BR102022006256A2 - SYSTEM FOR ENERGY EFFICIENT TRANSFORMATION OF VARIOUS PLASTIC WASTE INTO HYDROCARBONS, PROCESS FOR ENERGY EFFICIENT TRANSFORMATION OF VARIOUS PLASTIC WASTE INTO HYDROCARBONS, HYDROCARBONS, AND THEIR USES - Google Patents

Abstract

The present invention refers to a system and a process for energy-efficient transformation of varied plastic waste into hydrocarbons in liquid, pasty, solid and gaseous form for applications in products in the value chain of the circular economy of plastic.

Description

SYSTEM FOR ENERGY EFFICIENT TRANSFORMATION OF VARIOUS PLASTIC WASTE INTO HYDROCARBONS, PROCESS FOR ENERGY EFFICIENT TRANSFORMATION OF VARIOUS PLASTIC WASTE INTO HYDROCARBONS, HYDROCARBONS, AND THEIR USES FIELD OF THE INVENTION

[001] The present invention is part of the field of waste processing, more precisely in the area of reuse and conversion of waste materials into recycled products and describes an energy efficient system and a process for transforming various plastic waste into recycled hydrocarbons in liquid form , pasty, solid and gaseous for use in various applications as a substitute for fossil and non-fossil products preferably applied in the circular economy of the plastics chain, such as, r-naphtha as a recycled raw material substitute for fossil naphtha as an input for the petrochemical industry, r-light hydrocarbons used as substitutes for chemical inputs of fossil origin, r-light and heavy paraffins to replace fossil paraffins used in industrial use or in use in personal application products, r-carbon black recycled to replace carbon black fossil. Some by-products may also have other applications, such as products used in applications in the energy area, such as r-diesel, as a substitute for fossil diesel, r-waste recycled gas to replace fossil gases and electricity from renewable sources, in addition to other r -hydrocarbons as recycled raw materials used to replace solid hydrocarbons.

FUNDAMENTALS OF THE INVENTION

[002] The intense generation of solid waste represents one of the greatest challenges today. Due to economic and population growth and technological advances, a greater amount of waste is produced and natural resources become increasingly scarce.

[003] Thanks to technological advances, many products are discarded even before the end of their useful life, which increases the already significant load of solid waste that must be handled by the public authorities. In addition, the accelerated and constant industrial production of different sectors has also generated a high amount of waste in Brazil and in the world.

[004] In parallel, more severe legislation, such as the National Solid Waste Policy (PNRS), has led companies to assume responsibility for the environmental consequences of their operations. Such responsibilities include the environmental impact caused by waste generated in the production process.

[005] In this way, in view of the constant population growth and the accelerated development of the industrial sectors, it becomes necessary to seek solutions and innovations for the management and adequate final destination of the solid waste generated. The option of reusing waste as raw material for other industries can be an attractive possibility, as it can generate a reduction in financial expenses and environmental impacts, in addition to increasing the production chain with the creation of new jobs.

[006] In addition, it is known that most of the products we currently consume are made or packaged in plastic: packaging, toys, furniture, fabrics and automobiles are just a few examples. The use of the material revolutionized the industry, but also created a major challenge for the planet: the accumulation of plastic waste.

[007] The reuse of plastic waste still has a low rate when compared to the reuse of metallic waste. Plastic recycling in Brazil is around 20%.

[008] In this context, techniques and strategies are created in order to help the problem of generation and accumulation of waste. Employing plastic reuse methods is an urgent matter for industries that believe that sustainable development is possible, seeking a balance between economic growth and respect for the environment.

[009] The currently available plastic waste recovery processes focus on pure rigid plastics, making plastics in the form of films, flexible plastics, multilayer plastics or those that have several components in their composition do not have economically viable recycling routes. It is, therefore, essential to develop technologies that allow the valuation of flexible, multilayer or multicomponent plastic material through the transformation of these materials into products that have a quality that replaces traditional fossils and economic value that justifies the costs used in this transformation, promoting thus the circular economy.

[010] In general, plastic transformation processes developed or under development seek to produce hydrocarbons with the aim of generating energy or with the aim of producing different oils instead of reinserting the product as a raw material for chemical companies. Some processes that sought to produce materials, focused on the production of inputs for refineries and not on the production of raw materials directly applicable in chemical production processes.

[011] An additional important challenge to be overcome is the economic feasibility of transforming plastic waste into products. To achieve this viability, it is essential that production systems are efficient, particularly in energy consumption and in the ability to absorb raw materials with great variability and still deliver products that meet strict specifications.

STATE OF THE TECHNIQUE

[012] Some state-of-the-art documents describe ways to treat plastic waste to generate new products, for example:
Document US 10131847 describes a process for treating waste plastic material to provide at least one combustible product according to specifications. The plastic material is melted in an extruder and loaded into a pyrolysis reactor, which follows a batch process, and has an oxygen-free atmosphere to thermally degrade the material and thus form pyrolysis gases. The pyrolysis gases are brought into contact with the plates in a contactor vessel, so that some long-chain gas components are condensed and returned to be pyrolyzed again to achieve thermal degradation. Short chain gas components exit the contactor in gaseous form and proceed to distillation to provide one or more fuel products according to specifications. A pipe directly connects the pyrolysis chamber to the contactor, and is suitable for transporting upstream pyrolysis gases and long-chain liquid downflow for thermal degradation. Next, the pyrolysis gas undergoes a multi-step fractional distillation process using, among other elements, two distillation towers in series, one tower with atmospheric pressure and the other vacuum with a high volume of liquid recirculation.

[013] Thus, the present invention has the following advantages when compared to said document: i. Use of thermo-catalytic degradation as a way to ensure better product quality by facilitating the fractionation process; ii. Process uses extended batches and continuous feeding/production with fast discharges, increasing reactor productivity and reducing incrustations; iii. Quality improvement of carbon ash to reach carbon black and activated carbon specification; iv. Simpler fractionation process with lower capex without requiring, for example, a vacuum distillation tower, due to the better quality of the pyrolysis gas stream when going through a thermo-catalytic cracking process; saw. Higher energy efficiency, reducing opex, by reusing gas r-gas in the burners and high recirculation of heating gases.

[014] Document GB2158089 describes a process for treating plastic waste, which comprises the following steps: (a) melting of waste plastics, eg. in heavy oil; (b) heating the melt to produce gas; (c) gas cracking; (d) stabilizing the molecules; (e) cooling the gas to approximately ambient temperature and collecting the condensed oily liquid during gas cooling; and (f) fractional distillation of the oily liquid received from step (e) to obtain fuel oil of various boiling points.

[015] Thus, the present invention has the following advantages when compared to said document: i. Cracking reactor of the present deposit can produce pyrolysis gas without needing a series of three reactors of document GB 2158089; ii. Heating system of the present invention directly transfers heat to the input material without requiring the use of heavy oil which introduces greater complexity in the heating system and makes the control of contaminants in the final product more complex.

[016] Document PI 0508115-7 describes a process and a plant for the thermo-catalytic conversion of waste materials into reusable fuels and a fuel produced by the process, which involves the steps of applying the molten waste material in one or more chambers pyrolysis through heated and valve manifolds, and performing pyrolysis of waste material in a gaseous state in an oxygen-purged, pressure-controlled environment. The pyrolytic gases are then transferred to a catalytic converter where the molecular structure of the gaseous material is altered in structure and shape, and the gases are then transferred to one or more condensers to distill and cool the gases into their respective fractions. After post-pyrolysis treatment, the fuel fractions then form usable fuel, which is mostly equivalent to diesel with a final boiling point of 348.5°C. This includes melting the waste (plastic) material before application into any of the pyrolysis chambers, making the movement of material in the catalytic tower a semi-continuous operation, directing the molten waste material into one or more, but preferably four, chambers of pyrolysis, making each camera capable of operating independently and in a batch system. Optionally, there is the mechanical removal of residual carbonized material from the pyrolysis chamber through the use of an internal helical screw or other appropriate means after the completion of a batch followed by a cooling cycle of the pyrolysis chamber.

