.0, 13.0-15.5, 13.0-16.0, 13.0-16.5, 13.0-17.0, 13.0-17.5, 13.0-18.0, 13.0-18.5, 13.0-19.0, 13.0-19.5, 13.0-20.0, 13.5-14.0, 13.5-14.5, 13.5-15.0, 13.5-15.5, 13.5-16.0, 13.5-16.5, 13.5-17.0, 13.5-17.5, 13.5-18.0, 13.5-18.5, 13.5-19.0, 13.5-19.5, 13.5-20.0, 14.0-14.5, 14.0-15.0, 14.0-15.5, 14.0-16.0, 14.0-16.5, 14.0-17.0, 14.0-17.5, 14.0-18.0, 14.0-18.5, 14.0-19.0, 14.0-19.5, 14.0-20.0, 14.5-15.0, 14.5-15.5, 14.5-16.0, 14.5-16.5, 14.5-17.0, 14.5-17.5, 14.5-18.0, 14.5-18.5, 14.5-19.0, 14.5-19.5, 14.5-20.0, 15.0-15.5, 15.0-16.0, 15.0-16.5, 15.0-17.0, 15.0-17.5, 15.0-18.0, 15.0-18.5, 15.0-19.0, 15.0-19.5, 15.0-20.0, 15.5-16.0, 15.5-16.5, 15.5-17.0, 15.5-17.5, 15.5-18.0, 15.5-18.5, 15.5-19.0, 15.5-19.5, 15.5-20.0, 16.0-16.5, 16.0-17.0, 16.0-17.5, 16.0-18.0, 16.0-18.5, 16.0-19.0, 16.0-19.5, 16.0-20.0, 16.5-17.0, 16.5-17.5, 16.5-18.0, 16.5-18.5, 16.5-19.0, 16.5-19.5, 16.5-20.0, 17.0-17.5, 17.0-18.5, 17.0-19.0, 17.0-19.5, 17.0-20.0, 17.5-18.0, 17.5-18.5, 17.5-19.0, 17.5-19.5, 17.5-20.0, 18.0-18.5, 18.0-19.0, 18.0-19.5, 18.0-20.0, 18.5-19.0, 18.5-19.5, 18.5-20.0, 19.0-19.5, 19.0-20.0, 19.5-20 kV). In another embodiment, the reacting of the polymeric reactant is carried out in a plasma reactor operating at a frequency of 5.0 to 10.0 kHz. (e.g., 5.0-5.5, 5.0-6.0, 5.0-6.5, 5.0-7.0, 5.0-7.5, 5.0-8.0, 5.0-8.5, 5.0-9.0, 5.0-9.5, 5.0-10.0, 5.5-6.0, 5.5-6.5, 5.5-7.0, 5.5-7.5, 5.5-8.0, 5.5-8.5, 5.5-9.0, 5.5-9.5, 5.5-10.0, 6.0-6.5, 6.0-7.0, 6.0-7.5, 6.0-8.0, 6.0-8.5, 6.0-9.0, 6.0-9.5, 6.0-10.0, 6.5-7.0, 6.5-7.5, 6.5-8.0, 6.5-8.5, 6.5-9.0, 6.5-9.5, 6.5-10.0, 7.0-7.5, 7.0-8.0, 7.0-8.5, 7.0-9.0, 7.0-9.5, 7.0-10.0, 7.5-8.0, 7.5-8.5, 7.5-9.0, 7.5-9.5, 7.5-10.0, 8.0-8.5, 8.0-9.0, 8.0-9.5, 8.0-10.0, 8.5-9.0, 8.5-10.0, 9.0-9.5, 9.0-10.0, 9.5-10.0 kHz). In yet another embodiment, the reacting of the polymeric reactant is carried out for 2 to 60 minutes (e.g., 2-5, 2-10, 2-15, 2-20, 2-25, 2-30, 2-35, 2-40, 2-45, 2-50, 2-55, 2-60, 3-5, 3-10, 3-15, 3-20, 3-25, 3-30, 3-35, 3-40, 3-45, 3-50, 3-55, 3-60, 4-5, 4-10, 4-15, 4-20, 4-25, 4-30, 4-35, 4-40, 4-45, 4-50, 4-55, 4-60, 5-10, 5-15, 5-20, 5-25, 5-30, 5-35, 5-40, 5-45, 5-50, 5-55, 5-60, 6-10, 6-15, 6-20, 6-25, 6-30, 6-35, 6-40, 6-45, 6-50, 6-55, 6-60, 7-10, 7-15, 7-20, 7-25, 7-30, 7-35, 7-40, 7-45, 7-50, 7-55, 7-60, 8-10, 8-15, 8-20, 8-25, 8-30, 8-35, 8-40, 8-45, 8-50, 8-55, 8-60, 9-10, 9-15, 9-20, 9-25, 9-30, 9-35, 9-40, 9-45, 9-50, 9-55, 9-60, 10-15, 10-20, 10-25, 10-30, 10-35, 10-40, 10-45, 10-50, 10-55, 10-60, 11-15, 11-20, 11-25, 11-30, 11-35, 11-40, 11-45, 11-50, 11-55, 11-60, 12-15, 12-20, 12-25, 12-30, 12-35, 12-40, 12-45, 12-50, 12-55, 12-60, 13-20, 13-25, 13-30, 13-35, 13-40, 13-45, 13-50, 13-55, 13-60, 14-15, 14-20, 14-25, 14-30, 14-35, 14-40, 14-45, 14-50, 14-55, 14-60, 15-20, 15-25, 15-30, 15-35, 15-40, 15-45, 15-50, 15-55, 15-60, 16-20, 16-25, 16-30, 16-35, 16-40, 16-45, 16-50, 16-55, 16-60, 17-20, 17-25, 17-30, 17-35, 17-40, 17-45, 17-50, 17-55, 17-60, 18-20, 18-25, 18-30, 18-35, 18-40, 18-45, 18-50, 18-55, 18-60, 19-20, 19-25, 19-30, 19-35, 19-40, 19-45, 19-50, 19-55, 19-60, 20-25, 20-30, 20-35, 20-40, 20-45, 20-50, 20-55, 20-60, 25-30, 25-35, 25-40, 25-45, 25-50, 25-55, 25-60, 30-35, 30-40, 30-45, 30-50, 30-55, 30-60, 35-40, 35-45, 35-50, 35-55, 35-60, 40-45, 40-50, 30-55, 40-60, 45-35, 45-50, 45-55, 45-60, 50-55, 50-60, 55-60 minutes).
[0053] In one embodiment, the oxygen-functionalized products are selected from the group consisting of alcohols, carboxylic acids, esters, carbonyls other than carboxylic acids and esters, and mixtures thereof. As used herein, the term alcohol includes both mono-alcohols and di-alcohols. In another embodiment, the oxygen-functionalized products are in liquid and/or wax form.
