WO2025210070A1

WO2025210070A1 - Process for recycling rubber-based solid materials from solid automotive waste material

Info

Publication number: WO2025210070A1
Application number: PCT/EP2025/058942
Authority: WO
Inventors: Hannah Stephanie MANGOLD; Miika FRANCK; Nok-Young Choi; Rainer Xalter
Original assignee: BASF SE
Current assignee: BASF SE
Priority date: 2024-04-03
Filing date: 2025-04-02
Publication date: 2025-10-09
Anticipated expiration: 2026-10-03

Abstract

The present invention relates to a process for recycling rubber-based solid materials M1 from solid automotive waste material W, a recycling unit for carrying out said process, and an automotive material comprising the product(s) obtained by said process.

Description

Process for recycling rubber-based solid materials from solid automotive waste material

The recycling of end-of-life vehicles is known for years now. In particular, researches have been developed for recycling tires, windows, motors, etc. However, only very few processes for recycling automotive shredder residue (ASR) have been developed. As known in the art, ELVs (end- of-life vehicles) are processed according to a treatment scheme comprising three main phases: depollution, dismantling and shredding. The ferrous fraction represents about 70-75 weight-% of the weight of shredded material, while nonferrous metals represent about 5 weight-% of the total weight of shredded material. The remaining 20-25 weight-% is referred to as automotive shredder residue (ASR), such proportions in the ELV have increased over the past years and will most likely continue as may be taken from R. Cossu, et al., “Automotive shredder residue (ASR) management: An overview”, Waste Management, Volume 45, November 2015, Pages 143-151. Such that processes for recycling ASR have to be developed. For example, EP0692356 suggests to recycle automotive shredder residue by preparing a composite material comprising ASR and a virgin polymer; Vijayan, S.K.; Kibria, M.A.; Uddin, M.H.; Bhattacharya, S. “Pretreatment of Automotive Shredder Residues, Their Chemical Characterisation, and Pyrolysis Kinetics." Sustainability 2021 , 13, 10549 suggests to recycle automotive shredder residue by pyrolysis; and Juliana Argente Gaetano, Valdir Schalch, Javier Mazariegos Pablos “Characterization and recycling of the fine fraction of automotive shredder residue (ASR) for concrete paving blocks production" Clean Technologies and Environmental Policy (2020) 22:835-847 suggest to recycle ASR by solidification with cement, gravel and sand for paving blocks production. As may be taken from the prior art, there is no technique which would permit to obtain high valued pyrolysis oils from ASR, in particular for producing highly-valuable products. Therefore, there is still a need to provide improved process for recycling solid automotive waste material.

EP 3 907 267 A1 relates to a process for purifying a crude pyrolysis oil originating from the pyrolysis of plastic waste to obtain a purified pyrolysis oil having a reduced nitrogen, sulfur and halogen content in relation to the provided crude pyrolysis oil.

WO 2015/184343 A1 relates to the manufacturing of durable thermoset in-mold finishing films (TIMFFs) combining in-mold decorating and in-mold coating capabilities, to molded articles having TIMFFs adhering to their surfaces and both showing a decoration and providing protection, and to thermosetting resin formulations used in the manufacturing of TIMFFs. WO 2024/033212 A1 relates to process for the depolymerization of mixed automotive plastic waste via thermocatalytic degradation.

US 5,554,657 A relates to a process for recovering polyester polymers from a mixed polymer recycle stream through use of a solvent that selectively dissolves polyester polymers and substantially rejects dissolution of most other polymers expected to be present in the mixed polymer recycle stream.

Zhao Yi-Bo et al., “Solvent-based separation and recycling of waste plastics: A review”, CHEMOSPHERE, 1 October 2018, pages 707 to 720 focuses on an environmentally friendly and potentially profitable method for plastics separation and recovery and solvents extraction.

Therefore, it was an object of the present invention to provide an improved process for recycling solid automotive waste material W, in particular automotive shredder residue (ASR), which permits to obtain high valued pyrolysis oils, those being able to produce highly-valuable products. Indeed, it was an object to develop a process for improving sustainability of the recycling processes in the automotive industry.

Therefore, the present invention relates to a process for recycling rubber-based solid materials M1 from solid automotive waste material W, the process comprising

(i) providing the solid automotive waste material W comprising the rubber-based solid materials M1 , W further comprising one or more solid materials M2 having a chemical composition different to the rubber-based solid materials M1 , wherein the rubber-based solid materials M1 comprises, in addition to rubber and/or within rubber, one or more halogens;

(ii) separating M1 from M2 comprised in W provided according to (i), comprising subjecting the material W to kinetic energy separation method or electrostatic separation method, obtaining a mixture MS(1) comprising the rubber-based solid materials M1 , and a mixture MS(2), depleted in M1 compared to W, comprising the one or more solid materials M2;

(iii) sorting the rubber-based materials M1 comprised in MS(1) obtained according to (ii) by elemental composition, obtaining an halogen-rich rubber-based solid materials fraction f11 comprising the one or more halogens, and obtaining an halogen-poor rubber-based solid materials fraction f12, being depleted in the one or more halogens compared to M1, comprising rubber;

(iv) optionally subjecting the halogen-poor fraction f 12 obtained according to (iii) to a purification treatment, obtaining a purified solid mixture MP comprising rubber; (v) subjecting the halogen-poor rubber-based solid materials fraction f 12 comprising rubber obtained according to (iii), or the purified solid mixture MP comprising rubber obtained according (iv), to pyrolysis in a pyrolysis reaction unit RU(p), obtaining a pyrolysis oil.

Step (i)

Preferably the solid automotive waste material W is obtained from end-of-life vehicles, preferably the solid waste material W is an automotive shredder residue ASR.

The automotive shredder residue ASR may be obtainable, preferably is obtained, by shredding vehicles. Preferably, the automotive shredder residue is obtainable by depollution of the vehicles, dismantling the vehicles, shredding the vehicles, and separating metal particles from the shredded vehicles.

The vehicles are typically end-of-life vehicles (also called “ELV”), which are typically at least 15 years old. The vehicles can be passenger cars, light-duty or heavy-duty trucks, motorbikes, a utility vehicle, an agricultural vehicle, or recreational vehicles. The vehicle can be an electric vehicle, such as a fully electric vehicle or a hybrid electric vehicle.

In depollution of vehicles hazardous liquids such as fuel, lubricating oil, coolants, brake fluids and batteries can be removed from the vehicles prior to shredding.

The dismantling of vehicles may comprise selective removal of parts, such as engines, gearboxes, tires, glass, and plastics, for being reused as spare parts for the second-hand market. The dismantling may also comprise the removal of larger plastic components, such as bumpers, dashboard, fluid containers for recycling the plastics separately.

The ASR may comprise further waste from other sources. For examples, garbage from the last owners may remain in the trunk or interior of the vehicles. The advantage of the present process is that it can handle broadly varying compositions of the ASR.

The shredding can be made with a vehicle shredder machine. Vehicle shredder machines are manufactured in different sizes. Typically, a vehicle shredder machine comprises a heavy fastturning rotor, which may revolve in a vertical or a horizontal plane and is often equipped with swinging hammers. The vehicle shredder machine tears and shreds the car hulk until its parts are reduced to fragments with a desired fragment size, such as up to 30 cm, preferably 1 mm to 15 cm. Then the fragments may pass through grids and leave the rotor housing. After shredding, the metal fragments such as ferrous and non-ferrous metal fragments can be separated from the shredded vehicles. The ferrous metal fragments can be removed by magnetic separators. The non-ferrous metal fragments can be separated from the shredded vehicles by eddy current separators, by heavy media sink/float units which separate on the basis of density, or by manual sorting. Typically, 60 - 90 wt.-% of the vehicle weight is metal, which can be separated from the shredded vehicle.

The automotive shredder residue may represent about 10 - 40 wt.-%, preferably from 15 - 35 wt.-%, and in particular from 20 - 30 wt.-% of the original vehicle weight.

The automotive shredder residue may comprise fragments of various polymeric vehicle parts, such as fragments of bumpers, interior panels, dashboard, cable insulation, fuel tank, electrical insulation, flexible foam seating, foam insulation panels, automotive suspension bushings, electrical potting compounds, car body parts, pillar coverings, spoilers polymer parts coated with automotive paint, wheel covers, gears, bushes, cams, bearings, weatherproof coatings, interior and exterior trims, fuel systems, gear housings, headlamp retainer, engine cover, connector housings, door handles, carburetor components, exterior mirror components, windscreen wiper components, windscreen wiper protective housings, decorative grilles, cover strips, roof rails, window frames, sliding roof frames, antenna cladding covers, front and rear lights, radiator grill and body exterior parts, engine covers, cylinder head covers, intake pipes, cylinder head covers, engine covers, housings for charge air coolers, charge air cooler valves.

The automotive shredder residue may comprise fragments of various polymeric vehicle parts, such as fragments of

- bumpers, interior panels, dashboard, cable insulation, where these fragments are often made of polypropylene;

- fuel tank, electrical insulation, where these fragments are often made of polyethylene;

- flexible foam seating, foam insulation panels, automotive suspension bushings, electrical potting compounds, hard plastic parts, transmission mounts, motor mounts, seals, impact foam parts, where these fragments are often made of polyurethane;

- body parts, dashboards, wheel covers, where these fragments are often made of acryloni- trile-butadiene-styrene;

- gears, bushes, cams, bearings, charge air coolers, cylinder head covers, oil pans, engine cooling systems, thermostat and heater housings, exhaust systems including mufflers and housings for catalytic converters, air intake manifolds, timing chain belt front covers, where these fragments are often made of nylon 6 or nylon 6.6.;

- interior and exterior trims, fuel systems, small gears, where these fragments are often made of polyoxymethylene; - wiper arm and gear housings, headlamp retainer, connector housings, where these fragments are often made of polyethylene terephthalate; and

- door handles, bumpers, carburetor components, where these fragments are often made of polybutylene terephthalate.

The automotive shredder residue may comprise at least 30 wt.-%, preferably at least 40 wt.-%, and in particular at least 50 wt.-% of the fragments of the polymeric vehicle parts.

The automotive shredder residue may comprise at least 20 wt.-%, preferably at least 30 wt.-%, and in particular at least 40 wt.-% of the fragments of the polymeric vehicle parts, which are black polymeric vehicle parts. The black polymeric vehicle parts usually comprise carbon black pigments.

The automotive shredder residue may comprise up to 15 wt.-%, preferably up to 10 wt.-%, and in particular up to 5 wt.-% of metal fragments, such as ferrous and non-ferrous metal particles.

The automotive shredder residue may comprise up to 15 wt.-%, preferably up to 10 wt.-%, and in particular up to 5 wt.-% of wood and cardboard.

The automotive shredder residue may comprise up to 15 wt.-%, preferably up to 10 wt.-%, and in particular up to 5 wt.-% of glass fragments, e.g. broken window glass fragments.

The automotive shredder residue can be separated into a shredder light fraction (also called SLF) and a shredder heavy fraction (also called SHF). The separation of the SLF and the SHF can be achieved by air classification. Another air classification can be made by the rotary movement of the vehicle shredder machine may create a fanning action that can blow out the shredder light fraction, and the shredder heavy fraction may leave the vehicle shredder machine through a grid.

The SLF can be present in an amount of 55 - 90 wt.-%, preferably 65 - 85 wt.-%, and in particular at 70 - 80 wt.-% of the automotive shredder residue. The SHF may represent the remaining amount to 100 wt.-%.