[017] Thus, the present invention has the following advantages when compared to said document: i. Semi-continuous and continuous operation of each chamber substantially increasing the productivity of each pyrolysis reactor, due to the material feeding system and removal of solids from the pyrolysis chamber being dedicated to each reactor; ii. Valorization of the carbon ash product such as carbon black or activated carbon using the roasting reactor; iii. Ability to produce a larger fraction (above 50% by mass) of liquids and lighter hydrocarbons (boiling end point 220°C or 310°C) following strict specifications as this deposit employs a reflux system at the reactor outlet and also a catalysis process before the pyrolysis oil stream enters the fractionation system; iv. Lower energy consumption resulting from greater thermal efficiency through the recirculation of hot heating gases and the use of synthesis gas in the production of thermal energy, making the process self-sufficient in thermal energy.

[018] Document EP3311969A1 refers to a device for thermal decomposition of polyethylene and polypropylene waste. The device described by this prior art uses at least two reactors connected in parallel, one or both of which use a removable furnace. In addition, the device also uses: a fractionation unit for polymeric raw materials, which are in the form of a steam-gas mixture, which consists of a heat exchanger; a hydrocarbon collection tank with a boiler for accumulating and reheating the internal volume; a dewaxer; a rectification column to separate the diesel and gasoline fractions and a boiler; a tubular heat exchanger. This process also uses strip-shaped titanium metal catalysts that are installed inside the tubes/passages of the heat exchangers.

[019] However, it appears that the focus of such document is for the generation of motor fuels (gasoline, diesel), burning oil, hydrocarbon gas and coke/char. Nevertheless, the present invention has the following advantages when compared to said document: i. Exhaust gases from the pyrolysis reactor undergo reflux to prevent molecules with many carbons from passing to the condensation system, and with this, it could generate that of productivity due to clogging and encrustations, even if the system uses catalysts and "dewaxing" as a way of cracking the hydrocarbon molecules to the required size and thus avoid; ii. Continuos process; in the present invention there are no intermediate stocks of material in process such as a reservoir heated by a boiler, and thus it is more energy efficient and allows greater process stability resulting in better product quality; iii. Simpler and less expensive fractionation system by using a thermo-catalytic process followed by reflux and additional catalysis before starting the fractionation step; iv. Better use of the complete feedstock since the carbon ashes are treated by a specific roasting reactor. Said document also presents two versions for the pyrolysis reactor. In version 1 ("periodic mode implementation") the authors precisely detail a process that alternates two reactors producing pyrolysis gases to be processed downstream of the proposed system. In this version 1, the reactors are stopped, cooled, cleaned and recharged alternately, thus always having a reactor producing pyrolysis gases, and another one stopped. In version 2 ("continuous mode implementation") the authors describe very broadly without showing either the components of the system or how the feeding and continuous production system effectively operates to ensure the continuous and safe operation of the reactors. In this case, the present invention is more productive because it describes in detail a feeding system that allows operation of the pyrolysis reactors in an extended batch process and also in a continuous operation process, ensuring greater productivity and thus economy for the system.

[020] Document BR 112021000086-0 A2 describes a process of a plant for thermo-catalytic conversion that employs catalytic hydrogenation of waste materials into reusable fuels. In addition, this document proposes the reuse of energy obtained in the method so that the method is self-sufficient in terms of energy, for the method to use only a limited amount of extracted petroleum products, thus reducing potential man-made CO2 emissions.

[021] Even so, the present invention has the following advantages when compared to said document: i. does not use a hydrogenation process for the pyrolysis gas stream, which requires industrial hydrogen injection, which increases production costs. The present invention, due to the characteristics of the reactor-reflux set, process parameters and use of catalysts, reaches the product specifications with high yield without requiring the hydrogenation step; ii. There is no detailed description or specification of the system for feeding and removing solids from the reactor, which are fundamental parts to ensure productivity and quality of the product that comes out of the primary cracking, and which determines the need for downstream treatment and fractionation systems. The more crude and unstable the primary cracking reactor product is, the more complex and costly the treatment and fractionation required to obtain hydrocarbon products; iii. The document in question does not have a step in its process to treat the carbon ash from the output of the primary reactor to reach specification for use as a product either as carbon black or as activated carbon. Valuing this product is important for the economy of the process; iv. Another important part of the economy of the process is the maximum use of the synthesis gases formed during cracking to generate thermal energy for the process. That document does not specify the system for reusing such gases, nor the system for recovering hot gases to reduce the consumption of thermal energy and thus make the process energy self-sufficient.

[022] Document WO2021/209276 A1 describes a process and a plant for thermal conversion that does not require the use of catalysts to transform waste materials into reusable fuels. Additionally, this document provides a pyrolysis process for obtaining petrochemical products from plastic waste, particularly based on the use of reagents based on carbon nanoparticles, instead of the use of catalysts, in which lower temperature, pressure and energy are used for best results.

[023] Thus, the present invention has the following advantages when compared to said document: i. It does not use carbon nanoelements as reagents, which, as they are reagents and not catalysts, end up being consumed in the cracking process, which will require their constant purchase for use, which generates costs for the process; ii. The authors of that document describe very broadly without showing either the components of the system or how the continuous feeding and production system effectively operates to ensure the continuous and safe operation of the reactors. In this case, the present invention is more productive because it describes in detail a feeding system that allows operation of the pyrolysis reactors in an extended batch process and also in a continuous operation process, ensuring greater productivity and thus economy for the system; iii. The document in question uses industrial gas (natural gas) purchased on the market as a source of thermal energy, which makes the process very costly, since it does not reuse the synthesis gas generated by the cracking process itself as a source of thermal energy. The efficient use of this gas is crucial for the economy of the process.

[024] Therefore, the system proposed in the present invention has some advantages over the state of the art, such as: (i) High yield for naphtha-type petrochemical product equivalent to "R-naphtha" (density below 0.78 kg /l); (ii) Simpler process with lower capex and high modularity (much simpler downstream); (iii) High energy efficiency using hot air recirculation and flue gas as main fuel; (iv) it avoids the use of specific purge gas (pure N2), since it would hinder the efficient energy reuse of the residual gas; (v) extended batch and also possibility of continuous processing to optimize reactor productivity; (vi) it is capable of absorbing a wide variety of different plastic wastes and still delivering end products that meet very strict specifications. In addition, it is focused on the production of products that can be reinserted into the circular economy of the plastic chain. One of the products produced by the system and process of the present invention is the highest possible yield of the equivalent naphtha type "R-naphtha" with strict specifications (density below 0.78 kg/l) and without the presence of waxes, from assorted plastic waste (flexible, multilayer and multicomponent).

SUMMARY OF THE INVENTION

[025] The present invention aims to propose a system and a process for energy-efficient transformation of various plastic waste into hydrocarbons in liquid, pasty, solid and gaseous form for use in various applications, as a substitute for fossil and non-fossil products preferably applied in the circular economy of the plastics and chemical chain, such as r-naphtha (predominantly from 6 to 14 carbons) as a recycled raw material to substitute fossil naphtha as an input for the petrochemical industry, light r-hydrocarbons (from 5 to 11 carbons) used as a substitute for fossil-based chemical inputs, light and heavy r-paraffins (from 20 to 24 carbons) to replace fossil paraffins used in industrial use or in use in personal application products, r-recycled carbon black or r- Activated carbon (treated carbon ash) to replace fossil carbon black. Some by-products may also have other applications, such as products used in energy applications such as r-diesel (from 12 to 20 carbons) as a substitute for fossil diesel, recycled residual r-gas (from 1 to 4 carbons) to replace fossil gases and electricity from renewable sources, in addition to other r-hydrocarbons such as recycled raw materials used to replace solid hydrocarbons.

BRIEF DESCRIPTION OF THE FIGURE

[026] Figure 1 shows a general scheme of the system proposed in the present invention.

[027] Figure 2 shows a side view of the main reactor (7) used in the present invention.

[028] Figure 3 shows a side view of the reflux tower (8) used in the present invention.

[029] Figure 4 graphically shows the extended batch production with production cycles of 15 to 30 hours, showing the gas x liquid ratio in relation to the general production of a main reactor (7) operating individually.