[0054] The heating step is optional; it can take place during all of the method, some of the method, or none of the method. In one embodiment, the heating is terminated once the reacting is initiated. In another embodiment, the heating continues during the reacting.
[0055] In one embodiment, the oxygen containing ionized gas plasma is air. For example, air can be compressed air from a tank source. In a further embodiment, the oxygen containing ionized gas plasma comprises oxygen. In another embodiment, the oxygen containing ionized gas plasma comprises carbon dioxide. In another embodiment, the oxygen containing ionized gas plasma comprises carbon dioxide and oxygen. In yet another embodiment, the oxygen containing ionized gas plasma comprises carbon monoxide.
[0056] The present application relates to decomposition of a polymeric reactant. Decomposition, or deconstruction, of a polymeric reactant refers to depolymerizing the polymeric reactant by breaking the covalent carbon-carbon bonds in the polymer to produce smaller parts, including monomers.
[0057] Polymeric reactants refer to synthetic or natural polymers capable of decomposition according to the methods described herein. A polymer refers to a chemical compound or mixture of compounds whose structure is constituted of multiple repeating units (i.e. monomers) linked by covalent chemical bonds. Within the context of the present application, the term polymer includes natural or synthetic polymers, comprising a single type of repeating unit (i.e., homopolymers) or different types of repeating units (i.e., block copolymers and random copolymers). In certain embodiments, the present application relates to decomposition of natural polymeric reactants. Natural polymers include lignin, polysaccharides, such as cellulose, hemi-cellulose, starch, and polyhydroxyalkanoates and derivatives thereof In certain embodiments, the present application relates to decomposition of synthetic polymeric reactants. As an example, synthetic polymers include polymers derived from petroleum oil, such as polyolefins, polystyrenes, aliphatic or aromatic polyesters, polyamides, polyurethanes and polyvinyl chloride.
[0058] In one embodiment, the polymeric reactant is a polyolefin. In another embodiment, the polyolefin can be selected from the group consisting of polyethylene, polypropylene, polybutylene, polystyrene, and mixtures thereof.
[0059] The polymeric reactant of the present application may be part of a polymeric waste material or portions thereof. The polymeric waste material may include at least 60%, 65%, 70%, 75%, 80%, 81%, 82%, 83%, 84%, 85%, 90%, 91%, 92%, 93%, 94%, 95%, 96%, 97%, 98%, 99%, or 100% of a polymeric reactant (or mixture thereof) as described herein. Polymeric waste material can be a heterogeneous mixture of a wide range of plastics. These materials can be obtained from industrial, commercial and residential garbage by initially removing the bulk of non-plastic contaminants such as dirt, spoiled food, paper, cloth and metals.
[0060] In one embodiment, the plasma-based conversion can be performed with a catalyst. Catalysts can be added to improve energy efficiency, control product selectivity, and increase conversion efficiency. Broad types of solid catalysts can be used, including but not limited to, zeolite catalysts, metal catalysts, metal oxides, and bi-functional catalysts.
[0061] Another aspect of the present application relates to a method of removing carbon dioxide and/or carbon monoxide from a gas mixture. This method comprises providing a gas mixture comprising carbon dioxide and/or carbon monoxide and/or oxygen and contacting the gas mixture with a polymeric reactant in an ionized gas plasma to remove carbon dioxide and/or carbon monoxide from the gas mixture and produce oxygen-functionalized products.
[0062] This aspect of the present application can be carried out using substantially the same procedures, materials, and equipment described above.
[0063] As will be understood, for any and all purposes, all ranges disclosed herein also encompass any and all possible subranges and combinations of subranges thereof. Any listed range can be easily recognized as sufficiently describing and enabling the same range being broken down into at least equal halves, thirds, quarters, fifths, tenths, and so on. As a non-limiting example, each range discussed herein can be readily broken down into a lower third, middle third and upper third, and so on. As will also be understood by one skilled in the art all language such as up to, at least, and the like include the number recited and refer to ranges which can be subsequently broken down into subranges as discussed above. Finally, as will be understood by one skilled in the art, a range includes each individual member.
[0064] The term and/or as used herein means that the listed items are present, or used, individually or in combination. In effect, this term means that at least one of or one or more of the listed items is used or present.
[0065] Preferences and options for a given aspect, feature, embodiment, or parameter, unless the context indicates otherwise, should be regarded as having been disclosed in combination with any and all preferences and options for all other aspects, features, embodiments, and parameters described in this application.
[0066] The above disclosure is general. A more specific description is provided below in the following examples. The examples are described solely for the purpose of illustration and are not intended to limit the scope of the present application. Changes in the form and substitution of equivalents are contemplated as circumstances suggest or render expedient. Although specific terms have been employed herein, such terms are intended in a descriptive sense and not for the purposes of limitation.
EXAMPLES
[0067] The following Examples are presented to illustrate various aspects of the present application, but are not intended to limit the scope of the claimed application.
Example 1CO.SUB.2., Air, and Argon as Plasma Gas
[0068] Materials and Methods
[0069] Virgin high-density polyethylene (PE) was purchased from Yangli Tech Company (China) in powder form. All HPLC-grade solvents were purchased from Fisher Scientific. High-purity GC carrier gases were purchased from Airgas, and standard gases and gas mixtures were purchased from Praxair. The standard chemicals of alkanes (C.sub.6-C.sub.40), alkenes (C.sub.5-C.sub.23), dienes (C.sub.6-C.sub.14), alcohols (C.sub.6-C.sub.30), carboxylic acids (C.sub.6-C.sub.24) and carbonyl (C.sub.6-C.sub.18) compounds used for the GCMS calibration were purchased from Fischer Scientific, Thermo Scientific, TCI America, and Sigma Aldrich.
[0070] A tubular dielectric barrier discharge (DBD) reactor was made of quartz. A tungsten rod at the center of the reactor is used as a high electric electrode. The outer surface of the reactor was covered by a copper sheet, which acts as a grounded electrode. The reactor and electrodes were inserted into another quartz tube with a larger diameter. A coil heater and insulation material were wrapped around the external quartz tube. The high-voltage electrode was connected to an AC power supply (Suman Company, CTP-2000K) to actuate plasma. Electric voltage and current were also measured using a high voltage probe (i.e., P6015A from Tektronix) and a high response current probe (Pearson Electronics, Inc., Pearson 2877). The electric currentvoltage waveform was monitored using an oscilloscope (RIGOL DS1074Z). About 150 mg of HDPE was placed inside the reactor. Prior to applying plasma, the reactor was heated externally using the heater to melt plastics. Once the reactor temperature reached a preset temperature, the heater was turned off and plasma power source was turned on to initiate plasma. The ambient temperature gas was supplied to the reactor. The outlet of the plasma reactor was connected to a condenser cooled by dry ice to quench vapor products. The non-condensable gases were collected by a gas bag. After conversion, the solids remaining inside the reactor and the products collected in the condenser were weighed. Their yields were reported per initial mass of PE. The reaction time is accounted from the moment the plasma was turned on.