The SHF can be present in an amount of 10 - 45 wt.-%, preferably 15 - 35 wt.-%, and in particular at 20 - 30 wt.-% of the automotive shredder residue. The SLF may represent the remaining amount to 100 wt.-%.

The SLF usually contains a lower weight percentage of rubber particles than the SHF. The SLF usually contains a lower weight percentage of glass particles than the SHF. The SLF usually contains a lower weight percentage of metal particles than the SHF. The SLF usually contains a higher weight percentage of polyurethane foam particles than the SHF.

The SLF usually contains a lower weight percentage of solid and sand than the SHF.

Preferably at least 20 weight-%, more preferably at least 30 weight-%, more preferably at least 40 weight-%, more preferably at least 50 weight-%, more preferably at least 60 weight-%, of M1 consist of rubber.

Preferably M2 can be one or more of polymer-based materials, the polymer being other than rubber. Preferably the polymer-based materials other than rubber comprises one or more of polyurethanes, polyamide-based materials, such as polyamide 6 (PA6), polyolefin-based materials, such as of polyethylene (PE), polypropylene (PP), polymethylpentene (PMP), polybutene-1 (PB- 1), ethylene-octene copolymers, stereo-block PP, olefin block copolymers and/or propylene-bu- tane copolymers and polyisobutylene (PIB) and polyesters such as polyethylene terephthalate (PET) and polybutylene terephthalate (PBT).

Optionally, the process further comprises sorting M2, being one or more of polyurethanes, polyamide-based materials, and polyolefin- based materials, such as of polyethylene (PE), polypropylene (PP), polymethylpentene (PMP), polybutene-1 (PB-1), ethylene-octene copolymers, stereo-block PP, olefin block copolymers and/or propylene-butane copolymers and polyisobutylene (PIB), and polyesters such as such as polyethylene terephthalate (PET) and polybutylene terephthalate (PBT), by chemical composition, obtaining one or more fractions by type of polymer. For example, a fraction comprising the polyurethanes, a fraction comprising the polyamides, a fraction comprising the polyolefin- based materials such as PE and PP, and/or a fraction comprising the poylesters.

According to this option, the process further comprises subjecting each of the one or more fractions obtained from M2 separately to depolymerization conditions.

Preferably, providing the solid automotive waste material W comprising the rubber-based solid materials M1 , W further comprising one or more solid materials M2 having a chemical composition different to the rubber-based solid materials M1 according to (i) comprises shredding and/or cutting W in a shredding unit US1.

Preferably the length of each sides of the shredded and/or cut material W is in the range of from 0.5 to 10 cm, more preferably in the range of from 0.5 to 5 cm. Step (ii)

Preferably separating according to (ii) comprises the kinetic energy separation method being a ballistic separation method or a size separation method, more preferably a ballistic separation method.

Alternatively, preferably separating according to (ii) comprises the electrostatic separation method being a sink-float separation method.

Any ballistic separation method (sorting by size and density) known in the art can be used for the kinetic energy separation method according to (ii). For example, the ballistic separation method can be as disclosed in DE 19535296 A1.

Any size separation method (sorting by size) known in the art can be used for the kinetic energy separation method according to (ii). For example, the separation method can be as disclosed in WO 2012/015299 A1.

Any sink float separation method known in the art can be used for the kinetic energy separation method according to (ii). The sorting will depend on the density, the surface properties and hydrophobicity of the materials to be sorted. For example, the sink float separation method can be as disclosed in Markus Bauer, et al., “Sink-float density separation of post-consumer plastics for feedstock recycling”, November 6, 2017, Journal of Material Cycles and Waste Management (2018) 20:1781-1791 , https://doi.org/10.1007/s10163-018-0748-z.

More preferably separating according to (ii) comprises, more preferably consists of, a ballistic separation method.

Step (iii)

Preferably M1 has an halogen content in the range of from 0.5 to 5 weight-%, based on the weight of M1, determined as described in Analytics 2.

For example, X-ray determination method can be as disclosed in Cecilia Chaine, et al., “Optimized industrial sorting of WEEE plastics: Development of fast and robust h-XRF technique for hazardous components”, Case Studies in Chemical and Environmental Engineering 7 (2023) 100292. Optionally, after (ii) and prior to (iii), the process further comprises washing the rubber-based solid materials M1 comprised in MS(1) obtained according to (ii), more preferably the washing is performed with water, or one or more caustic agents, or one or more detergents, wherein the washing is followed by drying the washed materials M1.

Alternatively, the washing can be performed during separating according to (ii).

Preferably sorting according to (iii) is automated sorting.

Preferably sorting according to (iii) comprises using one or more of a conveyor, sensors, lights, a laser, an X-ray source, such as X-ray tubes, a radioisotopic source, a detector, and a camera.

Preferably sorting according to (iii) is an X-ray fluorescence sorting method.

In the context of the present invention, the halogen content in the halogen-rich rubber-based materials fraction f11 is superior to the halogen content in the halogen-poor rubber-based materials fraction f12.

Preferably the halogen content in the halogen-rich rubber-based materials fraction f 11 is superior to the halogen content in M1.

Preferably the halogen content in the fraction f12 is inferior to the halogen content in M1 and inferior to the halogen content in f11. Indeed, thanks to the separation by elemental composition according to (iii), the fraction to be pyrolysed is poor in, or even free of, halogen.

Without wanted to be bound to any theory it has been found that this sorting (iii) beneficial for the downstream treatment, in particular pyrolysis, as it will permit to provide high-quality pyrolysis which will preferably not require further treatment, such as hydroprocessing which are very expensive, prior to be cracked (steam cracked) or convert to syngas as in (vi).

Such treatment prior to (v) or (vi) can also permit to reduce the corrosion of the equipment used for the pyrolysis oil, such as the pipes and vessels.

Preferably at most 1000 ppmw, more preferably at most 500 ppmw, more preferably at most 250 ppmw, more preferably at most 100 ppmw, of the halogen-poor rubber-based solid materials fraction f 12 consist of halogen, the content being determined as described in Analytics 2. Preferably at least 20 weight-%, more preferably at least 30 weight-%, more preferably at least 40 weight-%, more preferably at least 50 weight-%, more preferably at least 60 weight-% preferably at least 70 weight-%, of the fraction f 12 consist of rubber.

Optionally sorting according to (iii) comprises comminuting the rubber-based solid materials M1 comprised in MS(1) obtained according to (ii), obtaining pieces of M1.

Preferably sorting according to (iii) comprises

(111.1) spreading out M1 , or pieces of M1 obtained as described in embodiment 10, comprised in MS(1) on a conveyor;

(111.2) automated analyzing the rubber-based solid materials M1 comprised in MS(1) obtained according to (ii), or the pieces of rubber-based solid materials M1 comprised in MS(1) as defined in embodiment 10, spread out on the conveyor according to (iii.1): using one or more of sensors, lights, a detector and an X-ray source to identify the elemental composition of rubber-based materials, or of the pieces of the rubber-based materials;

(111.3) separating the materials in at least two different fractions based on the presence of halogen, obtaining

- an halogen-rich rubber-based solid materials fraction f11 comprising the one or more halogens, and

- an halogen-poor rubber-based solid materials fraction f12, being depleted in the one or more halogens compared to M1 , comprising rubber;

(111.4) removing the fraction f12 obtained according to (iii.3) from the conveyor. Preferably the conveyor is a belt conveyor.

Step (iv)

Optionally, M1 comprises, in addition to rubber, one or more fillers F, the one or more fillers F preferably comprising one or more of magnesium silicate hydrate, glass fibers, aluminum hydroxide (inorganic flame retardant), ammonium polyphosphate (inorganic flame retardant), barium sulfate, calcium carbonate, wollastonite, carbon black, and titanium dioxide.

In the context of the present invention, the term “fillers”, as also known in the art, refers to inorganic materials (inert materials) having a structural function which are typically added to a substance (e.g. a polymer) to improve certain characteristics such as physical and/or mechanical properties. For example, fillers are incorporated into polymer-based materials to improve strength, stiffness, thermal conductivity, reduce shrinkage, and so on. Examples of fillers include glass fibers, carbon particles such as carbon black, or talc. Fillers are not additives which are rather active (non-inert) substances. Preferably the one or more fillers F are present in M1 in an amount in the range of from 0.05 to 75 weight-%, based on the weight of W.

Preferably the halogen-poor rubber-based solid materials fraction f12, comprises, in addition to rubber, one or more fillers F; wherein more preferably the one or more fillers F comprises one or more of magnesium silicate hydrate, glass fibers, aluminum hydroxide (inorganic flame retardant), ammonium polyphosphate (inorganic flame retardant), barium sulfate, calcium carbonate, wollastonite, carbon black, and titanium dioxide.

Preferably the one or more fillers F are present in the halogen-poor rubber-based solid materials fraction f12 in an amount in the range of from 0.1 to 75 weight-%, more preferably in the range of from 5 to 70 weight-%, based on the weight of the fraction f 12.

Preferably subjecting the halogen-poor rubber-based solid fraction f12 obtained according to (iii) to a purification treatment according to (iv) comprises

(iv.1 ) subjecting the fraction f 12, comprising impurities and/or one or more fillers F, to rubberdissolution conditions in presence of a solvent SD, wherein the impurities and F are inert to the rubber-dissolution treatment, obtaining an intermediate mixture comprising the impurities and/or the one or more fillers F and further comprising rubber dissolved in SD;

(iv.2) passing the intermediate mixture obtained according to (iv.1 ) in a solid-liquid separation unit Sil, obtaining a mixture M(F) comprising the impurities and/or the one or more fillers F, and a mixture MD, depleted in the impurities and the one or more fillers F, if any, compared to f12, comprising rubber dissolved in SD;

(iv.3) subjecting MD comprising rubber dissolved in SD obtained according to (iv.2) to precipitation conditions, obtaining a purified solid mixture MP comprising precipitated rubber.

Preferably the solvent SD used in (iv) is selected from the group consisting of n-hexane, n-hep- tane, 2,2-dimethylbutane, toluene, benzene, cyclohexane, methylcyclohexane, cyclopentane, methylcyclopentane, and mixtures of two or more thereof, more preferably is selected from the group consisting of n-hexane, n-heptane, 2,2-dimethylbutane, methylcyclohexane, and methylcyclopentane.

In the context of the present invention, the rubber-dissolution treatment is performed at a temperature below the ebullition temperature of SD.

Preferably, SD has a Hansen solubility parameter 5H in the range of from 0 to 10 MPa^1/2, more preferably in the range of from 0 to 8 MPa^1/2, more preferably in the range of from 0 to 7 MPa^1/2. In the context of the present invention, the Hansen solubility parameter <5_H is a known parameter which characterizes the solubility of a compound. <5_H relates to the energy from hydrogen bonds between molecules. For numerous compounds, such as xylene, toluene and cyclohexane, the Hansen parameter bn can be found in standard chemical books. The Hansen solubility parameters 5H mentioned in the present invention refers to values tabulated in: Hansen, C.M., Hansen Solubility Parameters - A user’s handbook, 2. Edition, CRC Press, Boca Raton, USA, 2007.

- (iv.1)

It is preferred that according to (iv.1 ), no solvent other than SD is involved in the rubber-dissolution treatment.

Preferably from 5 to 99 weight-%, more preferably from 20 to 98.5 weight-%, more preferably from 30 to 98 weight-%, of W consist of M 1.