[030] Figure 5 graphically shows the extended batch production with production cycles of 15 to 30 hours, showing the combined production of 3 main reactors (7) operating together. The top line shows total hydrocarbon production and the bottom line shows oil production (liquids and paraffin).

[031] Figure 6 shows a general scheme of the system detailing the example of implementation of the invention considering the mass and energy balance for a plant with three reactors operating together with a horizon of one year of operation.

[032] Figure 7 shows a graph of the accumulated distilled mass versus temperature, presenting empirical data that show the change in the distillation curves of the different products when subjected to three different scenarios: without catalyst, with Catalyst C and Catalyst F.

DETAILED DESCRIPTION OF THE INVENTION

• - sistema de preparação de material (1);
• - silo de armazenagem (2);
• - rosca alimentadora e dosadora (3);
• - medidor de fluxo de sólido (33);
• - dosador de catalisador (36);
• - compactador (4);
• - rosca de fusão (5);
• - trocador de calor (6);
• - ventilador rosca de fusão (19);

• Módulo de Reação;

• - reator principal (7);
• - medidor de nível (34);
• - queimador e fornalha (18);
• - torre de refluxo (8);
• - ventilador de refluxo (22);
• - trocador de calor (26);

• Módulo de Condensação/Separação;

• - torre de catálise (9);
• - sistema de condensação (10);
• - trocadores de calor (11a e 11b);
• - torre de resfriamento de água (23);
• - bomba sistema de resfriamento geral (30);
• - chiller (31);
• - bomba sistema de refrigeração (32);

• Módulo de Exaustão/r-gás residual;

• - lavador de gases (bubbler) (12);
• - compressor de baixa pressão (13);
• - trocador de calor recuperador (14);
• - tanques de gás de síntese (r-gás residual) (16);
• - tanques de GLP (17);
• - gerador de energia elétrica (24);
• - flare (25);

• Módulo de Descarga;

• - válvula de controle de descarga (35);
• - reator de torra (15);
• - queimador e fornalha do reator de torra (20);
• - ventilador da torre de catálise (21);
• - rosca de retirada do reator de torra (27);
• - resfriador de cinzas de carbono (28);
• - rosca de selagem (29).

[033] The present invention relates to an energy efficient transformation system of varied plastic waste into hydrocarbons in liquid, pasty, solid and gaseous form for application in products in the value chain of the circular economy of plastic and chemistry. Said system, as represented by Figure 1, comprises the following components:
• Power module;

• - material preparation system (1);
• - storage silo (2);
• - feeding and dosing screw (3);
• - solid flow meter (33);
• - catalyst doser (36);
• - compactor (4);
• - fusion thread (5);
• - heat exchanger (6);
• - fusion screw fan (19);

• Reaction Module;

• - main reactor (7);
• - level meter (34);
• - burner and furnace (18);
• - reflux tower (8);
• - reflux fan (22);
• - heat exchanger (26);

• Condensation/Separation Module;

• - catalysis tower (9);
• - condensation system (10);
• - heat exchangers (11a and 11b);
• - water cooling tower (23);
• - general cooling system pump (30);
• - chiller (31);
• - cooling system pump (32);

• Exhaust Module/residual r-gas;

• - gas scrubber (bubbler) (12);
• - low pressure compressor (13);
• - recovery heat exchanger (14);
• - synthesis gas tanks (r-residual gas) (16);
• - LPG tanks (17);
• - electric power generator (24);
• - flare (25);

• Download Module;

• - discharge control valve (35);
• - roasting reactor (15);
• - burner and furnace of the roasting reactor (20);
• - catalysis tower fan (21);
• - roasting reactor removal thread (27);
• - carbon ash cooler (28);
• - sealing thread (29).

• (a) Preparação do material com retirada e controle de contaminantes, e retirada de água;
• (b) Homogeneização e alimentação do material no reator de pirólise;
• (c) Reação de pirólise;
• (d) Tratamento, condensação e separação de hidrocarbonetos produzidos;
• (e) Tratamento e armazenagem de gás de síntese;
• (f) Utilização do gás de síntese armazenado para aquecimento dos reatores principal e secundário e geração de energia elétrica e térmica;
• (g) Reaproveitamento térmico e exaustão de gases queimados; e
• (h) Retirada e tratamento das cinzas de carbono.

[034] In a second embodiment, the present invention relates to a process for energy-efficient transformation of various plastic waste into liquid hydrocarbons using the previously described system. Said process comprising the following steps:

• (a) Preparation of material with removal and control of contaminants, and removal of water;
• (b) Homogenization and feeding of the material in the pyrolysis reactor;
• (c) Pyrolysis reaction;
• (d) Treatment, condensation and separation of produced hydrocarbons;
• (e) Syngas treatment and storage;
• (f) Use of stored synthesis gas to heat the main and secondary reactors and generate electrical and thermal energy;
• (g) Thermal reuse and exhaustion of burnt gases; and
• (h) Removal and treatment of carbon ash.

[035] The operation of the system and the transformation process will be detailed below.

• a.1 Peneiração separadora de finos, equivalente a uma peneira rotativa tipo trommel;
• a.2 Linha de separação manual para retirada de tecidos e volumosos;
• a.3 Separação magnética para retirada de material ferroso magnético;
• a.4 Trituração para atingir granulometria máxima de 250mm;
• a.5 Retirada de plásticos (filmes) por sucção;
• a.6 Moagem obtenção de partículas com dimensão máxima de 25mm;
• a.7 Lavagem com banho de solução para retirada de contaminantes tais como clorados, oxigenados e silício;
• a.8 Secagem em centrifuga para eliminação de impurezas residuais e secagem inicial;
• a.9 Aglutinação para secagem final do material e aumento da densidade aparente; e
• a.10 Estocagem e transporte.

[036] First, the material is prepared (1), through mechanical and chemical processing, with the objective of removing the main contaminants to meet the final specification of the products and removing water to optimize the processing. Such materials come from landfill or recycled materials. In addition to removing contaminants, procedures such as grinding and milling aim to decrease the particle size to about 1 inch to facilitate washing. Additionally, procedures with separation and agglutination aim to increase the density of the particles. The main stages of the preparation phase of their respective objectives vary according to the origin of the plastic material received and the acceptable limits of contamination in the final product, however, they can be composed of the following stages in their most extensive form:

• a.1 Fine separating sieve, equivalent to a rotating trommel sieve;
• a.2 Manual separation line for removal of tissues and bulky items;
• a.3 Magnetic separation to remove magnetic ferrous material;
• a.4 Grinding to reach a maximum granulometry of 250mm;
• a.5 Removal of plastics (films) by suction;
• a.6 Grinding obtaining particles with a maximum dimension of 25mm;
• a.7 Washing with solution bath to remove contaminants such as chlorinated, oxygenated and silicon;
• a.8 Centrifuge drying to eliminate residual impurities and initial drying;
• a.9 Agglutination for final drying of the material and increase in apparent density; and
• a.10 Storage and transport.

• - Teor máximo de humidade 5%;
• - Densidade aparente entre 200 kg/m3 e 450 kg/m3;
• - Tamanho máximo de partícula 25mm;
• - Máximo de 300 ppm-m de cloretos totais;
• - Máximo de 1100 ppb-m de oxigenados totais;
• - Máximo de 300 ppb-m de nitrogenados;
• - Máximo de 500 ppb-m de enxofre total;
• - Máximo de 15 ppm-m de arsênio;
• - Máximo de 50 ppm-m de cobre;
• - Máximo de 5 ppm-m de mercúrio;
• - Máximo de 5000 ppm-m de sódio;
• - Máximo de 150 ppm-m de chumbo; e
• - Máximo de 1100 ppm-m de silício.