[0071] The liquid products were analyzed using GC/MS-FID. Agilent 7890B gas chromatograph (GC) equipped with Agilent 5977A mass spectrometer (MS) and a flame ionization detector (FID) was used to analyze liquid products. Two ZB-1701 capillary columns (60 m?0.250 mm?0.250 ?m) were used in the GC. Initially, the GC oven temperature was held at 40? C. for 3 minutes and then heated to 280? C. at 4? C. min.sup.?1. Finally, the oven was held at 280? C. for additional 4 minutes. The GC inlet temperature was maintained at 280? C. The flow rate of helium gas was 1 mL min?1, and the split ratio at the GC inlet was 20:1. The temperature of the FID detector was 280? C., and hydrogen and airflow rates were 5 mL min.sup.?1. The standard chemicals of alkanes (C.sub.6-C.sub.40), alkenes (C.sub.5-C.sub.23), dienes (C.sub.6-C.sub.14), alcohols (C.sub.6-C.sub.30), carboxylic acids (C.sub.6-C.sub.24) and carbonyl (C.sub.6-C.sub.18) compounds used for the GCMS calibration were purchased from Fischer Scientific, Thermo Scientific, TCI America, and Sigma Aldrich.
[0072] Elemental analysis was performed using a CHNS Elemental Analyzer (Vario Micro Cube). Carbon, hydrogen, and nitrogen contents in the sample were measured, and oxygen content was calculated by mass difference.
[0073] Results and Discussion
[0074] Comparison of CO.sub.2 , Air, and Argon as Plasma Gas
[0075] During the initial thermal heating of the reactor prior to applying plasma, plastics only melted because the reactor temperature was insufficient to decompose PE. After plasma was initiated, PE decomposition and the evolution of volatiles were observed.
[0076]
[0077] The product group mass selectivity based on GC/MS (
[0078] Effect of Initial Reactor Temperature
[0079] In this work, the reactor was thermally heated prior to plasma initiation although thermal heating was terminated once the plasma was initiated. While preheating the reactor is not always necessary depending on the plasma power source and incoming gas temperature, there are several benefits for preheating the reactor in this work. Higher initial reactor temperature can lower the voltage requirement for dielectric breakdown and increase the plasma intensity. Preheating can also melt plastics and more uniform plasma could be applied to molten plastics. Thus, the effect of initial reactor temperature was studied by comparing an initial reactor temperature of 300, 350, and 400? C. using CO.sub.2 plasma. The dependency of the reactor temperature profile on the initial reactor temperature was straightforward. When the initial reactor temperature was 300? C., the reactor temperature throughout the reaction was lower than the higher temperature cases (
Example 2CO.SUB.2 .and CO.SUB.2./O.SUB.2 .as Plasma Gas
[0080] Materials and Methods
[0081] Virgin high-density polyethylene (PE) was purchased from Yangli Tech Company (China), while post-consumer (PC-PE) was collected from material recovery facilities with further processing by cryo-milling and ultrasonic washing before use. All HPLC-grade solvents (dichloromethane, toluene, pyridine, and tetrahydrofuran) were purchased from Fisher Scientific. High-purity GC carrier gases were purchased from Airgas. The silylation agent (N, O-Bis(trimethylsilyl)trifluoroacetamide with trimethylchlorosilane) for identification of carboxylic acid and alcohols compounds, and NMR relaxation agent (Chromium (III) acetylacetonate) were supplied by Sigma Aldrich. High-purity standard gases (CO, CO.sub.2, H.sub.2, O.sub.2) and light hydrocarbon gases were purchased from Praxair. Isotopic .sup.13CO.sub.2 was supplied by Cambridge Isotopes Laboratories, Inc. The standard chemicals of alkanes (C.sub.6-C.sub.40), alkenes (C.sub.5-C.sub.23), dienes (C.sub.6-C.sub.14), alcohols (C.sub.6-C.sub.30), carboxylic acids (C.sub.6-C.sub.24) and carbonyl (C.sub.6-C.sub.18) compounds used for the GCMS calibration were purchased from Fischer Scientific, Thermo Scientific, TCI America, and Sigma Aldrich.
[0082] Plasma-Based Conversion Experiment
[0083]
[0084] Initially, the reactor was briefly heated externally by a heater for about 4 min until the internal reactor gas temperature reached 350? C. so that the plastics were melted onto the reactor wall. After the temperature reached the set temperature, the heater was turned off, followed by turning on the plasma generator so that plasma became the sole energy source. The reaction was carried out under atmospheric pressure, and reaction time was calculated from the moment the plasma generator was turned on. The gas temperature inside the reactor was measured by quickly inserting a thermocouple into the reactor via the gas inlet at each time point to collect temperature data. The system was kept insulated during the entire conversion. The vapors and gases leaving the reactor at the other end were passed through a two-stage condenser cooled with methanoldry ice mixtures to collect liquids before non-condensable gases entered a micro-GC for gas analysis. The reactor outlet gas flow was continuously measured downstream of the condenser using the high-accuracy universal gas flowmeter during the reaction. The current and voltage were monitored during the reaction using an oscilloscope to determine plasma power. The reactor, condenser, and connector were weighed before and after the conversion using an analytical balance with an accuracy of 0.0001 g (Veritas, M124AS) to determine the masses of the liquids and solid residues. For liquid analysis, the liquid products (see
[0085] For converting a model compound using isotopic .sup.13CO.sub.2 plasma, the experiment was carried out using a sealable DBD plasma reactor. The reactor had similar dimensions to the above-mentioned plasma reactor, except it had inlet and exit valves. In the beginning, about 0.15 g of Eicosane (C.sub.20H.sub.42) was placed in the reactor and purged with regular CO.sub.2 to remove residual air. The compound was then melted at 60? C. and cooled down. The inlet valve of the reactor was closed after CO.sub.2 purging, and the exit valve was connected to a vacuum source to remove the purging gas. Subsequently, the exit value was closed, and the inlet valve was opened to fill the reactor with .sup.13CO.sub.2 gas. Subsequently, both valves were closed, and the plasma power source was turned on. After conversion, the products inside the reactor were collected by a toluene and pyridine solvent mixture (2.5/1.5 v/v). Eicosane was also converted using regular CO.sub.2 as plasma gas to collect products, aiding product identification during the isotopic tests.