Preferably the rubber-dissolution treatment according to (iv.1 ) is performed at a temperature in the range of from 55 to 200 °C, more preferably in the range of from 100 to 160 °C.

Preferably the rubber-dissolution treatment according to (iv.1 ) is performed at a pressure in the range of from 800 to 200 000 hPa, more preferably in the range of from 800 to 10000 hPa.

The present inventive process has an improved polymer extraction and isolation method by using a solvent SD at elevated temperatures, i.e. preferably from 55 to 200 °C, more preferably from 100 to 160 °C, to extract the desired polymers which are then obtained by precipitating (for example by cooling) the desired polyolefin/rubber from supersaturated solutions of the single non-polar solvent. This approach simplifies the overall process including the recycling of solvents as well as the equipment needed for carrying out the process on large continuous scale while reducing the energy expenditure compared to the process known in the art.

Preferably the dissolution treatment according to (iv.1 ) is performed in a reactor unit RD.

Preferably, the fraction f 12 is fed into the reactor unit RD via gravity or pneumatic transport.

Preferably the rubber-dissolution treatment according to (iv.1 ) comprising, bringing in contact f 12 with the solvent SD at a weight ratio of the solid fraction f 12 relative to the solvent SD being in the range of from 1 : 1 to 1 :20, more preferably in the range of from 1 :3 to 1 : 15, more preferably in the range of from 1 :4 to 1 :12, obtaining an intermediate mixture comprising the impurities and/or the one or more fillers F and further comprising rubber dissolved in SD.

Preferably, the temperature of the intermediate mixture obtained according to (iv.1 ) is essentially maintained, more preferably maintained, via one or more heated tubes used for transferring said intermediate mixture into Sil.

- (iv.2)

Preferably the solid-liquid separation unit Sil used in (iv.2) is a filtration unit or a centrifugation unit, more preferably a filtration unit, the filtration unit more preferably having a mesh size in the range of from 1 to 100 micrometers, more preferably in the range of from 10 to 50 micrometers.

Preferably the filtration unit comprises a filter for blocking the mixture M(F) comprising the impurities and/or the one or more fillers F and a receiving vessel for the mixture MD comprising the rubber dissolved in SD.

Preferably the filtration unit is operated under a pressure pp, with pp s 1 bar(abs), more preferably pp is in the range of from 1 to 30 bar(abs), more preferably in the range of from 1 to 10 bar(abs), more preferably in the range of from 1 to 6 bar(abs).

- (iv.3)

Preferably, the precipitated rubber is in the form of powder, the particles having an average size in the range of from 1 micrometer to 1 millimeter, more preferably in the range of from 10 micrometers to 100 micrometers, the particles average size being determined as defined in Analytics 1 .

Preferably the halogen content in MP obtained according to (iv.3) is inferior to the halogen content in W provided in (i).

Preferably MP obtained according to (iv.3) has a halogen content of at most 1000 ppmw, more preferably at most 500 ppmw, more preferably at most 250 ppmw, more preferably at most 100 ppmw, based on the weight of MP, the content being determined as described in Analytics 2. Preferably the precipitated rubber obtained according to (iv.3) has a halogen content of at most 1000 ppmw, more preferably at most 500 ppmw, more preferably at most 250 ppmw, more preferably at most 100 ppmw, based on the weight of the precipitated rubber, the content being determined as described in Analytics 2.

Preferably MP obtained according to (iii) has a Cl content of at most 1000 ppmw, more preferably at most 500 ppmw, more preferably at most 250 ppmw, more preferably at most 100 ppmw, based on the weight of MP, the content being determined as described in Analytics 2.

Preferably the precipitated rubber obtained according to (iii) has a Cl content of at most 1000 ppmw, more preferably at most 500 ppmw, more preferably at most 250 ppmw, more preferably at most 100 ppmw, based on the weight of the precipitated rubber, the content being determined as described in Analytics 2.

Preferably MP obtained according to (iv.3) has a O content of at most 1000 ppmw based on the weight of MP.

Preferably MP obtained according to (iv.3) has a N content of at most 1000 ppmw based on the weight of MP.

Temperature reduction

Preferably (iv.3) comprises

- subjecting MD comprising the rubber dissolved in SD obtained according to (iv.2) to precipitation at a temperature TP and a pressure pp, with TP < TD, being the temperature of dissolution according to (iv.1), and TP < 100 °C, obtaining an intermediate mixture IM comprising SD and the precipitated rubber;

- passing IM in a solid-liquid separation unit SU1 , obtaining a purified mixture MP comprising the precipitated rubber, and a liquid mixture comprising SD.

Preferably (iv.3) comprises

- cooling MD comprising the rubber dissolved in SD obtained according to (iv.2) for precipitation at a temperature TP and a pressure pp, with TP < TD, being the temperature of dissolution according to (iv.1), and TP < 100 °C, obtaining an intermediate mixture IM comprising SD and the precipitated rubber;

- passing IM in a solid-liquid separation unit SU1 , obtaining a purified mixture MP comprising the precipitated rubber, and a liquid mixture comprising SD. Preferably, TP < TD - 5 °C, more preferably TP < TD - 10 °C, more preferably TP < TD - 30 °C, more preferably TP < TD - 30 °C.

Preferably, cooling according to (iv.3) comprises

(iv.3.a) passing a cooling medium into a cooling jacket of a precipitation unit containing MD; or (iv.3.b) letting MD stand into a precipitation unit.

Preferably, the cooling rate is in the range of from 2 to 200 K/h, more preferably in the range of from 3 to 150 K/h, more preferably 20 to 120 K/h, more preferably 10 to 60 K/h.

Anti-solvent addition

Preferably (iv.3) comprises subjecting MD comprising the rubber dissolved in SD obtained according to (iv.2) to precipitation by contacting MD with a polar solvent, also called “anti-solvent”, obtaining an intermediate mixture IM’ comprising SD, the polar solvent and the precipitated rubber; passing IM’ in a solid-liquid separation unit SU2, obtaining the purified mixture MP comprising the precipitated rubber, and a liquid mixture comprising SD and the polar solvent.

Optionally (iii) further comprises. washing MP, more preferably the solid mixture MP is washed with one or more of methanol, ethanol, propanol, isopropanol, acetonitrile, ethyl acetate, acetone and water; and optionally drying the washed solid mixture MP comprising the precipitated rubber.

Preferably, contacting MD with the polar solvent is performed at a temperature in the range of from 10 to 120 °C, more preferably in the range of from 20 to 60 °C.

Preferably, contacting MD with the polar solvent is performed at a pressure in the range of from 0 to 10 bar(abs), more preferably in the range of from 0.5 to 2 bar(abs).

Preferably, the polar solvent is selected from the group consisting of water, ethanol, methanol, propanol, butanol, acetone, dimethylsulfoxide, acetonitrile, dimethylformamide, ethylacetate, sulfolane, dichloromethane, tetrahydrofurane, and a mixture of two or more thereof, more preferably selected from the group consisting of water, acetone, ethanol, methanol and a mixture of two or more thereof.

Preferably, the polar solvent has an Hansen solubility parameter <5_H of more than 5 MPa^1/2, preferably in the range of from 6 to 50 MPa^1/2, more preferably in the range of from 10 to 30 MPa^1/2. Flash evaporation

Preferably (iv.3) comprises subjecting MD comprising the rubber dissolved in SD obtained according to (iv.2) to precipitation by passing MD in a flash evaporator, obtaining a gaseous stream G3 comprising the evaporated solvent, and further obtaining the purified mixture MP comprising the precipitated rubber.

Optionally, the process further comprises recycling at least a portion of the solvent SD recovered after (iv.3) to the rubber-dissolution treatment according to (iv.1); wherein recycling preferably comprises passing the at least a portion of the solvent SD recovered after (iv.3) in a distillation unit D, obtaining a purified solvent; using the purified solvent to the rubber-dissolution treatment according to (iv.1 ).

Preferably, the distillation unit D is heated by a heating source, more preferably steam. Such heating source preferably is generated from the recycled gas stream obtained after pyrolysis according to (v).

Optionally the process further comprises recycling both the solvent SD and the polar solvent by fractional distillation.

Step (v)

Preferably, the solid fraction f 12 obtained according to (iii), or the purified mixture MP obtained according to (iv), comprises rubber in an amount in the range of from 90 to 100 weight-%, more preferably in the range of from 95 to 100 weight-%, based on the weight of the solid mixture.

Preferably (v) comprises

(v.1) feeding the solid fraction f 12 obtained according to (iii), or the purified mixture MP obtained according to (iv), into the pyrolysis reactor R(p);

(v.2) heating the rubber into the pyrolysis reactor R(p) to a temperature in the range of from

350 to 900 °C, more preferably in the range of from 400 to 550 °C, and a pressure in the range of from 0.5 to 2 bar(abs), more preferably in the range of from 0.9 to 1.5 bar(abs);

(v.3) removing a gas stream GS from the top of R(p) and subjecting GS to condensation conditions in a gas-liquid separation unit LGU, obtaining the pyrolysis oil. Preferably feeding according to (v.1) is performed via a dosing unit, the dosing unit being more preferably one or more of a screw, an extruder and a rotary valve.

It is also conceivable that feeding according to (v.1) is performed via pneumatic conveyor or liquid injector into the pyrolysis reactor R(p).

Preferably, the pyrolysis reactor R(p) is selected from the group consisting of a fluidized bed, a moving bed, an entrained flow, an auger, a screw reactor, an extruder, a stirred tank reactor, a moving bed rotor-stator type reactor, and a rotary kiln, more preferably a fluidized bed. Preferably the fluidized bed is bubbling, turbulent, fast or circulating.

Preferably, the pyrolysis is performed in the pyrolysis reactor R(p) under an atmosphere exempt of oxygen.

Preferably, the pyrolysis is performed by thermal cracking (absence of catalyst) or catalytic cracking, more preferably thermal cracking.

It is noted that such catalyst are used to influence the properties of the pyrolysis products as known by the skilled person.

Preferably the pyrolysis according to (v) is not a hydrothermal treatment.

Optionally, according to (v) the pyrolysis reactor R(p) contains trace amounts of water, wherein preferably trace amounts of water is less than 2 wt.% water calculated on the basis of the total weight of the precipitated polyolefin PP, more preferably less than 1 wt.% water, more preferably less than 0.1 wt.% water.

Preferably the pyrolysis reactor R(p) is free of water.

It is conceivable that prior to the pyrolysis according to (v), the solid fraction f 12 obtained according to (iii), or the purified mixture MP obtained according to (iv), may be subjected to a prepyrolysis at a temperature in the range of from 220 to 360 °C. Such pyrolysis at low temperature permits to pyrolysed PVC if present in the solid mixture. However, in the context of the present invention, such step can be avoided in view of the particular process steps (i) to (iii) prior to (iv) of the process according to the present invention.

Optionally, in the pyrolysis reactor R(p), the solid fraction f 12 obtained according to (iii), or the purified mixture MP obtained according to (iv), is mixed with one or more of CaO, Ca(OH)2 and CaCCh. Such additives permit to react with formed HCI and thus remove impurities such as chlorine from PVC.

In addition or as an alternative, it is conceivable that the gas stream GS exiting the pyrolysis reactor is passed through a catalyst bed or an adsorption bed, in order to reduce the concentration of impurities and atoms other than C and H.