[037] As a result of the preparation step (1), the material that goes on to the next steps must have its characteristics monitored so that it can meet the following specifications:

• - Maximum moisture content 5%;
• - Apparent density between 200 kg/m3 and 450 kg/m3;
• - Maximum particle size 25mm;
• - Maximum of 300 ppm-m of total chlorides;
• - Maximum of 1100 ppb-m of total oxygenates;
• - Maximum of 300 ppb-m of nitrogenous;
• - Maximum of 500 ppb-m of total sulfur;
• - Maximum of 15 ppm-m of arsenic;
• - Maximum of 50 ppm-m of copper;
• - Maximum of 5 ppm-m of mercury;
• - Maximum of 5000 ppm-m of sodium;
• - Maximum of 150 ppm-m of lead; and
• - Maximum 1100 ppm-m of silicon.

[038] These specifications of acceptable limits can be changed according to the application of the final products.

[039] From the preparation line, the raw material is sent to a storage silo of about 3 m3 (2) which aims to ensure homogeneity of the material, in addition to continuous feeding always as the reactor feeding system material demand.

[040] When the storage silo (2) is full, feeding starts. After leaving the storage silo (2), the raw material will pass through a feeder and dosing screw (3) that standardizes the flow of plastic material removed from the silo (2) and through a control that combines the reading on the solid flow meter (33) with the dosage made by the catalyst doser (36) allows the catalyst to be added precisely when entering the compactor (4) at a rate between 0.1% and 10% by mass depending on the input of raw material . This dosage control is carried out by continuous adjustment between the fed mass of plastic material which is measured by the volume meter (33) and the volume of catalyst introduced by the catalyst doser (36). The control parameters are given according to the material to be processed and specification/yield of the desired product.

[041] The catalyst aims to increase the speed of breakdown of polymeric molecules and favor the formation of light hydrocarbons. The catalyst, mainly zeolite-based acid catalyst, is inserted into the compactor (4), at a rate between 0.1% and 10% (according to the type of material and desired final product) by mass relative to the raw material input. cousin. This catalyst is stored in a silo-doser assembly (36) and is dosed into the compactor (4). The feeding system continues with sending the raw material to the compactor (4), which has the function of increasing the minimum density of the material to around 450 kg/m3 to reduce the risk of oxygen entering the system. In addition, the system works with a rotation of 5 to 60 rpm and consequent compression force and with a cooling system, capable of lowering the temperature to keep it at a maximum of 30 °C, to prevent the raw material from melting. inside. The compactor (4) is cooled by a jacketing system, which is based on a jacket that enters with the cooling liquid sent by a pump (30) of a cooling tower (23). After entering the raw material together with 0.1% to 10% of the catalyst, the compactor (4) compresses at a compression ratio of 1:2.5, and leads the two materials to a fusion screw (5) .

[042] The fusion screw (5) aims to preheat the material to a temperature between 200 °C and 350 °C. After leaving the melting screw (5), the material enters a heat exchanger (6), which heats the material between 350 °C and 450 °C. The residence time of the polymers in this melting and heating system can vary between 90 seconds and 600 seconds. This heat exchanger (6) receives heat from the burnt gas from the furnace (18), after it leaves the main reactor jacket (7) to heat the material.

[043] Upon leaving the heat exchanger (6), the material enters the main reactor (7). This cstr (continuous stirred-tank reactor) type reactor, with a centralized and split axis in the form of an anchor (Figure 2), which works at a rotation between 1 and 30 rpm, and can rotate both clockwise and counterclockwise . The reactor (7) has an L/D index (Length/Diameter) between 3.5 and 7.0. The main reactor (7) is jacketed to receive the necessary heat from the furnace to carry out the pyrolytic reaction. In an example of pilot implementation, a burner with a power of 440,000 kCal/h was used.

[044] The purpose of this reactor shaft is to homogenize the reagent mass, which weighs between 600 and 2000 kg, and to control the removal of carbon black ash. At the base of the shaft, right after the anchor, there is a termination in the form of a helicoid which, depending on the direction and speed of rotation of the shaft, leads the reactant mass in different directions. The rotation control of this termination, together with the discharge valve (35) and sealing thread (29) allows reactions to be semi-continuous or continuous. In semi-continuous reactions, the discharge valve (35) operates closed and the sealing screw (29) operates intermittently. In continuous reactions, the discharge valve (35) works with opening adjustments depending on the production of the main reactor (7) and consequent continuous operation of the sealing thread (29).

[045] The material enters the main reactor (7) at a temperature between 350 °C - 450 °C. Upon entry, the raw material in the pasty state is heated until its temperature reaches between 420 °C - 460 °C, so as to minimize the residence time in the reactor. In this temperature range and with a gauge pressure of - 2 0.0 to + 50.0 KPa (- 0.2 to + 0.5 Bar) the pyrolysis reaction takes place, which consists of breaking down the plastic molecules, with the absence of oxygen, in molecules of 20 to 40 carbons, preferably 24 to 28 carbons, which become in the gaseous state. The chemical reaction has a residence time between 10 minutes and 4 hours, preferably 2 to 3 hours, which must be applied depending on the desired distribution of products. This chemical reaction generates products in three different physical states: i. solid: carbon ash of ample form but meeting carbon black or activated carbon specifications; ii. pyrolytic oil, which contains the R-naphtha fractions; R-diesel, paraffins and others; iii. r-waste gas. The proportion formed is 1% to 35% solids, 1% to 35% residual r-gas and 30% to 98% pyrolytic oil. This gas is drawn through a radial compressor (13) and sent to the reflux tower (8).

[046] The reflux tower (8) (figure 3) is a jacketed conical vessel, without the presence of metals with a catalytic function, through which air circulates as a coolant, composed of baffles and rings, without the application of perforated plates, which make it difficult the upward flow, creating turbulence (Reynolds number between 30,000 and 300,000) which increases the thermal exchange with the refrigerated walls without causing condensate entrainment, preventing larger molecules from above 20 to 40 carbons (preferably 20 to 28 carbons) to pass for the next stage of the process. These larger molecules condense and return by gravity to the reactor where they will be cracked again. The reflux is maintained at a temperature of 220 °C to 320 °C, preferably 240 to 280 °C, where its temperature control is carried out by a fan (22) that circulates cold air in its jacket. When leaving the reflux current will enter a heat exchanger (26), which absorbs the gases from the main reactor (7), using the driving force of the fan (19), which can increase the temperature to a range between 220 °C and 600 °C. The adjustment of this temperature will depend on the operational conditions necessary for the catalysis tower.

[047] The catalysis tower (9), which has a L/D (Length/Diameter) index from 3.0 to 5.0, aims to finish the breakdown of molecules that have a size greater than the desired size in the specification of types of products being produced, thus allowing a more homogeneous production of products. The catalysis tower (9), which is composed of a solid catalytic bed of adequate dimensions, volume and porosity, depends directly on the type of catalyst used, as the residence time of the product must be sufficient for the desired breakdown of molecules to occur. . This hydrocarbon stream residence time can vary from 2 to 12 seconds depending on the desired product. Another fundamental factor for the effectiveness of the catalysis is the operating temperature, which must be between 350 °C and 550 °C according to the type of catalyst used and the desired end products. The catalysts used are, in general, acidic and of the zeolite type, with zeolite Y or clinoptilolite and ZSM5 aluminum silicate catalysts being preferably used.

[048] The process of the present invention can employ catalysts in two stages of the process: i. In the main reactor (7), where the primary cracking takes place, also called liquid phase catalyst, ii. In the catalysis tower (9) , where secondary cracking can occur, also called gas phase catalyst. The catalysts can be applied either individually in each phase or in joint operation, or the process of the present deposit can be operated without catalysts. But preferably, the catalysts are used together in their respective stages, as they generally reduce the energy level required to obtain lighter cracking products, either in the liquid phase or in the gaseous phase. Figure 7 (X axis is % of accumulated distilled mass, Y axis is temperature) shows empirical data that show the change in the distillation curves of different products when they have been subjected to three different scenarios: without catalyst, with Catalyst C and Catalyst F In the case of application of the catalyst in the liquid phase, which occurs in the reactor (7), a reduction in the energy level of about 10 to 15% can be expected, which translates into a reduction in the consumption of thermal energy. The gaseous phase, which occurs in the catalysis tower (9), can work with different types of catalysts or without any catalyst, but with a different efficiency in converting lighter products and in energy consumption for the reaction. Different specifications of catalysts found in the Brazilian and international markets can be successfully used to adapt the catalysis tower to the required working conditions. Table 1 below illustrates this relationship of some different types of catalysts with the mass yields of the output products.