[0086] Characterization Methods
[0087] High-Temperature Gas Chromatography with Mass Spectrometry and Flame Ionization Detector (HT-GC/MS-FID)
[0088] The liquid products were analyzed using HT-GC/MS-FID. Before analysis, the samples in a dissolving solvent were derivatized by adding 200 ?L of the BSTFA silylation agent to 3 mL of the solution and agitated for 60 min at 60? C. In this GC system (Agilent 7890Bs) with MS (MS 5977A, Agilent, USA) and FID, two high-temperature columns (400? C., Phenomenex ZB-5HTs, 60 m?250 ?m?0.25 ?m) were used. The GC oven temperature was initially kept at 40? C. for 3 min, increased to 400? C. with a heating rate of 3? C./min, and held at 400? C. for another 5 min. The GC/MS was also configured with a Polyarc reactor (Polyarc System, Activated Research Technologies, Inc., USA) in the front of the FID to provide a carbon mass-based response for the detected analytes irrespective of their functional group or boiling point. The helium gas flow rate in the columns was 1 mL/min, and the split ratio at the GC inlet was 20:1. The temperature of the FID detector was set at 375? C. Agilent MassHunter software was used to process the GC chromatograms and measure peak areas. The compounds in the liquid products were identified using a combination of tools, including the NIST MS spectral and mass ion database. High-purity standards of alkane, alkene, alcohol, diol, carboxylic acid, and aldehyde were injected into the GC to aid MS identification. Five different concentrations of the alkane standards were injected to calibrate the Polyarc-FID for liquid product quantification. Since the Polyarc-FID calibration is based on carbon response, the calibration factor from a particular carbon number of alkane can be used for any compound containing the same number of carbons. The resultant calibration curves had regression coefficients higher than 0.99.
[0089] In all liquid samples, individual products up to C.sub.28 carbon number could be quantified due to their good peak separations in the MS chromatograms. At >C.sub.28 compound region, co-elution of different class compound peaks was noticed in some liquid samples for higher molecular weight products. In this case, the mass yield of >C.sub.28 compounds was determined by the mass difference of total gravimetric liquid yield and the sum of GC-quantified compound yields (up to C.sub.28). In these limited cases, the functional group selectivity of compounds up to C.sub.28 was considered for the entire liquid product.
[0090] Gas Analysis
[0091] The gas products were analyzed online using the Varian CP4900 micro-GC system (Varian, Inc., now owned by Agilent Technologies). In the GC oven, four different columns were connected to four different thermal conductivity detectors (TCD). The first TCD quantifying H.sub.2, CH.sub.4, CO, and O.sub.2 used argon as a carrier gas, while the rest TCDs quantifying CO.sub.2 and other light hydrocarbons used helium as a carrier gas. Gas calibration was performed by injecting different volumes of the standard gas mixtures. Compass CDS software (Scion Instruments, UK) was used to operate, calibrate, and quantify the gaseous compounds. The gas product concentrations (v/v) were calculated using the calibration curves and the peak areas of the corresponding compound in TCD. The outlet flow rate of the reactor during the plasma conversion was used to measure the total gas product volume, which was then used to calculate the total mass of the inlet gas.
[0092] Elemental Analysis
[0093] Elemental analyses of the plastic feedstock and liquid products were performed using standard procedure in Elementar, vario MICRO cube (Elementar, Hanau, Germany) elemental analyzer and were triplicated. The element contents of C, H, N, and S were measured, while the oxygen content was calculated by subtracting C, H, N, and S contents from the total content.
[0094] Karl Fischer Analysis
[0095] Water content in liquid products was measured using a Volumetric Karl Fischer titrator (Mettler Toledo, model V30S) following the ASTM E203 Standard. About 0.04-0.06 g of samples were dissolved in 1 mL of Hydranal solvent (dry methanol), and the averages of triplicate measurements were reported.
[0096] Nuclear Magnetic Resonance (NMR)
[0097] .sup.13C Nuclear magnetic resonance (NMR) experiments for liquid samples were performed by Avance NEO-400 spectrometer. The NMR samples were prepared by adding 0.2 g of samples in 1 mL of chloroform-D solvent and a relaxation agent, 3M chromium (III) acetylacetonate, to improve the intensity of weak signals (Wang et al., Development of Quantitative .sup.13C NMR Characterization and Simulation of C, H, and O Content for Pyrolysis Oils Based on .sup.13C NMR Analysis, RSC Advances 10: 25918-25928 (2020), which is hereby incorporated by reference in its entirety). The sample mixtures were ultrasonicated for an hour before analysis. The .sup.13C NMR spectra were acquired using pulse sequence zgig at 25? C. with a relaxation delay of 2 seconds and 7200 scans over a total acquisition time of around 7 hours. Spectral widths f1 and f2 were 220 ppm and 12 ppm, with centers at 90 ppm and 5 ppm, respectively. The NEO-400 is operated using Topspin 4.0 software, and the NMR spectra were processed using MestReNova v14.3 software. The NMR peaks were assigned based on literature (Wang et al., Development of Quantitative .sup.13C NMR Characterization and Simulation of C, H, and O Content for Pyrolysis Oils Based on .sup.13C NMR Analysis, RSC Advances 10: 25918-25928 (2020); Partington et al., Quantitative Carbon Distribution Analysis of Hydrocarbons, Alcohols and Carboxylic Acids in a Fischer-Tropsch Product from a CO/TiO2 Catalyst During Gas Phase Pilot Plant Operation, Journal of Analytical Science and Technology 11: 42 (2020); Speight et al., 1H and 13C Solution- and Solid-State NMR Investigation into Wax Products from the Fischer-Tropsch Process, Solid State Nuclear Magnetic Resonance 39: 58-64 (2011); which are hereby incorporated by reference in their entirety). The selectivity of functional groups was calculated using the following equations adapted from the methods specified in literature (Partington et al., Quantitative Carbon Distribution Analysis of Hydrocarbons, Alcohols and Carboxylic Acids in a Fischer-Tropsch Product from a CO/TiO2 Catalyst During Gas Phase Pilot Plant Operation, Journal of Analytical Science and Technology 11: 42 (2020); Speight et al., 1H and 13C Solution- and Solid-State NMR Investigation into Wax Products from the Fischer-Tropsch Process, Solid State Nuclear Magnetic Resonance 39: 58-64 (2011); which are hereby incorporated by reference in their entirety). The peak areas of the carbons linked to the different functional groups in the liquid product are denoted by [A], [B], [C], [D], and [E] where [0098] [A]=peak area of RCH.sub.2OH (assigned 60-95 ppm), [0099] [B]=peak area of RCOOH (assigned 175-180 ppm), [0100] [C]=peak area of RCOH, RCOR and RCOOR (assigned 180-210 ppm), [0101] [D]=average of peak areas of RCH?CH.sub.2 (assigned 135-140 ppm) and RCH?CH.sub.2 (assigned 110-115 ppm), and [0102] [E]=peak area of RCH.sub.3 (assigned 10-20 ppm).