Preferably, in (v.3) after removing GS from R(p) and prior to subjecting GS to condensation conditions in LGU, the gas stream GS is passed through a filtration unit, more preferably a filter, or a cyclone. Such filtration unit or cyclone permits to remove dust particles from the gas stream GS before condensation. In addition to such removal of dust, a catalyst bed or an adsorption bed can be used upstream thereof or downstream thereof to reduce the concentration of impurities and atoms other than C and H.

Preferably, according to (v.3) GS is subjected to a condensation step in LGU at a temperature in the range of from 0 to 80 °C; wherein more preferably LGU is a condenser, a scrubber or a quench.

Preferably, the gas stream GS in (v.3) is subjected to a first condensation step at a temperature in the range of from 50 to 150 °C and to a second condensation step at a temperature in the range of from 35 to 0°C, obtaining the pyrolysis oil; each of the first and second condensation steps more preferably being performed in a separate condenser or quench. Alternatively, the gas stream GS in (v.3) is preferably subjected to only one condensation step at a temperature in the range of from 0 to 80 °C.

The non-condensable “permanent” gases G exiting LGU can be used to generate process heat /electricity by burning in a gas burner, gas motor or combined heat and power plant. The flue gases of this combustion might need to be cleaned according to emission laws to remove dust, ashes and other components.

Preferably the process further comprises, after (v), passing the pyrolysis oil obtained according to (v), as a stream So, into a purification unit PU, obtaining a purified pyrolysis oil.

Preferably, the purification unit PU comprises one or more of a filter, a centrifuge, a decanter, and a decanter centrifuge, more preferably one or more of a filter, a centrifuge and a decanter.

The pyrolysis oil obtained according to (v), more preferably (v.3), can be filtered including the possible use of a filter agent to remove solids. Alternatively, said pyrolysis oil can be centrifuged to remove solids. Further, in the purification unit Pll, water residue can be removed from the pyrolysis oil by decanting or centrifugation. Furthermore, the pH can be adjusted to a pH value of at most 3 or, alternatively, a pH value of at least 8, preferably at least 9. Preferably, the adjustement is performed by the addition of an acid or a base such as an alkali metal hydroxide, for example sodium hydroxide (NaOH), potassium hydroxide (KOH), alkaline earth metal hydroxide, for example calcium hydroxide (Ca(0H)2, NH3, or mixtures thereof sulfuric acid (H2SO4), nitric acid (HNO3) or phosphoric acid (H3PO4).

Steps (vi) and (vii)

Preferably the process further comprises

(vi) subjecting at least a portion of the pyrolysis oil obtained according to (v) to (vi.1 ) cracking, obtaining a stream P1 comprising cracked hydrocarbons; and/or

(vi.2) partial oxidation, obtaining a syngas stream P2 comprising CO and H2.

Optionally the at least a portion of the pyrolysis oil obtained according to (v) is mixed/blended with one or more of a pyrolysis oil other than the one obtained according to (v), bio-oil, hydrotreated bio-oil, naphtha, and feedstocks other than the oils listed in the foregoing suited for such (steam) cracking, prior to cracking according to (vi.1).

Optionally the at least a portion of the pyrolysis oil obtained according to (v) is mixed/blended with one or more of a pyrolysis oil other than the one obtained according to (v), bio-oil, hydrotreated bio-oil, and fossil co-feedstocks suited for partial oxidation, such as heating oils, vacuum residues, preferably vacuum distillation residues, crude oil residues, heavy crude oils, extra heavy crude oils, tar sand bitumen, visbreaker bottom residues, deasphalter bottom residues, C5 asphalthene fraction, high viscous residues, fuel oils, pyrolysis gasolines, waste oils, tar oils, prior to partial oxidation according to (vi.2).

Preferably cracking according to (vi.1) is performed in a cracker, more preferably a steam cracker.

Preferably the cracker is supplied by gas or electrically, more preferably electrically, more preferably from renewable sources.

In the context of the present invention, the stream P1 is a gaseous stream.

Preferably cracking according to (vi.1 ) is performed at a temperature in the range of from 400 to 1000 °C, more preferably in the range of from 500 to 900 °C.

The cracking is preferably performed according to processes know in the art such as those cited in Ullmann’s Encyclopedia of Industrial Chemistry, Ethylene, Ch. 5.1 , pages 469-475 (2012). Preferably the partial oxidation according to (vi.2) is performed in a gasifier, such an entrained flow reactor and/or a fluidized bed reactor.

The partial oxidation is preferably performed according to processes known in the art.

Preferably the process further comprises

(vii) preparing a polymer PA, comprising using one or more of the pyrolysis oil obtained according to (v), the cracked hydrocarbons comprised in the stream P1 contained according to (vi) as described herein, and the CO and/or H2 syngas comprised in the stream P2 obtained according to (vi) as described herein.

Preferably the polymer PA is rubber.

Any process known in the art can be used for preparing the polymer PA being rubber such as the processes as disclosed in Ullmann’s Encyclopedia of Industrial Chemistry, Rubber, 3. Synthetic Rubbers, Introduction and Overview, p. 602-604 (2011),

DO110.1002/14356007. a23_239. pub5.

Preferably the process further comprises

(viii) preparing an automotive material, comprising using one or more of the pyrolysis oil obtained according to (v), the cracked hydrocarbons comprised in the stream P1 obtained according to (vi) as described herein, and the CO and/or H2 comprised in the syngas stream P2 obtained according to (v) as described herein, and the polymer PA obtained according to (vii) as described herein.

The present invention further relates to a recycling unit for carrying out the process according to the present invention, the recycling unit comprising a first separation unit Sll(a) for kinetic energy separation or electrostatic separation; a second separation unit Sll(b) for sorting by elemental composition; a means for transporting MS(1) to Sll(b), preferably being one or more conveyors; a pyrolysis reaction unit RU(p); an outlet means for removing the pyrolysis oil from RU(p); optionally a purification unit Pll; optionally an inlet means for introducing f 12 into Pll; optionally an outlet means for removing the purified mixture MP from Pll; an inlet means for introducing f12 or MP into RU(p).

Preferably Pll comprises a dissolution unit DU, a solid-liquid separation SU and a precipitation unit PPU. Preferably SU is as disclosed herein. Preferably Rll(p) is selected from the group consisting of a fluidized bed, a moving bed, an entrained flow, an auger, a screw reactor, an extruder, a stirred tank reactor, a moving bed rotorstator type reactor, and a rotary kiln, more preferably a fluidized bed. Preferably the fluidized bed is bubbling, turbulent, fast or circulating

The present invention further relates to an automotive material, preferably an automotive vehicle, comprising a polymer PA obtained according to the process of the present invention.

The present invention further relates to a process as described above, preferably the process comprising (i) to (v), or (i) to (vi), as described above, wherein said process (further) comprises the step of converting the pyrolysis oil obtainable or obtained according to (v), or the cracked hydrocarbons comprised in P1 obtainable or obtained according to (vi) as described herein, or the CO and/or H2 comprised in P2 obtainable or obtained according to (vi) as described herein, or a chemical material obtainable or obtained by the process described herein, to obtain a product Q. Said product Q is preferably selected from building block or monomer; or polymer, preferably polymer A, polymer composition, preferably polymer composition A, or polymer product, preferably polymer product A; or cleaning polymer, cleaning surfactant, descaling compound, cleaning biocide or composition or formulation thereof; or agrochemical composition, agrochemical formulation auxiliary or agrochemically active ingredient; or active pharmaceutical ingredient or intermediate thereof, pharmaceutical excipient, animal feed additive, human food additive, dietary supplements, aroma chemical or aroma composition; or aqueous polymer dispersion, preferably polyurethane or polyurethane - poly(meth)acry- late hybrid polymer dispersion, emulsion, binder for paper and fiber coatings, UV-curable acrylic polymer for hot melts and coatings polyisocyanates, hyperbranched polyester polyol, polymeric dispersant for inorganic binder compositions, unsaturated polyester polyol or 100% curable composition; or cosmetic surfactant, emollient, wax, cosmetic polymer, UV filter, further cosmetic ingredient or composition or formulation thereof; or polymer B, polymer composition B, coating composition, other functional composition, foil, molded body, coating or coated substrate.

Further regarding said product Q, it is preferred that the content of the pyrolysis oil obtainable or obtained according to (v), or the cracked hydrocarbons comprised in P1 obtainable or obtained according to (vi) as described herein, or the CO and/or H2 comprised in P2 obtainable or obtained according to (vi) as described herein, in the product Q is 1 weight-% or more, more preferably 2 weight-% or more, more preferably 5 weight-% or more, more preferably 15 weight-% or more, more preferably 30 weight-% or more, more preferably 40 weight-% or more, more preferably 60 weight-% or more, more preferably 80 weight-% or more, more preferably 90 weight-% or more, more preferably 95 weight-% or more; and/or the content of the pyrolysis oil obtainable or obtained according to (v), or the cracked hydrocarbons comprised in P1 obtainable or obtained according to (vi) as described herein, or the CO and/or H2 comprised in P2 obtainable or obtained according to (vi) as described herein, in the product Q is 100 weight-% or less, more preferably 95 weight-% or less, more preferably 90 weight-% or less, more preferably 50 weight-% or less, more preferably 25 weight-% or less, more preferably 10 weight-% or less; and wherein the content is preferably determined based on identity preservation and/or segregation and/or mass balance and/or book and claim chain of custody models, preferably based on mass balance, preferably the International Sustainability and Carbon Certification (ISCC) standard.

The publication Prior Art Disclosure; Issue 684; paragraphs [1000] to [8005]; ISSN: 2198-4786; published: February 12, 2024 will be regarded as Reference RF1 , which is incorporated herein by reference in its entirety. Preferably, the product Q referred to in the preceding paragraph is a product as described in Reference RF1 ; paragraphs [1000] to [8005], Preferably, the process described herein is further a process for the production of a product referred to in the preceding paragraph.

The converting step to obtain the product Q preferably comprises one or more step(s) as described below and can be performed by conventional methods well known to a person skilled in the art. The converting step preferably comprises one or more step(s) selected from: recycling, preferably depolymerizing, gasifying, pyrolyzing, and/or steam cracking; and/or purifying, preferably crystallizing, (solvent) extracting, distilling, evaporating, hydrotreating, absorbing, adsorbing and/or subjecting to ion exchanger; and/or assembling, preferably foaming, synthesizing, chemical conversion, chemically transforming, polymerizing and/or compounding; and/or forming, preferably foaming, extruding and/or molding; and/or finishing, preferably coating and/or smoothing.

In addition, the one or more step(s) are described in detail in Reference RF1 ; paragraphs [1000] to [8005],

The term “building block”, as used in the context of the product Q herein, comprises compounds, which are in a gaseous or liquid state under standard conditions of 0°C and 0.1 MPa. Building blocks are typically used in chemical industry to form secondary products, which provide a higher structural complexity and/or higher molecular weight than the building block on which the secondary product is based. The building block is preferably selected from the group consisting of hydrogen, carbon monoxide, carbon dioxide, ethylene oxide, ethylene glycols, syngas comprising a mixture of hydrogen and carbon monoxide, alkanes, alkenes, alkynes and aromatic compounds. The alkanes, alkenes, alkynes and aromatic compounds comprise in particular 1 to 12 carbon atoms, respectively.