[049] After leaving the catalysis tower (9), the gas passes through a condensation system (10), which has the function of condensing this gas at temperatures of 240 °C and 310 °C. The volume of non-condensed gas in this stage, which is composed of lighter molecules, will go to condensers to be condensed at lower temperatures. Both products, after being condensed, are sent to storage tanks.

[050] The second stage of condensation occurs in the heat exchangers (11a and 11b). The hot fluid condenses at a temperature of up to 110 °C and is sent to the storage area. The heat exchanger (11b) reduces the temperature of the hydrocarbon stream to 10 °C, using cold water, between 0 °C and -15 °C, preferably -5 °C, coming from a chiller (31). This condensate is also sent for storage. These last condensed oil fractions are called R-naphtha.

[051] The third and last dew point is in the recuperator heat exchanger (14). This condensation is primarily favored by the pressure increase obtained by the compressor (13), instead of the pure temperature reduction. The working pressure can vary from 1.5 bar to 6 bar, using condensing temperature from 30 °C to 70 °C. This additional light pyrolytic oil can be mixed with the pyrolytic oil condensed in the heat exchangers (11a and 11b) as part of the R-naphtha composition or it can be stored separately and used in different chemical inputs. This option is defined according to the application and need defined for the desired production.

[052] There is a yield of 1% - 40% by mass of heavy pyrolytic oil (r-paraffin), 1% - 40% by mass of medium pyrolytic oil (r-diesel) and 20% - 98% by mass light and very light pyrolytic oil (r-naphtha).

[053] The incondensable gas (r-waste gas) that comes out of the heat exchangers (14) is then compressed to a higher pressure, between 1.5 bar and 6 bar and sent to the gas storage system. It will be reused by the system for the production of thermal energy, for power generation and/or as r-LPG for feedstock from petrochemical crackers.

[054] Before the gas is compressed for use, it can be washed in a gas scrubber (bubbler) (12) with a solution of CaOH or NaOH, between 0.1 and 5%, preferably 0.5%, depending on the material to be used. be processed. Another base can be used to remove existing impurities. The bubbler (12) works like a washer, in which the gas enters upwards, passing through an alkaline solution. This step is used in particular for the gases generated in the roasting process that takes place in the secondary reactor/roasting reactor (15).

[055] The compressor (13) has the function of stabilizing the production flow throughout the process from the main reactor (7) and also ensures the conditions for condensation of the very light pyrolytic oil in the recuperator heat exchanger (14), as previously described.

[056] The residual r-gas tanks (16) have the function of storing the residual r-gas at a pressure of 1.5 to 6 bar.

[057] The main use of the waste r-gas produced is to provide thermal energy for the pyrolysis reaction, as will be described below. However, there may be excess production of residual r-gas that can be sent for additional energy use through an electric power generator (24). This generator, when generating electrical energy, also allows thermal utilization, either for heating through combustion gases, or for cooling through thermal adsorption. All three energy uses (electricity, heat and cold) are used in the industrial process and contribute to the energy efficiency of the process as a whole.

[058] The flare (25) is the safety system that burns the gas at sporadic times, and can be used in times of emergency or to empty the system for any maintenance.

[059] The main use for the gas stored in the residual gas tanks (16) is to feed the burners that provide thermal energy for the furnaces (18 and 20). The burner and furnace (18) heats the entire reaction system, working at temperatures between 750 °C and 1,200 °C. The pyrolysis reaction uses part of this energy with an operating temperature of 700 to 900 °C. The thermal energy generated in this same furnace also provides thermal energy for the plastic melting system in the heat exchanger (6) and for the heat exchanger (26) for heating the stream after reflux.

[060] The burner and furnace (20) provide thermal energy for the roasting reactor (15) and also provides energy for the catalysis tower (9).

[061] An alternative fuel gas can also be used for plant startups or in other eventualities. Both LPG and Syngas are transported to the burner and furnace (18) of the main reactor (7), and to the burner and furnace (20) of the roasting reactor (15) by the storage pressure of their tanks.

[062] The energy use of the burner and furnace (18) is done through recirculation in a closed circuit of hot gas using a fan (19). This circuit circulates hot air between: i. furnace (18), ii. main reactor jacket (7), iii. heat exchanger (26) post reflux tower (8) and iv. plastic melting heat exchanger (6). This closed circuit has adequate gas exchange by removing saturated gases and entering fresh air to ensure ideal conditions for syngas or LPG burning in the furnace burner. The return gas to the furnace (18) has a temperature between 400 and 550 °C. The ideal burning conditions for the burner, for example, pressure at the reactor jacket inlet of -7 mbar to -10 mbar, involve not only the chemical composition of the recirculated air (assuring the necessary presence of oxygen without excesses of contaminants), but also pressure balancing and removal of solid impurities eventually generated in the burning process.

[063] Similarly, the burner and furnace (20) also have energy reuse through hot gas recirculation using the catalysis tower fan (22) as the driving force. This temperature varies between 450 and 650 °C. In this case, the energy reuse circuit circulates the hot gas between: i. furnace (20), ii. roasting reactor jacket (15), and iii. catalysis tower sleeve (9). This closed circuit has adequate gas exchange by removing saturated gases and entering fresh air to ensure ideal conditions for burning the r-gas/syngas or LPG in the furnace burner, such as the fan circuit (19).

[064] The fixed bed pyrolysis reaction produces as a by-product carbon ash (carbon black or activated carbon). In the case of extended batch reactions, the presence of carbon ash is imperceptible, in terms of reaction dynamics, until the moment when the reaction/extended batch ends and it is necessary to remove the residual solid material from the reactor bed. In the case of extended batch reactions or continuous reactions, it is essential to monitor and remove carbon ash when the accumulation and respective increase in concentration of this component reduces the efficiency of the reaction. The developed process has mechanisms for monitoring and removing the carbon ash formed during the reaction.

[065] There are two forms of production using the process design developed here: i. Extended batch production with production cycles of 15 to 30 hours (Figure 4), ii. Continuous production without the need for stops to remove ash due to saturation of the reagent mass. In both cases, it is essential to monitor the state of the reagent mass and to act on the reagent mass to remove the carbon ashes, using a level sensor.

[066] In the case of extended batch, , the discharge valve (35) operates closed and opens only at the time of complete discharge of the material contained in the main reactor (7). Once the material removed from the main reactor (7) enters the roasting reactor (15), the material roasting process begins, which occurs at a temperature between 500°C and 600°C. The reagent mass in the main reactor (7), when reaching the saturation point, between 25 and 45%, preferably 30% of carbon ash, this value being calculated according to the production volume, it will be necessary to unload the carbon ash that are inside the main reactor (7). The saturation point is determined by the relationship between the temperature of the reagent mass and gas production (Figure 5). When the increase in temperature does not generate greater production, preferably 450 to 480 °C, the reaction must be stopped and the process of removing the reagent mass begins.

[067] After ensuring the formation of carbon ash in the lower third of the main reactor (7), the manual unloading of the material begins. To this end, the split shaft has its direction of rotation reversed and its speed increased, so the split shaft sends the material out of the main reactor (7) and into the roasting reactor (15) where the ash roasting process carbon is performed. This roasting process seeks to ensure that the carbon ash will be processed to the point of meeting the specifications required for the application of this product as carbon black or activated carbon. For the application of this product, in this case activated carbon, for example, the product must meet the following specifications: Humidity up to 5% (ASTMD2867), Density between 400 and 600 kg/m3 (DIN ISO 78711), Surface area min 300 m2/ g (DIN 66132) and Particle size (<100μm) minimum 80% (CT-PA 17) . During this phase, in addition to heating and continuous mechanical revolution of the material, chemical components can be added to contribute to the required final chemical composition. The roasting reactor (15) has an L/D index (Length/Diameter) between 4.3 and 5.6, and has a heating jacket supplied by the burner and furnace (20). The material inside the reactor is heated and mixed until the temperature sensor in the roasting reactor (15) reads 500-6000 °C. After reaching this determined temperature and processing time, the final product whether carbon black or activated carbon is extracted and stored. The gases eventually generated by this roasting process are also absorbed by the compression system and used as plant gases, once they are inserted into the bubbler (12).