The .sup.13C-NMR selectivity of the different functional groups was calculated as follows:
[0103] Definitions for Product Yield, Selectivity and Energy Consumption
Liquid or solid yields based on the initial plastic mass are calculated as shown below:
Time-accumulative CO.sub.2 conversion up to the given reaction time is calculated as:
The mass yield of an individual gas compound per plastics are calculated as:
where gas compound mass is calculated using eq. (S12)
Mass of a gas compound=Mass fraction of the gas?Total mass of all gas products(S11)
The mass selectivity of individual gas compound among the total gas product was calculated as:
The yield of an individual liquid compound per initial plastic mass is calculated as:
The mass selectivity of a compound with a functional group in the liquid is calculated as:
For mass balance of the conversion system including all reactants, the calculations are given below:
[0104] External Energy Consumption in this Work
[0105] The external energy consumed during CO.sub.2/O.sub.2 plasma-based co-conversion is reported for converting two different PE mass loading and inlet gas flow rates using the original and scaled-up reactors. Since the plastic and inlet gases were heated briefly before applying plasma, the energy consumption included thermal energy and plasma energy. Thermal energy is the energy spent on the pre-plasma heating process, calculated by considering the sensible heats of CO.sub.2, O.sub.2, and PE from room temperature to 350? C., and the latent heat of PE melting. The plasma energy was measured during the conversion using the process mentioned in the methods section. In the reactor, the external energy input is used to heat the inlet gases (both converted and unconverted), heat plastics, convert the feed gases and plastics, and vaporize the products. Some energy was also lost through the reactor wall.
[0106] The total energy consumed per kg of feedstock (MJ/kg) is reported based on the following equation:
[0107] External Energy Consumption for Thermal Liquefaction Plants
[0108] The energy consumptions for the Niigata, Mikasa and Sapporo thermal liquefaction plants from Japan discussed above were calculated based on the energy balance provided in the reference (J. Scheirs and W. Kaminsky, Feedstock Recycling and Pyrolysis of Waste Plastics, J. Wiley & Sons (2006), which is hereby incorporated by reference in its entirety). Based on the plant in question, the process energy was from hybrid sources, either generated by burning a part of the pyrolysis oils and other fuels such as liquefied petroleum gas (LPG) and fuel gas or directly through electricity. The lower heating values of 47.1, 45.5 and 42.8 MJ/kg were used for calculating the process energy derived from fuel gas, LPG, and pyrolysis oil, respectively. Unless the process energy per converted mass (MJ/kg) was specified in literature directly, this number was calculated based on the total process energy (MJ) and plastic waste feed mass.
[0109] Results and Discussion
[0110] In this work, virgin high-density PE was first converted using a co-axial tubular dielectric discharge barrier (DBD) plasma reactor operating under a continuous-flow semi-batch configuration (
TABLE-US-00001 TABLE 1 Internal gas temperature in the plasma reactor and plasma power for different reaction conditions. All conditions used 0.15 g of PE sample. Plasma type Gas CO.sub.2 CO.sub.2/O.sub.2 Flow rate residence f V Time Power Temperature Power Temperature (mL/min) time, t.sub.R (s)* (kHz) (kV) (min) (W) (? C.) (W) (? C.) 50 13.19 8 12.5 0 0 350 10 49 232 12.5 47 221 15 46 212 17.5 46 201 20 44 181 50 13.19 8 15 0 0 350 0 350 2.5 107 382 88 388 5 102 357 85 364 7.5 101 319 84 324 10 98 286 84 293 50 13.19 8 17.5 0 0 350 2.5 136 459 5 138 406 7.5 138 368 50 13.19 7.5 15 0 0 350 2.5 98 370 5 97 349 7.5 98 304 10 96 274 50 13.19 8.5 15 0 0 350 2.5 108 398 5 109 379 7.5 115 357 10 118 312 32.5 20.29 8 15 0 0 350 0 350 2.5 99 388 82 393 5 97 370 79 378 7.5 100 338 77 345 10 100 317 65 10.15 8 15 0 0 350 2.5 93 367 5 90 333 7.5 91 301 10 90 271 12.5 90 245 15 89 223 *Calculated using the inlet gas flow rate, plasma discharge zone length, and the inner diameter of the reactor.
The time-dependent yields of solid residue remaining inside the reactor and liquid product collected outside of the reactor are shown in
TABLE-US-00002 TABLE 2 Reproducibility of the experiment using PE conversion by CO.sub.2 plasma and t.sub.R = 13 s as example. The reaction conditions: voltage 15 kV, frequency 8 kHz, CO.sub.2 inlet flow rate of 50 mL/min, initial reactor temperature 350? C., reaction time 10 min. CO.sub.2 Reactor mass (g) Condenser mass (g) conversion Test No PE mass (g) Before After Before After Liquid mass (g) Liquid yield (%) (%) 1 0.1532 26.2991 26.3065 180.4964 180.6585 0.1695 110.6 6.25 2 0.1481 26.5579 26.5993 169.8593 169.9832 0.1653 111.6 6.30 3 0.1528 26.7436 26.7846 181.8198 181.95 0.1712 112.0 6.27 Average (%) 111.4 6.27 Standard error (%) ?0.7% ?0.03%
[0111] In addition to the liquid products, PE conversion by CO.sub.2 or CO.sub.2/O.sub.2 plasma also produced gas products consisting of CO, O.sub.2, H.sub.2, and light hydrocarbons (C.sub.1-C.sub.5 alkanes and alkenes,
[0112] Liquid products from the PE conversion by CO.sub.2 or CO.sub.2/O.sub.2 plasma manifest as oily and waxy substances at room temperature. However, they transition into flowable liquids at 80? C. and display complete solubility in a mixture of toluene and pyridine (
TABLE-US-00003 TABLE 3 Characterization of liquids obtained from different feedstock and reaction conditions* Con- A B C D E F G H I dition* wt % wt % wt % wt % wt % wt % wt % wt % wt % Liquid 111.4 109.9 120.7 111.1 105.9 108.8 106.4 80.6 110.8 yield Product carbon number distribution C.sub.5-C.sub.12 28.2 50.1 64.4 60.1 39.6 22.4 39.2 15.6 56.7 C.sub.13-C.sub.20 23.4 24.4 37.1 32.7 33.3 21.9 25.2 13.1 29.2 C.sub.21-C.sub.28 22.6 19.2 13.2 15.6 20.1 21.2 27.1 12.0 16.5 C.sub.28+ 37.2 16.3 6.1 2.6 12.9 43.3 15.0 35.2 8.4 Elemental analysis (wt %) C (%) 80.9 79.6 76.7 77.0 82.3 81.2 80.6 82.8 76.8 H (%) 12.9 12.5 12.1 12.1 13.3 13.0 13.0 13.3 12.2 O (%) 6.2 7.8 11.2 10.9 4.8 5.8 6.3 3.9 11.0 *Reaction conditions A: PE, CO.sub.2 plasma, 50 mL/min or 13 s, 15 kV, 8 kHz, 10 min B: PE, CO.sub.2 plasma, 32.5 mL/min or 20 s, 15 kV, 8 kHz, 10 min C: PE, CO.sub.2/O.sub.2 plasma, 50 mL/min or 13 s, 15 kV, 8 kHz, 10 min D: PC-PE, CO.sub.2/O.sub.2 plasma, 50 mL/min or 13 s, 15 kV, 8 kHz, 10 min. E: PE, CO.sub.2 plasma, 50 mL/min or 13 s, 17.5 kV, 8 kHz, 7.5 min F: PE, CO.sub.2 plasma, 50 mL/min or 13 s, 15 kV, 7.5 kHz, 10 min G: PE, CO.sub.2 plasma, 50 mL/min or 13 s, 15 kV, 8.5 kHz, 10 min H: PE, CO.sub.2 plasma, 65 mL/min or 10 s, 15 kV, 8 kHz, 12.5 I: PE, CO.sub.2/O.sub.2 plasma, 32.5 mL/min or 20 s, 15 kV, 8 kHz, 7.5 min In the above, the initial reactor temperature is 325? C. for the case D and 350? C. for the rest cases.