The term “monomer”, as used in the context of the product Q herein, comprises molecules, which can react with each other to form polymer chains by polymerization. The monomer is preferably selected from the group consisting of (meth)acrylic acid, salts of (meth)acrylic acid; in particular sodium, potassium and zinc salts; (meth)acrolein and (meth)acrylates. (Methacrylates comprising 1 to 22 carbon atoms are preferred, in particular comprising 1 to 8 carbon atoms. The terms (meth)acrylic acid, (meth)acrolein or (meth)acrylate relate to acrylic acid, acrolein or acrylate and also to methacrylic acid, methacrolein or methacrylate, where applicable. Further, the monomer can be selected from hexamethylenediamine (HMD) and adipic acid.

The building block can further be an intermediate compound. The term “intermediate compound”, as used in the context of the product Q herein, comprises organic reagents, which are applied for formation of compounds with higher molecular complexity. The intermediate compound can be selected for example from the group consisting of phosgene, polyisocyanates and propylene oxide. The polyisocyanates are in particular aromatic di- and polyisocyanates, preferably toluene diisocyanate (TDI) and/or diphenylmethane diisocyanate (MDI).

The building block and the monomer and typical converting step(s) to obtain the building block or monomer are described in more detail in paragraphs [1000] to [1012] of Reference RF1.

The term “polymer A”, as used in the context of the product Q herein, comprises thermoplastic, e.g., polyamide or thermoplastic polyurethane, thermoset, e.g., polyurethane, elastomer, e.g., polybutadiene, or a copolymer or a mixture thereof and is defined in more detail in paragraphs [2001] to [2007] of Reference RF1.

The term “polymer composition A”, as used in the context of the product Q herein, comprises all compositions comprising a polymer as described above and one or more additive(s), e.g. reinforcement, colorant, modifier and/or flame retardant, and is defined in more detail in paragraph [2008] of Reference RF1. The term “polymer product A”, as used in the context of the product Q herein, comprises any product comprising the polymer A and/or polymer composition A as described above and is defined in more detail in paragraphs [2009] and [2010] of Reference RF1.

The step(s) to obtain the polymer, preferably polymer A, polymer composition, preferably polymer composition A or polymer product, preferably polymer product A is/are described in more detail in paragraph [2011] of Reference RF1.

The term “industrial use polymer”, as used in the context of the product Q herein, comprises rheology, polycarboxylate, alkoxylated polyalkylenamine, alkoxylated polyalkylenimine, poly- ether-based, dye inhibition and soil release cleaning polymers defined in more detail in paragraphs [3035] to [3044] of Reference RF1. The term “industrial use surfactant”, as used in the context of the product Q herein, comprises non-ionic, anionic and amphoteric industrial use surfactants defined in more detail in paragraphs [3008] to [3034] of Reference RF1. The term “industrial use descaling compound”, as used in the context of the product Q herein, comprises non-phosphate based builders (NPB) and phosphonates (CoP) described in more detail in paragraphs [3001] to [3005] of Reference RF1. The term “industrial use biocide”, as used herein, refers to a chemical compound that kills microorganisms or inhibits their growth or reproduction defined in more detail in paragraphs [3006] to [3007] of Reference RF1. The term “industrial use solvent”, as used in the context of the product Q herein, comprises alkyl amides, alkyl lactamides, alkyl esters, lactate esters, alkyl diester, cyclic alkyl diester, cyclic carbonates, aromatic aldehydes and aromatic esters defined in more detail in paragraphs [3045] to [3055] of Reference RF1 . The term “industrial use dispersant”, as used in the context of the product Q herein, comprises anionic and non-ionic industrial use dispersants defined in more detail in paragraphs [3056] to [3058] of Reference RF1. The term “composition and/or formulation thereof’ with reference to the industrial use polymers, industrial use surfactants, descaling compounds and/or industrial use biocides refers to industrial use compositions and/or institutional use products and/or fabric and home care products and/or personal care products defined in more detail in paragraph [3059] of Reference RF1. The converting step(s) to obtain the industrial use polymer, industrial use surfactant, descaling compound and/or industrial use biocide are defined in more detail in paragraph [3060] of Reference RF1. The converting steps to obtain the industrial use composition or formulation of the industrial use polymer, industrial use surfactant, descaling compound and/or industrial use biocide are defined in more detail in paragraph [3061] of Reference RF1.

The term “agrochemical composition”, as used in the context of the product Q herein, typically relates to a composition comprising an agrochemically active ingredient and at least one agrochemical formulation auxiliary. Examples of agrochemical compositions, active ingredients and auxiliaries are described in more detail in Reference RF1 , paragraph [4001], The agrochemical composition may take the form of any customary formulation. The agrochemical compositions are prepared in a known manner, e.g. described by Mollet and Grubemann, Formulation technology, Wiley VCH, Weinheim, 2001 ; or Knowles, New developments in crop protection product formulation, Agrow Reports DS243, T&F Informa, London, 2005. The converting step(s) to obtain the agrochemically active ingredients and auxiliaries may be conducted in analogy to the production step(s) of their analogues that are based on petrochemicals or other precursors that are not gained by recycling processes. In addition, conversion to compounds mentioned in sections “Polymer” and “Cosmetic surfactant, emollient, wax, cosmetic polymer, UV filter, further cosmetic ingredient or compositions or formulations thereof” may be performed as described in these sections as well as the respective paragraphs in Reference RF1.

The term active pharmaceutical ingredients and/or intermediates thereof, as used in the context of the product Q herein, comprises substances that provide pharmacological activity or other direct effect in the diagnosis, cure, mitigation, treatment, or prevention of disease, or to affect the structure or any function of the body. Intermediates thereof are isolated products that are generated during a multi-step route of synthesis of an active pharmaceutical ingredient. The term pharmaceutical excipients, as used in the context of the product Q herein, comprises compounds or compound mixtures used in compositions for various pharmaceutical applications, which are not substantially pharmaceutically active on itself. Active pharmaceutical ingredients and/or intermediates thereof and pharmaceutical excipients are defined in more detail in paragraph [5001] of Reference RF1.

The converting step(s) to obtain the active pharmaceutical ingredients and/or intermediates thereof and pharmaceutical excipients may comprise one or more synthesis steps and can be performed by conventional synthesis and techniques well known to a person skilled in the art.

The terms animal feed additives, human food additives, dietary supplements, as used in the context of the product Q herein, comprises Vitamins, Pro-Vitamins and active metabolites thereof including intermediates and precursors, especially Vitamin A, B, E, D, K and esters thereof, like acetate, propionate, palmitate esters or alcohols thereof like retinol or salts thereof and any combinations thereof; Tetraterpenes, especially isoprenoids like carotenoids and xanthophylls including their intermediates and precursors as well as mixtures and derivates thereof, especially beta carotene, Canthaxanthin, Citranaxanthin, Astaxanthin, Zeaxanthin, Lutein, Lycopene, Apo-carotenoids, and any combinations thereof; organic acids, especially formic acid, propionic acid and salts thereof, such as sodium, calcium or ammonium salts, and any combinations thereof, such as but not limited to mixtures of formic acid and sodium formiate, propionic acid and ammonium propionate, formic acid and propionic acid, formic acid and sodium formiate and propionic acid, propionic acid and sodium propionate and formic acid and sodium formiate; glycerides of carboxylic acids and short and medium chain fatty acids, conjugated linoleic acids, such as omega-6 fatty acid (C18:2) methyl ester and 1 ,2-propandiol and beverage stabilizers, such as polyvinylpyrrolidone-polymer or polyvinylimidazole/polyvinylpyrrolidone-co- polymer. Animal feed additives, human food additives and dietary supplements are defined in more detail in paragraph [5002] of Reference RF1.

The converting step(s) to obtain the animal feed additives, human food additives, dietary supplements may comprise one or more synthesis steps and can be performed by conventional synthesis and techniques well known to a person skilled in the art.

The terms aroma chemical and aroma composition as used in the context of the product Q herein, comprise a volatile organic substance with a molecular weight between 70-250 g/mol comprising a functional group with a carbon skeleton of C5-C16 carbon atoms comprising linear, branched, cyclic, for example with a ring size of C5-C18, bicyclic or tricyclic aliphatic chains and but not necessarily one or more unsaturated structural elements like double bonds, triple bonds, aromatics or heteroaromatics and preferably the one or more additional functional groups are selected from alcohol, ether, ester, ketone, aldehyde, acetal, carboxylic acid, nitrile, thiol, amine. In one aspect, the aroma chemical is a terpene-based aroma chemical, for example selected from monoterpenes and monoterpenoids, sesquiterpenes and sesquiterpenoids, diterpenes, triterpenes or tetraterpenes. Aroma chemicals can be combined with further aroma chemicals to give an aroma composition. Aroma chemicals and aroma compositions are defined in more detail in paragraph [5003] of Reference RF1.

The converting step(s) to obtain the aroma chemical and aroma composition may comprise one or more synthesis steps and can be performed by conventional synthesis and techniques well known to a person skilled in the art.

The term “aqueous polymer dispersion”, as used in the context of the product Q herein, comprises aqueous composition(s) comprising dispersed polymer(s) and is defined in more detail in the section [6001] entitled “aqueous polymer dispersion” of Reference RF1. The dispersed polymers) may be selected from acrylic emulsion polymer(s), styrene acrylic emulsion polymer(s), styrene butadiene dispersion(s), aqueous dispersion(s) comprising composite particles, acrylate alkyd hybrid dispersion(s), polyurethane(s) (including UV-curable polyurethanes) and polyurethane - poly(meth)acrylate hybrid polymer(s). The term “emulsion polymer”, as used herein, comprises polymer(s) made by free-radical emulsion polymerization. Aqueous polyurethane dispersions) are defined in more detail in the section [6002] entitled “Polyurethane dispersions” of Reference RF1. UV-curable polyurethane(s) is/are defined in more detail in the section [6017] of Reference RF1. Polyurethane - poly(meth)acrylate hybrid polymer(s) is/are defined in more detail in the section [6016] of Reference RF1.

The term “polymeric dispersant”, as used in the context of the product Q herein, comprises preferably polymer(s) comprising polyether side chain, in particular polycarboxylate ether polymer(s) and polycondensation product(s) defined in more detail in paragraph [6020] entitled “Polymeric dispersant” of Reference RF1.

The converting (polymerization) step(s) to obtain the aqueous polymer dispersion(s) comprising emulsion polymer(s) is/are defined in more detail in the section [6003] entitled “Emulsion polymerization” of Reference RF1.

The converting (polymerization) step(s) to obtain the aqueous polyurethane dispersion(s) is/are defined in more detail in the section [6014] entitled “Process for the preparation of aqueous polyurethane dispersions” and section [6017)] entitled “Aqueous UV-curable polyurethane dispersions, their preparation and use and compositions containing them” of Reference RF1. Composition(s) and uses of aqueous polymer dispersion(s) and of polymeric dispersant(s) are defined in more detail in the following sections of Reference RF1: section [6004] entitled “Uses of aqueous polymer dispersions”, section [6005] entitled “Binders for architectural and construction coatings” section [6006] entitled “Binders for paper coating” section [6007] entitled “Binders for fiber bonding” section [6008] entitled “Adhesive polymers and adhesive compositions” section [6015] entitled “Aqueous polyurethane dispersions suitable for use in coating compositions” section [6016] entitled “Aqueous polyurethane - poly(meth)acrylate hybride polymer dispersions suitable for use in coating compositions” section [6017] entitled “Aqueous UV-curable polyurethane dispersions, their preparation and use and compositions containing them” section [6018] entitled “Inorganic binder compositions comprising polymeric dispersants and their use” [6019] 100% curable coating compositions

UV-crosslinkable poly(meth)acrylate(s) and its/their uses are defined in more detail in section [6009] entitled “UV-crosslinkable poly(meth)acrylates for use in UV-curable solvent-free hot melt adhesives and their use for making pressure-sensitive self-adhesive articles” of Reference RF1.