[068] This process can also operate continuously to remove carbon ash. In this case, the continuous form occurs with the discharge valve (35) having its opening controlled, the sealing thread (29) inserting material and the main reactor shaft (7) rotating between 20 and 30 rpm in the discharge direction. Therefore, it is necessary that an equilibrium point of carbon ash concentration (between 10% and 30%) is reached. In this case, the split shaft of the main reactor (7) must rotate in the direction of removal of the reactant mass from the material at adequate rotation, between 20 and 100 rpm, preferably 30 rpm, to maintain the balance between the removal rate and the stability of the reagent mass. This balance is also maintained through the operation of the discharge valve (35) which works with opening adjustments depending on the production of the main reactor (7) and consequent continuous operation of the sealing screw (29).

[069] This continuous withdrawal also takes place for the roasting reactor (15), where, as described above, the material removed from the reactor will undergo a roasting process and eventual addition of chemical components to reach the desired specification of the carbon ash. Process parameters and specifications are the same as described above in extended batch operation.

[070] After going through the roasting process in the roasting reactor (16), the activated carbon or carbon black products are conducted through a withdrawal screw (27) from the roasting reactor (15) to the cooling tank (28) by where it will remain for 5 to 15 hours until cooled (about 70 °C). Next, the activated carbon or carbon black products can be used in the sealing thread (29) of the main reactor material removal system (7) or they can be sent to the final stock silo and packaged for use by the customer.

• - 300 ppm-m de cloretos totais;
• - 1100 ppb-m de oxigenados totais;
• - 300 ppb-m de nitrogenados
• - 500 ppb-m de enxofre total;
• - 50 ppb-m de dissulfeto de carbono;
• - 100 ppb-m de mercaptanos
• - 10 ppb-m de Sulfeto de carbonila
• - 50 ppb-m de sulfeto de hidrogênio;
• - 15 ppm-m de arsênio;
• - 50 ppm-m de cobre;
• - 300 ppm-m de ferro;
• - 5 ppm-m de mercúrio;
• - 5000 ppm-m de sódio;
• - 150 ppm-m de chumbo; e
• - 1100 ppm-m de silício.

[071] In a third embodiment, the present invention refers to hydrocarbons produced according to the described process. It should be noted that the aforementioned hydrocarbons may contain contaminants in the following maximum concentration alone or together. The control to meet such maximum levels of contaminants is done, for the most part, in the material preparation system (1):

• - 300 ppm-m of total chlorides;
• - 1100 ppb-m of total oxygenates;
• - 300 ppb-m of nitrogenous
• - 500 ppb-m of total sulfur;
• - 50 ppb-m carbon disulfide;
• - 100 ppb-m of mercaptans
• - 10 ppb-m of carbonyl sulfide
• - 50 ppb-m of hydrogen sulfide;
• - 15 ppm-m of arsenic;
• - 50 ppm-m of copper;
• - 300 ppm-m of iron;
• - 5 ppm-m of mercury;
• - 5000 ppm-m sodium;
• - 150 ppm-m of lead; and
• - 1100 ppm-m silicon.

[072] Additionally, the hydrocarbons produced can be mainly synthesis gases, preferably propane, butane, methane, ethane, propylene and iso-propylene, with a final boiling point of 30 °C; light hydrocarbon, preferably pentane, hexane and heptane, with an initial boiling point of 30 °C and a final boiling point of 80 °C; naphtha and diesel, mainly alkanes, paraffins, iso-paraffins and olefins, with an initial boiling point of 80 °C and a final boiling point of 240 °C, respectively (r-naphtha), and an initial boiling point of 240 °C C and final boiling point of 310 °C (r-diesel); paraffin, mainly low-density linear chain paraffins, with an initial boiling point of 310 °C and a final boiling point above 330 °C, preferably solid at room temperature, and liquid between 35 °C and 55 °C; carbon ash under the characterization of carbon black product, having a particle size between 10 and 320 nm and apparent density (dbp) between 50 to 120, and under the characterization as activated carbon product, Moisture up to 5% (ASTMD2867), Density between 400 and 600 kg/m3 (DIN ISO 787-11), Surface area min 300 m2/g (DIN 66132) and Particle size (<100μm) min 80% (CT-PA 17).

• - Gás reciclado engarrafado para substituição de gás fóssil em aplicações para aquecimento (r-gás residual);
• - Fonte para geração de energia renovável advindo de gás reciclado (r-gás residual);
• - Nafta reciclada em cracker petroquímico para produção de plásticos virgens (r-nafta);
• - Aditivo reciclado para óleo diesel fóssil (r-diesel);
• - Matérias-primas recicladas para a indústria química substituindo hidrocarbonetos fósseis (r-nafta leve/ r-diesel) ;
• - Insumos químicos reciclados substituindo insumos fósseis (r-nafta leve/ r-diesel);
• - Óleos de queima sustentável para substituição de óleos fósseis (r-nafta leve/r-diesel);
• - Parafinas recicladas para aplicação industrial e não industrial substituindo parafinas fósseis (r-parafinas);
• - Negro de fumo e carvão ativado reciclado substituindo negro de fumo e carvão ativado fósseis (negro de fumo e carvão ativado);
• - Valorização de plásticos de baixo valor agregado, plásticos multicamadas e plásticos multicomponentes que poderiam terminar no aterro;
• - Produção de nafta petroquímica advinda de fontes recicladas (r-nafta) para substituição de nafta fóssil;
• - Produção de diesel advindo de fontes recicladas (r-Diesel) e substituição de Diesel fóssil;
• - Produção de outros hidrocarbonetos (r-hidro) com aplicação na indústria química;
• - Produção de parafinas leves (r-parafinas leves);
• - Produção de parafinas pesadas (r-parafinas pesadas);
• - Produção de negro de fumo e carvão ativado (r-negro de fumo e r-carvão ativado);
• - Produção de gás de síntese (r-gás residual); e
• - Produção de energia elétrica advinda de fontes renováveis.

[073] In a fourth modality, the present invention also refers to the uses of the produced hydrocarbons, among them:

• - Recycled bottled gas to replace fossil gas in heating applications (r-waste gas);
• - Source for generating renewable energy from recycled gas (r-residual gas);
• - Naphtha recycled in petrochemical crackers to produce virgin plastics (r-naphtha);
• - Recycled additive for fossil diesel oil (r-diesel);
• - Recycled raw materials for the chemical industry replacing fossil hydrocarbons (r-light naphtha/r-diesel);
• - Recycled chemical inputs replacing fossil inputs (r-light naphtha/r-diesel);
• - Sustainable burning oils to replace fossil oils (light r-naphtha/r-diesel);
• - Recycled paraffins for industrial and non-industrial application replacing fossil paraffins (r-paraffins);
• - Recycled carbon black and activated carbon replacing fossil carbon black and activated carbon (carbon black and activated carbon);
• - Valuation of plastics with low added value, multilayer plastics and multicomponent plastics that could end up in landfills;
• - Production of petrochemical naphtha from recycled sources (r-naphtha) to replace fossil naphtha;
• - Production of diesel from recycled sources (r-Diesel) and replacement of fossil diesel;
• - Production of other hydrocarbons (r-hydro) with application in the chemical industry;
• - Production of light paraffins (r-light paraffins);
• - Production of heavy paraffins (heavy r-paraffins);
• - Production of carbon black and activated carbon (r-carbon black and r-activated carbon);
• - Production of synthesis gas (r-waste gas); and
• - Production of electricity from renewable sources.

Example of embodiment of the invention

[074] For the sole purpose of demonstrating the operation of the present invention, not being limited to these parameters, details of the process are provided as shown in Figure 6 and Table 2 below. Figure 6 contains an example of the general process flowchart of an operational plant and the mass and energy balance of this plant.