The water content was negligible in all three liquids (<0.7%, Table 4). These results combine to show that oxidative depolymerization of PE using CO.sub.2 plasma was successful, where increasing t.sub.R or using CO.sub.2/O.sub.2 plasma promotes oxygenated products.
TABLE-US-00004 TABLE 4 Moisture content of liquid products obtained from PE or PC-PE conversion using CO.sub.2 plasma or CO.sub.2/O.sub.2 plasma. Reaction conditions: 15 kV, 8 kHz, 10 min, t.sub.R is given. PE PC-PE t.sub.R = 20 s t.sub.R = 13 s t.sub.R = 13 s CO.sub.2 plasma CO.sub.2 plasma CO.sub.2/O.sub.2 Plasma CO.sub.2/O.sub.2 Plasma Moisture 0.6 0.2 0.5 0.7 (%)
[0113] The chemical compositions of the liquids were analyzed using high-temperature gas chromatogram/mass spectrometry (HT-GC/MS). Overall, the liquids produced with a higher t.sub.R or using CO.sub.2/O.sub.2 plasma instead of CO.sub.2 plasma exhibited narrower molecular weight distributions of shorter-carbon chain-length compounds attributing to the higher degrees of bond cleavages in PE (the GC/MS chromatograms compared in
[0114] The selective production of fatty alcohols by CO.sub.2/O.sub.2 plasma was further confirmed by conducting .sup.13C NMR analysis on the liquids (
TABLE-US-00005 TABLE 5 .sup.13C NMR-based functional group selectivity of liquids produced from PE using CO.sub.2 and CO.sub.2/O.sub.2 plasma. Reaction conditions: 15 kV, 8 kHz, 10 min. t.sub.R is 20 s for CO.sub.2 plasma, and 13 s for CO.sub.2/O.sub.2 plasma. Plasma type Functional Group CO.sub.2 CO.sub.2/O.sub.2 Alcohols 54.3 74.9 Carboxylic acids 16.2 5.1 Other oxygenated compounds 3.3 1.6 Hydrocarbons 26.2 18.5
[0115] As shown above, CO.sub.2 could initiate oxidative PE depolymerization, forming oxygenated chemicals and producing CO gas. On the other hand, the effect of PE on CO.sub.2 conversion was evaluated by converting pure CO.sub.2 or the CO.sub.2/O.sub.2 mixture gas in an empty plasma reactor to determine CO.sub.2 conversion without PE. CO.sub.2 conversions with PE co-present inside the reactor are higher than those without PE in all the tested cases (
[0116] Plasma discharge causes CO.sub.2 and O.sub.2 (in the case of CO.sub.2/O.sub.2 plasms) to generate a series of carbon and oxygen-containing species. During the co-conversion, PE also produces hydrogen and hydrocarbon fragments if varying chain lengths. Although PE, CO.sub.2, and O.sub.2 can form a complex mixture of species inside the plasma reactor, the resultant products displayed a high selectivity towards specific functional groups. Therefore, multiple reactions involving different plasma species most likely funneled down to the same type of products. The interactions between CO.sub.2 and PE were investigated in this work by converting isotopic .sup.13CO.sub.2 and eicosane (as a model compound of PE) by plasma. The CO.sub.2-originated carbon atoms in the compounds were tracked by analyzing the liquid product using GC/MS and comparing the mass-to-charge ratios (m/z) of the compounds resulting from the isotopic test with that of the corresponding standard compounds. Despite .sup.13CO.sub.2 being more difficult to dissociate than regular CO.sub.2 (Zeng et al., Carbon Isotope Effects in the Artificial Photosynthesis Reactions Catalyzed by Nanostructured Co/CoO, Chemical Physics Letters 754: 137731 (2020), which is hereby incorporated by reference in its entirety), .sup.13C carbons were successfully identified in the conversion products (See
[0117] Isotopic Study for the Reaction Mechanism
[0118] CO.sub.2-based plasma conversions of model compound (eicosane) were carried out using .sup.13CO.sub.2 to distinguish CO.sub.2-originated carbon and plastic-originated carbon in the products. The model compound was also converted using regular .sup.12CO.sub.2 plasma to aid product identification in GC/MS. The number of CO.sub.2-originated carbons and their possible positions in a molecule were determined by comparing the mass-to-charge ratio (m/z) of the .sup.13CO.sub.2 plasma-based molecule in its mass spectra (MS) and that of the corresponding regular molecule obtained using regular CO.sub.2 plasma or NIST library database. When one .sup.12C atom in a molecule having m/z=M is substituted by one .sup.13C atom, it would cause an increase of the m/z value by one mass unit (m/z=M+1). In this work, .sup.13C carbons were observed in product compounds with four different functional groups (e.g., hydrocarbon, alcohol, carboxylic acid, and carbonyl). The results are discussed below using representative compounds found in liquid product analysis.