Polyisocyanate(s), composition(s) comprising them and their uses are defined in more detail in section [6010] entitled “Polyisocyanates” of Reference RF1. Hyperbranched polyester polyol(s) and its/their uses are defined in more detail in section [6011] entitled “Organic solvent based hyperbranched polyester polyols suitable for use in coating compositions” of Reference RF1. The converting step(s) to obtain the hyperbranched polyester polyols is/are defined in more detail in the section [6012] entitled “Preparation of organic solvent based hyperbranched polyester polyols” of Reference RF1. Coating composition(s) comprising hyperbranched polyester polyol(s), polyisocyanate(s) and additive(s) and substrate(s) coated therewith are defined in more detail in section [6013] entitled “Organic solvent based two component coating compositions comprising hyperbranched polyester polyols and polyisocyanates” of Reference RF1.

Unsaturated polyester polyol(s), solvent-based coating composition(s) comprising said unsaturated polyester polyol(s) and substrate(s) for coating with said coating composition(s) are defined in more detail in section [6018] entitled “Organic solvent based coating composition comprising unsaturated polyester polyols” of Reference RF1.

100% curable coating composition(s) is/are defined in more detail in section [6019] of Reference RF1.

Polymeric dispersant(s) for inorganic binder compositions is/are defined in more detail in section [6020] of Reference RF1. The inorganic binder composition(s) comprising the polymeric dispersants and their use are defined in more detail in section [6021] of Reference RF1. The converting step(s) to obtain the polymeric dispersant(s) are defined in more detail in section [6020] of Reference RF1. The term “inorganic binder composition” comprising the polymeric dispersants), as used herein, comprises preferably in particular hydraulically setting compositions and compositions comprising calcium sulfate and is defined in more detail in section [6021] of Reference RF1 entitled “Inorganic binder compositions comprising the polymeric dispersant and their use”. Specific building material formulation(s) comprising polymeric dispersant(s) or building product(s) produced by a building material formulation comprising a polymeric dispersant are disclosed in more detail in section [6021] of Reference RF1.

The term “cosmetic surfactant”, as used in the context of the product Q herein, comprises nonionic, anionic, cationic and amphoteric surfactants and is defined in more detail in paragraph [7002] of Reference RF1. The term “emollient”, as used in the context of the product Q herein, refers to a chemical compound used for protecting, moisturizing, and/or lubricating the skin and is defined in more detail in paragraph [7003] of Reference RF1. The term “wax”, as used in the context of the product Q herein, comprises pearlizers and opacifiers and is defined in more detail in paragraph [7004] of Reference RF1. The term “cosmetic polymer”, as used in the context of the product Q herein, comprises any polymer that can be used as an ingredient in a cosmetic formulation and is defined in more detail in paragraph [7005] of Reference RF1. The term “UV filter”, as used in the context of the product Q herein, refers to a chemical compound that blocks or absorbs ultraviolet light and is defined in more detail in paragraph [7006] of Reference RF1. The term “further cosmetic ingredient”, as used in the context of the product Q herein, comprises any ingredient suitable for making a cosmetic formulation. Several sources disclose cosmetically acceptable ingredients. E. g. the database Cosing on the internet pages of the European Commission discloses cosmetic ingredients and the International Cosmetic Ingredient Dictionary and Handbook, edited by the Personal Care Products Council (PCPC), discloses cosmetic ingredients. The term “composition and/or formulation thereof’ with reference to the cosmetic surfactant, emollient, wax, cosmetic polymer, UV filter and/or further cosmetic ingredient refers to personal care and/or cosmetic compositions or formulations defined in more detail in paragraph [7007] of Reference RF1. The converting step(s) to obtain the cosmetic surfactant, emollient, wax, cosmetic polymer, UV filter or further cosmetic ingredient is/are defined in more detail in paragraph [7008] of Reference RF1.

The terms “polymer B”, “polymer composition B”, “coating composition”, “other functional composition”, “foil”, “molded body”, “coating” and “coated substrate” are well known to the person skilled in the art and are defined in more detail from paragraph [8000] to [8005] of Reference RF1.

The present invention is further illustrated by the following set of embodiments and combinations of embodiments resulting from the dependencies and back-references as indicated. In particular, it is noted that in each instance where a range of embodiments is mentioned, for example in the context of a term such as "The process of any one of embodiments 1 to 3", every embodiment in this range is meant to be explicitly disclosed for the skilled person, i.e. the wording of this term is to be understood by the skilled person as being synonymous to "The process of any one of embodiments 1 , 2 and 3". Further, it is explicitly noted that the following set of embodiments represents a suitably structured part of the general description directed to preferred aspects of the present invention, and, thus, suitably supports, but does not represent the claims of the present invention.

1 . A process for recycling rubber-based solid materials M1 from solid automotive waste material W, the process comprising

(i) providing the solid automotive waste material W comprising the rubber-based solid materials M1 , W further comprising one or more solid materials M2 having a chemical composition different to the rubber-based solid materials M1 , wherein the rubberbased solid materials M1 comprises, in addition to rubber and/or within rubber, one or more halogens; (ii) separating M1 from M2 comprised in W provided according to (i), comprising subjecting the material W to kinetic energy separation method or electrostatic separation method, obtaining a mixture MS(1) comprising the rubber-based solid materials M1 , and a mixture MS(2), depleted in M1 compared to W, comprising the one or more solid materials M2;

(iii) sorting the rubber-based materials M1 comprised in MS(1) obtained according to (ii) by elemental composition, obtaining an halogen-rich rubber-based solid materials fraction f 11 comprising the one or more halogens, and obtaining an halogen-poor rubber-based solid materials fraction f 12, being depleted in the one or more halogens compared to M1 , comprising rubber;

(iv) optionally subjecting the halogen-poor fraction f 12 obtained according to (iii) to a purification treatment, obtaining a purified solid mixture MP comprising rubber;

(v) subjecting the halogen-poor rubber-based solid materials fraction f 12 comprising rubber obtained according to (iii), or the purified solid mixture MP comprising rubber obtained according (iv), to pyrolysis in a pyrolysis reaction unit RU(p), obtaining a pyrolysis oil. The process of embodiment 1 , wherein the solid automotive waste material W is obtained from end-of-life vehicles, preferably the solid waste material W is an automotive shredder residue ASR. The process of embodiment 1 or 2, wherein separating according to (ii) comprises the kinetic energy separation method being a ballistic separation method or a size separation method, preferably a ballistic separation method; or wherein separating according to (ii) comprises the electrostatic method being a sink-float separation method. The process of any one of embodiments 1 to 3, wherein, after (ii) and prior to (iii), the process further comprises washing the rubber-based solid materials M1 comprised in MS(1) obtained according to (ii), preferably the washing is performed with water, or one or more caustic agents, or one or more detergents, wherein the washing is followed by drying the washed materials M1. The process of any one of embodiments 1 to 4, wherein sorting according to (iii) is automated sorting. 6. The process of any one of embodiments 1 to 5, wherein sorting according to (iii) comprises using one or more of a conveyor, sensors, lights, a laser, a X-ray source, a radioisotopic source, a detector, and a camera.

7. The process of any one of embodiments 1 to 6, wherein sorting according to (iii) is an X- ray fluorescence sorting method.

8. The process of any one of embodiments 1 to 7, wherein at most 1000 ppmw, preferably at most 500 ppmw, more preferably at most 250 ppmw, more preferably at most 100 ppmw, of the halogen-poor rubber-based solid materials fraction f12 consist of halogen, the content being determined as described in Analytics 2.

9. The process of any one of embodiments 1 to 8, wherein at least 60 weight-% preferably at least 70 weight-%, of the fraction f 12 consist of rubber.

10. The process of any one of embodiments 1 to 8, wherein sorting according to (iii) comprises comminuting the rubber-based solid materials M1 comprised in MS(1) obtained according to (ii), obtaining pieces of M1.

11. The process of any one of embodiments 1 to 10, wherein sorting according to (iii) comprises

- an halogen-poor rubber-based solid materials fraction f 12, being depleted in the one or more halogens compared to M1 , comprising rubber;

(111.4) removing the fraction f 12 obtained according to (iii.3) from the conveyor. The process of any one of embodiments 1 to 10, wherein the halogen-poor rubber-based solid materials fraction f12, comprises, in addition to rubber, one or more fillers F; wherein preferably the one or more fillers F comprises one or more of magnesium silicate hydrate, glass fibers, aluminum hydroxide, ammonium polyphosphate, barium sulfate, calcium carbonate, wollastonite, carbon black, and titanium dioxide. The process of any one of embodiments 1 to 11 , wherein subjecting the halogen-poor rubber-based solid fraction f 12 obtained according to (iii) to a purification treatment according to (iv) comprises

(iv.1 ) subjecting the fraction f12, comprising impurities and/or one or more fillers F, to rubber-dissolution conditions in presence of a solvent SD, wherein the impurities and F are inert to the rubber-dissolution treatment, obtaining an intermediate mixture comprising the impurities and/or the one or more fillers F and further comprising rubber dissolved in SD;

(iv.3) subjecting MD comprising rubber dissolved in SD obtained according to (iv.2) to precipitation conditions, obtaining a purified solid mixture MP comprising precipitated rubber. The process of embodiment 12, wherein the solvent SD used in (iv) is selected from the group consisting of n-hexane, n-heptane, 2,2-dimethylbutane, toluene, benzene, cyclohexane, methylcyclohexane, cyclopentane, methylcyclopentane, and mixtures of two or more thereof, more preferably is selected from the group consisting of n-hexane, n-hep- tane, 2,2-dimethylbutane, methylcyclohexane, and methylcyclopentane. The process of embodiment 12 or 13, wherein the rubber-dissolution treatment according to (iv.1 ) is performed at a temperature in the range of from 55 to 200 °C, preferably in the range of from 100 to 160 °C. The process of any one of embodiments 12 to 14, wherein the rubber-dissolution treatment according to (iv.1) comprising. bringing in contact f 12 with the solvent SD at a weight ratio of the solid fraction f 12 relative to the solvent SD being in the range of from 1 : 1 to 1 :20, preferably in the range of from 1 :3 to 1 : 15, more preferably in the range of from 1 :4 to 1 :12, obtaining an intermediate mixture comprising the impurities and/or the one or more fillers F and further comprising rubber dissolved in SD. 16. The process of any one of embodiments 12 to 15, wherein the solid-liquid separation unit Sil used in (iv.2) is a filtration unit or a centrifugation unit, preferably a filtration unit, the filtration unit more preferably having a mesh size in the range of from 1 to 100 micrometers, more preferably in the range of from 10 to 50 micrometers.

17. The process of any one of embodiments 12 to 16, wherein the filtration unit comprises a filter for blocking the mixture M(F) comprising the impurities and/or the one or more fillers F and a receiving vessel for the mixture MD comprising the rubber dissolved in SD.

18. The process of embodiment 16 or 17, wherein the filtration unit is operated under a pressure PF, with PF S 1 bar(abs), preferably pp is in the range of from 1 to 30 bar(abs), more preferably in the range of from 1 to 10 bar(abs), more preferably in the range of from 1 to 6 bar(abs).