[075] It is important to mention that the present invention is implemented in operational plants having the supply module, the reaction module and the discharge module in modules, which allows a plant to have its production capacity adjusted to the availability of raw material at the implantation site. The process of this invention considers the use of 2 to 9 modules operating in parallel in the same plant. The rest of the modules (material preparation module, fractionation module, exhaustion module) are unique, regardless of the number of modules a plant has. In the specific case of Figure 6 and Table 2, the mass and energy balance is made for a plant with three reaction modules.

[076] Finally, considering that the present invention can be implemented in different ways, without departing from its essential characteristics, the examples above should be understood as non-limiting, since they only illustrate how the present invention can be reproduced.

Claims (49)

System for energy-efficient transformation of varied plastic waste into hydrocarbons characterized by the fact that it comprises:

• • Power module;
• • Reaction module;
• • Condensation/Separation Module;
• • Exhaust Module/residual r-gas; and
• • Download Module;

wherein the supply module comprises:

• - material preparation system (1);
• - storage silo (2);
• - feeding and dosing screw (3);
• - solid flow meter (33);
• - catalyst doser (36);
• - compactor (4);
• - fusion thread (5);
• - heat exchanger (6);
• - fusion screw fan (19); the reaction module comprises:
• - main reactor (7);
• - level meter (34);
• - burner and furnace (18);
• - reflux tower (8);
• - reflux fan (22);
• - heat exchanger (26);

the Condensation/Separation module comprises:

• - catalysis tower (9);
• - condensation system (10);
• - heat exchangers (11a and 11b);
• - water cooling tower (23);
• - general cooling system pump (30);
• - chiller (31);
• - cooling system pump (32);

the Exhaust/r-waste gas module comprises:

• - gas scrubber (bubbler) (12);
• - low pressure compressor (13);
• - recovery heat exchanger (14);
• - synthesis gas tanks (r-residual gas) (16);
• - LPG tanks (17);
• - electric power generator (24);
• - flare (25);

the Download module comprises:

• - discharge control valve (35);
• - roasting reactor (15);
• - burner and furnace of the roasting reactor (20);
• - catalysis tower fan (21);
• - roasting reactor removal thread (27);
• - carbon ash cooler (28);
• - sealing thread (29).

System, according to claim 1, characterized by the fact that the feeding and dosing screw (3) uniforms the flow and through a control that combines the reading on the solid flow meter (33) with the dosage made by the catalyst doser ( 36) allow the catalyst to be added precisely when entering the compactor (4). System, according to claim 1, characterized in that the catalyst is inserted into the compactor (4) by the catalyst doser (36), at a rate between 0.1% and 10% by mass depending on the raw material input. cousin. System, according to claim 1, characterized in that the compactor (4) works with a rotation and consequent compression force generated by a rotation of 5 to 60 rpm in order to reach a minimum density of 450kg/m3 to ensure good feeding in the fusion screw (5) and avoiding the return of gases. System, according to claim 1, characterized in that the compactor (4) compresses the raw material together with the catalyst and leads them to a fusion screw (5). System, according to claim 1, characterized in that the melting screw (5) preheats the material to a temperature between 200 °C and 350 °C. System, according to claim 1, characterized in that after leaving the fusion screw (5), the material enters a heat exchanger (6), which heats the material between 350 °C and 450 °C. System, according to claim 1, characterized in that the pyrolysis reaction takes place in the main reactor (7) in the temperature range between 420 °C and 460 °C and with a gauge pressure of - 20.0 to + 50, 0 KPa (-0.2 to + 0.5 Bar), for a residence time of 10 minutes to 4 hours, preferably 2 to 3 hours. System, according to claim 8, characterized in that the main reactor (7) is of the cstr type (continuous stirred-tank reactor), with a centralized and split axis in the form of an anchor, which works at a rotation between 1 and 30 rpm, and can rotate both clockwise and counterclockwise. System, according to claim 9, characterized in that the main reactor (7) has an L/D index between 3.5 and 7.0, and is jacketed to receive the necessary heat from the furnace to carry out the pyrolytic reaction. System, according to claim 10, characterized by the fact that the main reactor (7) still comprises an axis weighing between 600 and 2000 kg and presenting at its base, just after the anchor, a termination in the form of a helicoid that, together with the discharge valve (35) and sealing thread (29) allow the removal of carbon ash either continuously or intermittently. System, according to claim 1, characterized in that the temperature of the hydrocarbon stream at the outlet of the reflux tower (8) is maintained between 220°C and 320°C, preferably between 240°C and 280°C with turbulence of Reynolds number between 30,000 and 300,000, and without catalytic metals, in which the temperature control is done by a fan (22) that circulates the cold air in its shirt. System, according to claim 12, characterized by the fact that the reflux tower (8) has a divergent conical shape in its jacket with a system of rings and "Chinese hats" that combined with the flow of the output current of the main reactor ( 7) provide a turbulent flow to maximize thermal exchange and at the same time allow the heavy fraction (molecules with chains greater than C20-C28) to flow and return to the main reactor (7). System, according to claim 1, characterized in that the catalysis tower (9) with an L/D index of 3.0 to 5.0, allows a residence time of 2 to 12 seconds and presents a catalysis temperature between 350 °C and 550 °C. System, according to claim 1, characterized in that the condensation system (10) condenses the gas at temperatures between 240 °C and 310 °C. System, according to claim 1, characterized in that the fluid is condensed at a temperature of up to 110 °C and at a second point up to 10 °C, using cold water, between 0 °C and -15 °C, preferably -5 °C, coming from a chiller (31). System, according to claim 1, characterized in that the condensation is carried out in the heat exchanger (14) by the pressure increase obtained by the compressor (13), with working pressure ranging from 1.5 bar to 5 bar, and condensing temperature from 30 °C to 70 °C. System, according to claim 1, characterized in that the gas is washed in a gas scrubber (bubbler) (12) mainly with a solution of CaOH or NaOH. System, according to claim 1, characterized in that the residual r-gas tanks (16) store the residual r-gas at a pressure of 4 to 12 bar, and feed the burners that provide thermal energy for the furnaces ( 18 and 20). System, according to claim 1, characterized in that both the LPG and the r-gas/Syngas are transported to the burner and furnace (18) of the main reactor (7), and to the burner and furnace (20) of the roasting reactor (15) by the storage pressure of its tanks. System, according to claim 1, characterized in that the energy reuse of the burner and furnace (18) is done through recirculation in a closed hot gas circuit using a melting screw fan (19), in which the return of the hot gas at the inlet of the burner and furnace (18) is 450°C to 550°C. System, according to claim 1, characterized in that the hot air recirculation in the burner and furnace (18) is carried out in a closed circuit between furnace (18), main reactor jacket (7) heat exchanger (26) post tower reflux (8), and plastic melting heat exchanger (6). System, according to claim 1, characterized in that the discharge of the carbon ash generated in the main reactor (7) is carried out by the joint operation between the discharge valve (35), the sealing thread (29) and the shaft of the main reactor (7), being coupled to the roasting reactor (15) which continuously revolves the material and heats it up to 500-6000 °C. System, according to claim 23, characterized in that the roasting reactor (15) has an L/D index between 4.3 and 5.6, and has a heating jacket supplied by the burner and furnace (20). System, according to any one of claims 1 to 24, characterized in that the final product is extracted through the removal screw of the roasting reactor (27) and cooled to 70°C in the carbon ash cooler (28), in which the gases generated by this roasting process are also absorbed by the compression system and used as plant gases, being inserted into the bubbler (12) and, after cooling, the material is sent through conveyor screws to be stored. Process for energy-efficient transformation of varied plastic waste into hydrocarbons using the system as defined in any one of claims 1 to 25, characterized in that it comprises the following steps:

• (a) Preparation of material with removal and control of contaminants, and removal of water;
• (b) Homogenization and feeding of the material in the pyrolysis reactor;
• (c) Pyrolysis reaction;
• (d) Treatment and fractionation of produced hydrocarbons;
• (e) Syngas treatment and storage;
• (f) Use of stored synthesis gas to heat the main and secondary reactors and generate electrical and thermal energy;
• (g) Thermal reuse and exhaustion of burnt gases; and
• (h) Removal and treatment of carbon ash.