[0119] Hydrocarbon
[0120]
[0121] Alcohol
[0122]
[0123] Carboxylic Acid
[0124]
[0125] The fragment peaks were also considered to locate the position of the .sup.13C atoms in the molecule. Both spectra (
[0126] Carbonyl
[0127]
TABLE-US-00006 TABLE 6 m/z peak intensity ratios of palmitic acid, TMS derivative, and arachidonic acid, TMS derivative for their regular molecules and .sup.13CO.sub.2 plasma-based molecules. Entry m/z Regular .sup.13CO.sub.2 plasma-based Palmitic acid, TMS derivative 1 118/117 9.8% 10.3% 2 119/117 4.0% 5.5% 3 314/313 24.1% 24.2% 4 315/313 6.4% 6.1% 5 329/328 27.3% 29.1% 6 330/328 7.9% 13.4% Arachidonic acid, TMS derivative 7 118/117 14.7% 91.1% 8 119/117 43.0% 53.2%
TABLE-US-00007 TABLE 7 m/z peak intensity ratios of 9-octadecanone for the regular molecule and .sup.13CO.sub.2 plasma-based molecule. Entry m/z Regular .sup.13CO.sub.2 plasma 1 142/141 13% 50.9% 2 143/141 0% 24.5%
[0128] Based on the isotopic test results, the possible reaction mechanisms of PE and CO.sub.2 co-conversion are proposed in
[0129] PE-derived H and CO.sub.2-derived O could form OH, which can further combine hydrocarbon radicals to produce fatty alcohols (eq. (4)). The CO.sub.2-originated C atom linked to the OH in alcohols was also detected in the isotope results (
[0130] CO and OH can react with hydrocarbon radicals to form fatty acids (eqs. (6)-(7)) (Martini et al., Oxidation of CH.sub.4 by CO.sub.2 in a Dielectric Barrier Discharge, Chemical Physics Letters 593: 55-60 (2014); Yu et al., A Theoretical Study of the Potential Energy Surface for the Reaction OH+CO.fwdarw.H+CO.sub.2, Chemical Physics Letters 349: 547-554 (2001); which are hereby incorporated by reference in their entirety). The metastable CO.sub.2 and H could directly react with the hydrocarbon radicals to form the acids. However, this route has a much higher energy barrier than the previous route (Yu et al., A Theoretical Study of the Potential Energy Surface for the Reaction OH+CO.fwdarw.H+CO.sub.2, Chemical Physics Letters 349: 547-554 (2001); Wang et al., A DFT Study of Synthesis of Acetic Acid From Methane and Carbon Dioxide, Chemical Physics Letters 368: 313-318 (2003); which are hereby incorporated by reference in their entirety). Carbonyl products are generated from O bonding with the hydrogen-abstracted hydrocarbon radicals (eq. (8)) or carbonylation reactions of CO with hydrocarbon radicals (eq. (9)). The isotope results confirmed the CO.sub.2-originated C atoms in carboxylic (COOH) (
[0131] The above work shows that the co-conversion of CO.sub.2 and PE by plasma was highly effective in synergistically promoting the conversion of both CO.sub.2 and PE while chemically storing CO.sub.2 into valuable platform chemicals using PE is a carbon sink.
TABLE-US-00008 TABLE 8 Mass closures of plasma-based co-conversion of plastics and CO.sub.2 including all reactants and measured products. The gas, liquid and solid residue yields are calculated based on the total reactant masses, which are converted PE and CO.sub.2 for the CO.sub.2 plasma case, and converted PE, CO.sub.2 and O.sub.2 for the CO.sub.2/O.sub.2 plasma cases. Solid Gas Liquid Residue Total Plastic t.sub.R Plasma (%) (%) (%) (%) PE 20 s CO.sub.2 13.4 83.5 0.0 96.9 PE 13 s CO.sub.2/O.sub.2 10.3 87.7 0.6 98.6 PC-PE 13 s CO.sub.2/O.sub.2 9.8 82.1 1.8 93.7
[0132] The applicability of the plasma-based co-conversion was evaluated using waste plastics as the feedstock. Mix-colored post-consumer PE (PC-PE) collected from a material recovery facility was washed and sized before conversion (
[0133] The potential for broader adaptation and applicability of the co-conversion concept was further evaluated by measuring external energy consumption for CO.sub.2/O.sub.2 plasma-based conversion using two different feedstock loadings and reactor sizes. A 107.8 wt % of liquid was obtained by converting 1 g of PE for 7.5 min in a larger reactor, compared to 120.7 wt % liquid produced after 10 min with 0.15 g PE in the original reactor. Meanwhile, external energy consumption dropped drastically in the reactor with higher PE and gas flow rate, from 237.2 MJ/kg with 0.15 g PE to 44 MJ/kg with 1 g PE, partially attributed to more effective utilization of plasma discharge zone for converting larger feedstock masses in the larger reactor (Table 9). It is common knowledge that process energy strongly depends on the conversion scale and decreases as it increases. Literature reported the external energy consumed for pyrolyzing plastics at a bench scale reactor to be 118 MJ/kg for PP at 1.007 kg/h plastic feed rate, 77.6 MJ/kg at 1.496 kg/h, and 35.2 MJ/kg at 3.088 kg/h for polypropylene-polyethylene terephthalate (PP-PET) films (Kodera et al., Energy- and Economic-Balance Estimation of Pyrolysis Plant for Fuel-Gas Production from Plastic Waste Based on Bench-Scale Plant Operations, Fuel Communications, 7: 100016 (2021), which is hereby incorporated by reference in its entirety). The same literature reported that the energy consumption of plastic pyrolysis decreases substantially in a commercial plant operation, estimating 9.9 MJ/kg for PP-PET films at a plastic feed of 200 kg/h. Another literature reported the energy demand for three Japanese thermal liquefaction plants converting waste plastics (see Section E of the Supplementary text for additional information) to be 21.1, 22.8, and 20.1 MJ/kg, respectively, for a feedstock capacity of 6000 tons/yr (or ?$2300 kg/h, when 320 days/year and 8 h/day reactor operation is assumed (J. Scheirs and W. Kaminsky, Feedstock Recycling and Pyrolysis of Waste Plastics, J. Wiley & Sons (2006), which is hereby incorporated by reference in its entirety). The energy consumption rate in this work for converting much smaller feed mass was already comparable to other conventional conversion technologies for waste plastics and also the energy consumption showed a decrease as the feed mass increased, suggesting potentially higher energy efficiencies for plasma-based co-conversion if scaled up. Future studies will focus on innovative reactor designs and efficient feedstock feeding mechanisms to increase throughput while ensuring effective interactions among feedstocks under plasma discharge, which are essential in scaling the technology.