19. The process of any one of embodiments 12 to 18, wherein (iv.3) comprises

20. The process of embodiment 19, wherein (iv.3) comprises

21 . The process of any one of embodiments 12 to 18, wherein (iv.3) comprises subjecting MD comprising the rubber dissolved in SD obtained according to (iv.2) to precipitation by contacting MD with a polar solvent, obtaining an intermediate mixture IM’ comprising SD, the polar solvent and the precipitated rubber; passing IM’ in a solid-liquid separation unit SU2, obtaining the purified mixture MP comprising the precipitated rubber, and a liquid mixture comprising SD and the polar solvent. The process of any one of embodiments 12 to 18, wherein (iv.3) comprises subjecting MD comprising the rubber dissolved in SD obtained according to (iv.2) to precipitation by passing MD in a flash evaporator, obtaining a gaseous stream G3 comprising the evaporated solvent, and further obtaining the purified mixture MP comprising the precipitated rubber. The process of any one of embodiments 12 to 21 , further comprising recycling at least a portion of the solvent SD recovered after (iv.3) to the rubber-dissolution treatment according to (iv.1 ); wherein recycling preferably comprises passing the at least a portion of the solvent SD recovered after (iv.3) in a distillation unit D, obtaining a purified solvent; using the purified solvent to the rubber-dissolution treatment according to (iv.1 ). The process of any one of embodiments 1 to 23, wherein (v) comprises

(v.2) heating the rubber into the pyrolysis reactor R(p) to a temperature in the range of from 350 to 900 °C, preferably in the range of from 400 to 550 °C, and a pressure in the range of from 0.5 to 2 bar(abs), more preferably in the range of from 0.9 to 1 .5 bar(abs);

(v.3) removing a gas stream GS from the top of R(p) and subjecting GS to condensation conditions in a gas-liquid separation unit LGU, obtaining the pyrolysis oil. The process of any one of embodiments 1 to 24, wherein the process further comprises, after (v), passing the pyrolysis oil obtained according to (v), as a stream So, into a purification unit Pll, obtaining a purified pyrolysis oil. The process of any one of embodiments 1 to 25, wherein the process further comprises (vi) subjecting at least a portion of the pyrolysis oil obtained according to (v) to

(vi.1 ) cracking, obtaining a stream P1 comprising cracked hydrocarbons; and/or

(vi.2) partial oxidation, obtaining a syngas stream P2 comprising CO and H2. The process of embodiment 26, wherein cracking according to (vi.1 ) is performed in a cracker, preferably a steam cracker. The process of embodiment 26 or 27, wherein the partial oxidation according to (vi.2) is performed in a gasifier, such an entrained flow reactor and/or a fluidized bed reactor. The process of any one of embodiments 1 to 28, further comprising (vii) preparing a polymer PA, comprising using one or more of the pyrolysis oil obtained according to (v), the cracked hydrocarbons comprised in the stream P1 contained according to (vi) as described in any one of embodiment 26 to 28, and the CO and/or H2 syngas comprised in the stream P2 obtained according to (vi) as described in any one of embodiments 26 to 28.

30. The process of any one of embodiments 1 to 29, further comprising

(viii) preparing an automotive material, comprising using one or more of the pyrolysis oil obtained according to (v), the cracked hydrocarbons comprised in the stream P1 obtained according to (vi) as described in any one of embodiment 26 to 28, and the CO and/or H2 comprised in the syngas stream P2 obtained according to (v) as described in any one of embodiments 26 to 28, and the polymer PA obtained according to (vii) as described in embodiment 29.

31 . A recycling unit for carrying out the process according to any one of embodiments 1 to 30, the recycling unit comprising a first separation unit Sll(a) for kinetic energy separation or electrostatic separation; a second separation unit Sll(b) for sorting by elemental composition; a means for transporting MS(1) to Sll(b), preferably being one or more conveyors; a pyrolysis reaction unit RU(p); an outlet means for removing the pyrolysis oil from RU(p); optionally a purification unit Pll; optionally an inlet means for introducing f 12 into Pll; optionally an outlet means for removing the purified mixture MP from Pll; an inlet means for introducing f12 or MP into RU(p).

32. An automotive material, preferably an automotive vehicle, comprising a polymer PA obtained according to the process of embodiment 29.

33. A process, preferably according to any one of embodiments 1 to 28, comprising the step of converting the pyrolysis oil obtainable or obtained according to (v), or the cracked hydrocarbons comprised in P1 obtainable or obtained according to (vi) as described in any one of embodiments 26 to 28, or the CO and/or H2 comprised in P2 obtainable or obtained according to (vi) as described in any one of embodiments 26 to 28, to obtain a product Q.

34. The process of embodiment 33, wherein the product Q is selected from: building block or monomer; or polymer, preferably polymer A, polymer composition, preferably polymer composition A, or polymer product, preferably polymer product A; or cleaning polymer, cleaning surfactant, descaling compound, cleaning biocide or composition or formulation thereof; or agrochemical composition, agrochemical formulation auxiliary or agrochemically active ingredient; or active pharmaceutical ingredient or intermediate thereof, pharmaceutical excipient, animal feed additive, human food additive, dietary supplements, aroma chemical or aroma composition; or aqueous polymer dispersion, preferably polyurethane or polyurethane - poly(meth) acrylate hybrid polymer dispersion, emulsion, binder for paper and fiber coatings, UV-curable acrylic polymer for hot melts and coatings polyisocyanates, hyperbranched polyester polyol, polymeric dispersant for inorganic binder compositions, unsaturated polyester polyol or 100% curable composition; or cosmetic surfactant, emollient, wax, cosmetic polymer, UV filter, further cosmetic ingredient or composition or formulation thereof; or polymer B, polymer composition B, coating composition, other functional composition, foil, molded body, coating or coated substrate. The process of embodiment 33 or 34, wherein the content of the pyrolysis oil obtainable or obtained according to (v), or the cracked hydrocarbons comprised in P1 obtainable or obtained according to (vi) as described in any one of embodiments 26 to 28, or the CO and/or H2 comprised in P2 obtainable or obtained according to (vi) as described in any one of embodiments 26 to 28, in the product Q is 1 weight-% or more, preferably 2 weight-% or more, more preferably 5 weight-% or more, more preferably 15 weight-% or more, more preferably 30 weight-% or more, more preferably 40 weight-% or more, more preferably 60 weight-% or more, more preferably 80 weight-% or more, more preferably 90 weight-% or more, more preferably 95 weight-% or more; and/or wherein the content of the pyrolysis oil obtainable or obtained according to (v), or the cracked hydrocarbons comprised in P1 obtainable or obtained according to (vi) as described in any one of embodiments 26 to 28, or the CO and/or H2 comprised in P2 obtainable or obtained according to (vi) as described in any one of embodiments 26 to 28, in the product Q is 100 weight-% or less, preferably 95 weight-% or less, more preferably 90 weight-% or less, more preferably 50 weight-% or less, more preferably 25 weight-% or less, more preferably 10 weight-% or less; and preferably wherein the content is determined based on identity preservation and/or segregation and/or mass balance and/or book and claim chain of custody models, preferably based on mass balance, preferably the International Sustainability and Carbon Certification (ISCC) standard.

It is explicitly noted that the above set of embodiments represents a suitably structured part of the general description directed to preferred aspects of the present invention, and, thus, suitably supports, but does not represent the claims of the present invention.

In the context of the present invention, a term “X is one or more of A, B and C”, wherein X is a given feature and each of A, B and C stands for specific realization of said feature, is to be understood as disclosing that X is either A, or B, or C, or A and B, or A and C, or B and C, or A and B and C. In this regard, it is noted that the skilled person is capable of transfer to above abstract term to a concrete example, e.g. where X is a chemical element and A, B and C are concrete elements such as Li, Na, and K, or X is a temperature and A, B and C are concrete temperatures such as 10 °C, 20 °C, and 30 °C. In this regard, it is further noted that the skilled person is capable of extending the above term to less specific realizations of said feature, e.g. “X is one or more of A and B” disclosing that X is either A, or B, or A and B, or to more specific realizations of said feature, e.g. “X is one or more of A, B, C and D”, disclosing that X is either A, or B, or C, or D, or A and B, or A and C, or A and D, or B and C, or B and D, or C and D, or A and B and C, or A and B and D, or B and C and D, or A and B and C and D.

The present invention is further illustrated by the following examples.

Analytics

1 . Average particle size

The average particle size was measured with a Mastersizer 3000 which uses laser diffraction to measure the particle size, and size distribution. This is described in Particle Size Measurements: Fundamentals, Practice, Quality (Particle Technology Series Book 17), Henk G. Merkus, 2009 Edition.

2. Halogen content, Cl content

2. 1 Calibration: a. Prepare a halogen-free sample that closely matches the composition and matrix of the samples to be analyzed. b. Analyze the halogen-free sample using the XRF instrument to establish a calibration curve or calibration factors for halogen detection. 2.2 Sample Preparation: a. If the sample is in a solid form, grind it using a mortar and pestle to obtain a homogeneous powder. b. Weigh an appropriate amount of the sample using an analytical balance. The amount will depend on the expected halogen content and the sensitivity of the XRF instrument.

2.3 XRF Analysis: a. Turn on the XRF instrument and allow it to warm up according to the manufacturer's instructions. b. Set the instrument to the appropriate X-ray tube voltage and current based on the expected halogen content and the instrument's capabilities. c. Load the calibration standards onto the instrument, including the halogen-free sample and any additional standards for intermediate halogen concentrations if available. d. Analyze the calibration standards to verify the accuracy and precision of the calibration curve or calibration factors. e. Load the prepared sample(s) onto the instrument, ensuring that the sample is evenly distributed and covers the detection area as much as possible. f. Analyze the sample(s) using the XRF instrument, following the manufacturer's instructions for sample positioning and measurement duration. g. Repeat the analysis for each sample to ensure reproducibility.

2.4 Data Analysis: a. Retrieve the XRF data from the instrument's software. b. Apply the calibration curve or calibration factors to the measured XRF intensities to determine the halogen content in each sample. c. Calculate the average and standard deviation of the halogen content for replicates, if available.

Examples 1 . Preparation of starting ASR Samples (Solid automotive waste material W)

To prepare the model ASR-1 to ASR-3 the single components are collected from a local End-of- Life Vehicles “ELV” collector company (an authorized treatment facility which depollutes ELV) from about 15 year-old passenger cars. For example, glass is the glass from front windshields and rear windows, dirt is collected as attached to the car exterior, PUR foam is collected from the seat foam, and plastic is collected from selected plastic parts of the cars, such as wheel covers, dashboard, wiper arm, door handle, gears, and bushes, where the type of polymer is known.

The model ASR-1 to ASR-3 are prepared in 5 kg batches by weighing in the components and by shredding the components listed in Table 1 first by hand with a hammer and metal scissors, followed by shredding with a four-shaft shredder (like Model “JFS 8080” from Jogindra, India with main blade rotation diameter 245 mm, assistant rotation diameter 270 mm, 42 main blades, 20 assistant blades, 25 rpm main axle rotation speed, 120-200 kg/hr capacity). The maximum fragment size is 10 cm.