Process, according to claim 26, characterized in that step (a) comprises the following substeps:

• a.1 Fine separating sieve, equivalent to a rotating trommel sieve;
• a.2 Manual separation line for removal of tissues and bulky items;
• a.3 Magnetic separation to remove magnetic ferrous material;
• a.4 Grinding to reach a maximum granulometry of 250mm;
• a.5 Removal of plastics (films) by suction;
• a.6 Grinding obtaining particles with a maximum dimension of 25mm;
• a.7 Washing with solution bath to remove contaminants such as chlorinated, oxygenated and silicon;
• a.8 Centrifuge drying to eliminate residual impurities and initial drying;
• a.9 Agglutination for final drying of the material and increase in apparent density; and
• a.10 Storage and transportation.

Process, according to claim 26 or 27, characterized in that step (a) also allows the receipt of plastic material contained in various types of waste and treat them mechanically and chemically with a process involving a specific sequence of sieving, grinding, suction, grinding, washing, centrifugation and agglutination, in which the treated waste meets the following specifications:

• - Maximum moisture content 5%;
• - Apparent density between 200 kg/m3 and 450 kg/m3;
• - Maximum particle size 25mm;
• - Maximum of 300 ppm-m of total chlorides;
• - Maximum of 1100 ppb-m of total oxygenates;
• - Maximum of 300 ppb-m of nitrogenous;
• - Maximum of 500 ppb-m of total sulfur;
• - Maximum of 15 ppm-m of arsenic;
• - Maximum of 50 ppm-m of copper;
• - Maximum of 5 ppm-m of mercury;
• - Maximum of 5000 ppm-m of sodium;
• - Maximum of 150 ppm-m of lead; and
• - Maximum 1100 ppm-m of silicon.

Process, according to claim 26, characterized by the fact that in step (b), the feed into the pyrolysis reactor is started when the storage silo (2) is full, in which, when leaving the silo, the raw material passes by a feeder and dosing screw (3) standardizing the flow and through a control that combines the reading on the solid flow meter (33) with the dosage made by the catalyst doser (36) allows the catalyst to be added precisely to the enter the compactor (4) at a rate between 0.1% and 10% by mass depending on the input of raw material. Process, according to claim 26, characterized in that the compactor (4) feeds a melting screw (5) melting the material and raising its temperature to between 200 °C and 350 °C, in which after leaving the screw (5), the material enters a heat exchanger (6), which receives heat from the gas burned in the furnace (18), heats the material between 350 °C and 450 °C and feeds it into the main reactor (7). Process, according to claim 26, characterized in that in step (c), the pyrolysis reaction occurs in the main reactor (7) in the temperature range between 420 °C and 460 °C and with a gauge pressure of -20, 0 to +50.0 KPa (-0.2 to +0.5 Bar), for a residence time between 10 minutes and 4 hours, preferably 2 to 3 hours. Process, according to claim 26, characterized in that in step (d) the hydrocarbons produced are condensed at three points, the first in the condensation system (10), the second in the heat exchangers (11a and 11b) and the third in the recuperative heat exchanger (14). Process, according to claim 32, characterized by the fact that in the condensation system (10) condense the gas at temperatures between 240 °C and 310 °C. Process, according to claim 32, characterized by the fact that in the heat exchangers (11a and 11b), the fluid is condensed at a temperature of up to 110 °C and at a second point up to 10 °C. Process, according to claim 32, characterized by the fact that in the recovering heat exchanger (14), the working pressure varies from 1.5 bar to 5 bar, using a condensation temperature of 30 °C to 70 °C. Process, according to claim 26, characterized in that in step (e), the residual r-gas is stored in the residual r-gas tanks (16) at a pressure of 4 to 12 bar. Process, according to claim 36, characterized in that the gas stored in the residual gas tanks (16) are used to feed the burners that provide thermal energy for the furnaces (18 and 20), in which they work at temperatures between 750 °C and 1200 °C. Process, according to claim 26, characterized in that in step (g) the recirculation of hot air in the burner and furnace (18) is carried out in a closed circuit between furnace (18), main reactor jacket (7) heat exchanger heat (26) post reflux tower (8), and heat exchanger (6) for melting plastics, in which the return gas to the furnace (18) has a temperature between 400°C and 550°C. Process, according to claim 26, characterized by the fact that in step (h), after being dried in the roasting reactor (15), the carbon ash is conducted through a withdrawal screw (27) from the roasting reactor to the cooling tank (28) where it will remain for 5 to 15 hours until cooled. Process, according to claim 39, characterized in that the carbon ash is used in the sealing thread (29) of the main reactor material removal system (7) or is sent to the final stock silo and packaging for use . Process, according to any one of claims 26 to 40, characterized in that it is carried out continuously or in extended batches, in which the continuous form occurs with the discharge valve (35) having its opening controlled, the sealing thread (29) inserting material and the shaft of the main reactor (7) rotating between 20 and 30 rpm in the direction of discharge, and in the extended batch, the discharge valve (35) operates closed and opens only at the moment of complete discharge of the contained material in the main reactor (7). Hydrocarbons produced according to the process defined in any one of claims 26 to 41, characterized in that they are liquid, pasty, solid and gaseous, from recycled sources, consisting of synthesis gas, light hydrocarbon, r-naphtha, r-diesel, paraffin and carbon black or activated carbon. Hydrocarbons, according to claim 42, characterized in that the synthesis gas has a final boiling point of 30 °C, and is selected from the group consisting mainly of propane, butane, methane, ethane, propylene and iso-propylene. Hydrocarbons, according to claim 42, characterized in that the r-naphtha has an initial boiling point of 30 °C and a final boiling point of 240 °C, and is selected from the group consisting mainly of alkanes, paraffins, iso- paraffins and olefins. Hydrocarbons, according to claim 42, characterized in that the r-diesel has an initial boiling point of 240 °C and a final boiling point of 310 °C, and is selected from the group consisting mainly of alkanes, paraffins, i.e. paraffins and olefins. Hydrocarbons, according to claim 42, characterized in that the paraffin has an initial boiling point of 310 °C and a final boiling point above 330 °C, in which it is preferably solid at room temperature, liquid between 35 °C and 55 °C, and be selected from the group consisting mainly of low density straight chain paraffins. Hydrocarbons, according to claim 42, characterized in that the carbon black has a particle size between 10 and 320 nm and apparent density (dbp) between 50 and 120, and the activated carbon has a humidity of up to 5%, density between 400 and 600 kg/m3, min surface area of 300 m2/g and particle size (<100μm) minimum of 80%. Use of hydrocarbons as defined in any one of claims 42 to 47, characterized by the fact that it is as follows:

• - Recycled bottled gas to replace fossil gas in heating applications (r-waste gas);
• - Source for generating renewable energy from recycled gas (r-residual gas);
• - Naphtha recycled in petrochemical crackers to produce virgin plastics (naphtha);
• - Recycled additive for fossil diesel oil (diesel);
• - Recycled raw materials for industry
• chemistry replacing fossil hydrocarbons
• (naphtha/light/diesel);
• - Recycled chemical inputs replacing fossil inputs (light/diesel);
• - Sustainable burning oils to replace fossil oils (/light/diesel);
• - Recycled paraffins for industrial and non-industrial application replacing fossil paraffins (paraffins);
• - Recycled carbon black replacing fossil carbon black (carbon black) and recycled activated carbon replacing fossil material;

Use of hydrocarbons, according to claim 48, characterized by the fact that it is also for:

• - Valuation of plastics with low added value, multilayer plastics and multicomponent plastics that could end up in landfills;
• - Production of petrochemical naphtha from recycled sources (r-naphtha) to replace fossil naphtha;
• - Production of diesel from recycled sources (r-Diesel) and replacement of fossil diesel;
• - Production of other hydrocarbons (r-hydro) with application in the chemical industry;
• - Production of light paraffins (r-light paraffins);
• - Production of heavy paraffins (heavy r-paraffins);
• - Production of carbon black (r-carbon black) and activated carbon (r-activated carbon);
• - Production of synthesis gas (r-waste gas); and
• - Production of electricity from renewable sources.

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