TABLE-US-00009 TABLE 9 Energy consumption of PE conversion by CO.sub.2/O.sub.2 plasma in two different reactors. Reaction conditions: Run A - 50 mL/min CO.sub.2 with 8% v/v O.sub.2, 15 kV, 8 kHz, 10 min; Run B - 100 mL/min CO.sub.2 with 12% v/v O.sub.2, 15 kV, 7 kHz, 7.5 min; time required to preheat to 350? C. is 4 min for Run A and 7 min for Run B. Run A Run B PE (kg) 1.55 ? 10.sup.?4 1.015 ? 10.sup.?3 Converted CO.sub.2 (kg) 3.8 ? 10.sup.?5 1.08 ? 10.sup.?4 Converted O.sub.2 (kg) 2.1 ? 10.sup.?5 3.0 ? 10.sup.?5 Thermal energy (for pre-plasma 3.02 ? 10.sup.?4 1.479 ? 10.sup.?3 heating) (MJ) CO.sub.2: sensible heating* 1.57 ? 10.sup.?4 5.24 ? 10.sup.?4 O.sub.2: sensile heating* .sup.8 ? 10.sup.?6 4.3 ? 10.sup.?5 PE: sensile heating 1.1 ? 10.sup.?4 7.31 ? 10.sup.?4 PE: latent heating for melting 2.7 ? 10.sup.?5 1.82 ? 10.sup.?4 Plasma energy (MJ) 5.0303 ? 10.sup.?2 4.9234 ? 10.sup.?2 Total energy consumption (MJ) 5.0604 ? 10.sup.?2 5.0713 ? 10.sup.?2 Energy consumption per feeds 237.23 43.97 (MJ/kg) *Calculated for the total flow-in CO.sub.2 or O.sub.2 gas mass at the inlet during the pre-plasma heating stage
[0134] The state-of-the-art technologies for chemically upcycling polyolefins to platform chemicals usually require harsh reaction conditions, costly reactants, catalysts, toxic chemicals, or multi-step processes. In this context, the presented non-catalytic low-temperature plasma approach can selectively convert waste plastics into valuable chemicals in a single step using waste CO.sub.2 as the co-reactant. Based on this approach, while the oleochemicals and aliphatic hydrocarbon products can be used as platform chemicals for various applications, the CO in the gas stream can be used for chemical synthesis, or as an energy source. When the gas product is used for energy, CO.sub.2 produced after the gas combustion can be recycled in the plasma reactor. Moreover, CO.sub.2/O.sub.2 mixture gases could achieve higher product selectivity in this work, suggesting pure CO.sub.2 gas is not required for this closed-loop conversion. Another compelling aspect of this approach is that the co-conversion process relies only on electricity to generate plasma, offering an opportunity to leverage increasingly abundant, low-cost renewable electricity generated from winds or solar to reduce carbon emissions and achieve a truly green upcycling of plastics and greenhouse gas sequestration. In future work, techno-economic analysis and life cycle assessment of the co-conversion approach for various final product compositions will be studied based on different electricity source scenarios (renewable vs. fossil-based). Overall, this study provides a promising solution to mitigate two major environmental problems by utilizing waste plastics and CO.sub.2 in a circular carbon approach.
[0135] Thermal Effect on Plastic Conversion
[0136] Before plasma actuation started, the reactor was externally heated to 350? C. to melt plastic powders. The molten plastic mass right before applying plasma was the same as the initial PE mass, confirming no plastic decomposed during the preheating process. Although external heating was removed after the plasma actuation, the gas temperature inside the insulated reactor was higher than room temperature (Table 1) due to the mild joule heating during the plasma discharge. This thermal effect during the plasma-based conversion was evaluated by using a heater to maintain the reactor temperature at 350? C. or 400? C. without applying plasma. With a CO.sub.2 flow of 50 mL/min (or t.sub.R=13s) and a 20 min thermal heating without plasma, 95 or 88 wt % of PE remained unconverted. These results align with previous knowledge that the thermal decomposition of polyolefins requires much higher temperatures (Aboulkas et al., Thermal Degradation Behaviors of Polyethylene and Polypropylene. Part I: Pyrolysis Kinetics and Mechanisms, Energy Conversion and Management 51: 1363-1369 (2010), which is hereby incorporated by reference in its entirety). Since the measured reactor gas temperature during the plasma-based conversion was between 300 and 400? C. for most cases, this thermal heating-based test result suggests that the joule heating alone had a negligible effect on PE conversion. However, the gas temperature inside the plasma reactor can indirectly affect plastics and CO.sub.2 conversion by influencing the intensity of plasma discharge. Stronger plasma discharge can be obtained with the same voltage and frequency conditions when the gas temperature is higher.
[0137] Parametric Study on Plastic Conversion
[0138] The effect of experimental conditions on plasma-based conversion is discussed in this section for CO.sub.2 plasma.
The effect of voltage during PE conversion by CO.sub.2 plasma was studied using three voltages (12.5 kV 15 kV, and 17.5 kV) at a constant gas flow rate of 50 mL/min (t.sub.R=13s) and frequency of 8 kHz. The reactor gas temperature was lowest (Table 1) and PE conversion was minimal with the 12.5 kV case (
[0139] The frequency effect was studied by carrying out PE conversion using CO.sub.2 plasma with three different frequencies (7.5 kHz, 8 kHz, and 8.5 kHz) at a constant gas flow rate of 50 mL/min (t.sub.R=13s) and 15 kV. The frequency effect was similar to the voltage effect described above; an increase in frequency caused increases in the reactor gas temperature (Table 1) and PE conversion rate (
[0140] The effect of gas residence time (t.sub.R) was studied using the gas flow rates of 32.5, 50, and 65 mL/min using a fixed voltage (15 kV) and frequency (8 kHz), which correspond to t.sub.R=20s, 13s and 10s, respectively. Compared to the two cases with higher t.sub.R, the reactor gas temperature and PE conversion rate were both lower for the t.sub.R=10s case (Table 1 and
[0141] For the CO.sub.2/O.sub.2 plasma case, the gas flow rates of 32.5 mL/min (t.sub.R=20s) and 50 mL/min (t.sub.R=13s) were studied under the optimized plasma discharge conditions of 8 kHz and 15 kV. PE devolatilization was completed within 7.5 min for the t.sub.R=20s case (
[0142] The synergistic enhancement of CO.sub.2 conversion by PE was compared for different plasma conditions in
[0143] Although preferred embodiments have been depicted and described in detail herein, it will be apparent to those skilled in the relevant art that various modifications, additions, substitutions, and the like can be made without departing from the spirit of the invention and these are therefore considered to be within the scope of the invention as defined in the claims which follow.