Table 1 : Composition of model ASR (amounts in wt.-%)

2. Preparation of SLF and SHF Samples from ASR (Solid automotive waste material W)

To prepare the model shredder light fractions SLF-1 to SLF-3 and the shredder heavy fractions SHF-1 to SHF-3 the single components are collected from a local ELV collector company as described in Example 1. The samples are prepared in 5 kg batches by weighing in the components and by shredding the components listed in Tables 2 and 3 first by hand with a hammer and metal scissors, followed by shredding with a four-shaft shredder. The maximum fragment size is 10 cm. Table 2: Composition of SLF (amounts in wt.-%)

Table 3: Composition of SHF (amounts in wt.-%)

The process of the present invention is reproduced by using the materials in 1. and in 2. as the material W in (i).

Brief description of the figure Figure 1 shows a possible flow scheme with a suitable process sequence for obtaining the automotive shredder residue ASR. Starting from the vehicles, followed by optional depollution, followed by optional dismantling, followed by shredding the vehicles, followed by optional separating the metal fragments from the shredded vehicle, then the ASR is obtained, followed by optional separation of the ASR in shredder light fraction and shredder heavy fraction.

Figure 2 is a schematic representation of a recycling unit used for the process according to embodiments of the present invention. The recycling unit comprises a separation unit Sll(a), a separation unit Sll(b), a pyrolysis reaction unit Rll(p) and optionally a purification unit Pll. The solid material W (ASR), comprising a rubber-based solid materials M1 , W further comprising one or more solid materials M2 having a chemical composition different to the rubber-based solid materials M1 , wherein the rubber-based solid materials M1 comprises, in addition to rubber and/or within rubber, one or more halogens, is separated in Sll(a) via a kinetic energy separation unit or electrostatic separation method, obtaining a mixture MS(1) comprising the rubberbased solid materials M1, and a mixture MS(2), depleted in M1 compared to W, comprising the one or more solid materials M2. The mixture MS(1) is further passed in the separation unit Sll(b) for sorting the materials M1 by elemental composition, obtaining an halogen-rich rubberbased solid materials fraction f 11 comprising the one or more halogens, and obtaining an halo- gen-poor rubber-based solid materials fraction f12, being depleted in the one or more halogens compared to M1 , comprising rubber. Further, the fraction f12 is optionally passed through the purification unit Pll for obtaining a purified solid mixture MP comprising rubber. Said MP being then introduced into Rll(p) for pyrolysis, obtaining a pyrolysis oil. Alternatively, f12 can directly be introduced into Rll(p) for pyrolysis, obtaining a pyrolysis oil.

Cited Literature

- R. Cossu, et al., “Automotive shredder residue (ASR) management: An overview”, Waste Management, Volume 45, November 2015, Pages 143-151. Such that processes for recycling ASR have to be developed

- EP0692356

- Vijayan, S.K.; Kibria, M.A.; Uddin, M.H.; Bhattacharya, S. “Pretreatment of Automotive Shredder Residues, Their Chemical Characterisation, and Pyrolysis Kinetics." Sustainability 2021 , 13, 10549

- Juliana Argente Caetano, Valdir Schalch, Javier Mazariegos Pablos “Characterization and recycling of the fine fraction of automotive shredder residue (ASR) for concrete paving blocks production" Clean Technologies and Environmental Policy (2020) 22:835-847

- DE 19535296 A1

- WO 2012/015299 A1 - Markus Bauer, et al., “Sink-float density separation of post-consumer plastics for feedstock recycling”, November 6, 2017, Journal of Material Cycles and Waste Management (2018) 20:1781-1791 , https://doi.org/10.1007/s10163-018-0748-z

- Cecilia Chaine, et al., “Optimized industrial sorting of WEEE plastics: Development of fast and robust h-XRF technique for hazardous components”, Case Studies in Chemical and Environmental Engineering 7 (2023) 100292

- Hansen, C.M., Hansen Solubility Parameters - A user’s handbook, 2. Edition, CRC Press, Boca Raton, USA, 2007

- Ullmann’s Encyclopedia of Industrial Chemistry, Ethylene, Ch. 5.1, pages 469-475 (2012)

- Ullmann’s Encyclopedia of Industrial Chemistry, Rubber, 3. Synthetic Rubbers, Introduction and Overview, p. 602-604 (2011), DO110.1002/14356007.a23_239.pub5

- Prior Art Disclosure; Issue 684; paragraphs [1000] to [8005]; ISSN: 2198-4786; published: 5 February 12, 2024

- Mollet and Grubemann, Formulation technology, Wiley VCH, Weinheim, 2001

- Knowles, New developments in crop protection product formulation, Agrow Reports DS243, T&F Informa, London, 2005

- Database Cosing on the internet pages of the European Commission discloses cosmetic ingredients and the International Cosmetic Ingredient Dictionary and Handbook, edited by the Personal Care Products Council (PCPC)

- EP 3 907267 A1

- WO 2015/184343 A1

- WO 2024/033212 A1

US 5,554,657 A

Zhao Yi-Bo et al., “Solvent-based separation and recycling of waste plastics: A review”, CHEMOSPHERE, 1 October 2018, pages 707 to 720

Claims

(i) providing the solid automotive waste material W comprising the rubber-based solid materials M1 , W further comprising one or more solid materials M2 having a chemical composition different to the rubber-based solid materials M1 , wherein the rubberbased solid materials M1 comprises, in addition to rubber and/or within rubber, one or more halogens;

(iii) sorting the rubber-based materials M1 comprised in MS(1) obtained according to (ii) by elemental composition, obtaining an halogen-rich rubber-based solid materials fraction f 11 comprising the one or more halogens, and obtaining an halogen-poor rubber-based solid materials fraction f12, being depleted in the one or more halogens compared to M1 , comprising rubber;

(v) subjecting the halogen-poor rubber-based solid materials fraction f 12 comprising rubber obtained according to (iii), or the purified solid mixture MP comprising rubber obtained according (iv), to pyrolysis in a pyrolysis reaction unit RU(p), obtaining a pyrolysis oil.

2. The process of claim 1 , wherein the solid automotive waste material W is obtained from end-of-life vehicles, preferably the solid waste material W is an automotive shredder residue ASR.

3. The process of claim 1 or 2, wherein separating according to (ii) comprises the kinetic energy separation method being a ballistic separation method or a size separation method, preferably a ballistic separation method.

4. The process of any one of claims 1 to 3, wherein, after (ii) and prior to (iii), the process further comprises washing the rubber-based solid materials M1 comprised in MS(1) obtained according to (ii), preferably the washing is performed with water, or one or more caustic agents, or one or more detergents, wherein the washing is followed by drying the washed materials M1.

5. The process of any one of claims 1 to 4, wherein sorting according to (iii) is an X-ray fluorescence sorting method.

6. The process of any one of claims 1 to 5, wherein sorting according to (iii) comprises

(111.1) spreading out M1 comprised in MS(1) on a conveyor;

(111.2) automated analyzing the rubber-based solid materials M1 comprised in MS(1) obtained according to (ii) spread out on the conveyor according to (iii.1): using one or more of sensors, lights, a detector and a X-ray source to identify the elemental composition of rubber-based materials, or of the pieces of the rubber-based materials;

(111.4) removing the fraction f12 obtained according to (iii.3) from the conveyor.

7. The process of any one of claims 1 to 6, wherein subjecting the halogen-poor rubberbased solid fraction f 12 obtained according to (iii) to a purification treatment according to (iv) comprises

(iv.1 ) subjecting the fraction f 12, further comprising impurities and/or one or more fillers F, to rubber-dissolution conditions in presence of a solvent SD, wherein the impurities and F are inert to the rubber-dissolution treatment, obtaining an intermediate mixture comprising the impurities and/or the one or more fillers F and further comprising rubber dissolved in SD;

8. The process of claim 7, wherein the rubber-dissolution treatment according to (iv.1 ) comprises bringing in contact f 12 with the solvent SD at a weight ratio of the solid fraction f 12 relative to the solvent SD being in the range of from 1 : 1 to 1 :20, preferably in the range of from 1 :3 to 1 : 15, more preferably in the range of from 1 :4 to 1 :12, obtaining an intermediate mixture comprising the impurities and/or the one or more fillers F and further comprising rubber dissolved in SD.

9. The process of claim 7 or 8, wherein (iv.3) comprises

- passing IM in a solid-liquid separation unit SU1 , obtaining a purified mixture MP comprising the precipitated rubber, and a liquid mixture comprising SD; wherein preferably (iv.3) comprises

- passing IM in a solid-liquid separation unit SU1 , obtaining a purified mixture MP comprising the precipitated rubber, and a liquid mixture comprising SD; or wherein (iv.3) comprises subjecting MD comprising the rubber dissolved in SD obtained according to (iv.2) to precipitation by contacting MD with a polar solvent, obtaining an intermediate mixture IM’ comprising SD, the polar solvent and the precipitated rubber; passing IM’ in a solid-liquid separation unit SU2, obtaining the purified mixture MP comprising the precipitated rubber, and a liquid mixture comprising SD and the polar solvent.

10. The process of claim 7 or 8, wherein (iv.3) comprises subjecting MD comprising the rubber dissolved in SD obtained according to (iv.2) to precipitation by passing MD in a flash evaporator, obtaining a gaseous stream G3 comprising the evaporated solvent, and further obtaining the purified mixture MP comprising the precipitated rubber.

11 . The process of any one of claims 1 to 10, wherein (v) comprises

(v.1 ) feeding the solid fraction f 12 obtained according to (iii), or the purified mixture MP obtained according to (iv), into the pyrolysis reactor R(p); (v.2) heating the rubber into the pyrolysis reactor R(p) to a temperature in the range of from 350 to 900 °C, preferably in the range of from 400 to 550 °C, and a pressure in the range of from 0.5 to 2 bar(abs), more preferably in the range of from 0.9 to 1.5 bar(abs);

(v.3) removing a gas stream GS from the top of R(p) and subjecting GS to condensation conditions in a gas-liquid separation unit LGU, obtaining the pyrolysis oil.

12. The process of any one of claims 1 to 11 , wherein the process further comprises

(vi) subjecting at least a portion of the pyrolysis oil obtained according to (v) to

(vi.1 ) cracking, obtaining a stream P1 comprising cracked hydrocarbons; and/or

(vi.2) partial oxidation, obtaining a syngas stream P2 comprising CO and H2; wherein the process further comprises

(vii) preparing a polymer PA, comprising using one or more of the pyrolysis oil obtained according to (v), the cracked hydrocarbons comprised in the stream P1 contained according to (vi.1 ), and the CO and/or H2 syngas comprised in the stream P2 obtained according to (vi.2).

13. A recycling unit for carrying out the process according to any one of claims 1 to 12, the recycling unit comprising a first separation unit Sll(a) for kinetic energy separation or electrostatic separation; a second separation unit Sll(b) for sorting by elemental composition; a means for transporting MS(1) to Sll(b), preferably being one or more conveyors; a pyrolysis reaction unit RU(p); an outlet means for removing the pyrolysis oil from RU(p); optionally a purification unit Pll; optionally an inlet means for introducing f 12 into Pll; optionally an outlet means for removing the purified mixture MP from Pll; an inlet means for introducing f 12 or MP into RU(p).

14. An automotive material, preferably an automotive vehicle, comprising a polymer PA obtained according to the process of claim 12.

15. A process, preferably according to any one of claims 1 to 12, comprising the step of converting the pyrolysis oil obtainable or obtained according to (v), or the cracked hydrocarbons comprised in P1 obtainable or obtained according to (vi) as described in claim 12, or the CO and/or H2 comprised in P2 obtainable or obtained according to (vi) as described in claim 12, to obtain a product Q.