Smuda process catalysts

Nickel silicate and ferrous silicate are the preferred catalysts in the Smuda process. The Smuda catalyst is a layered silicate clay framework with ordered nickel (or iron) atoms inside. The catalyst is charged at 10 wt% ratio of the plastic feedstock. The catalysts are based on layered silicates with Lewis acid activity [24]. Catalytic cracking results in very little noncondensable gas (<1%) and minimal carbonaceous char. The hfe of the Smuda catalyst is approximately 1 month [24]. 

A number of low-grade transition metal ores (for example, minerals containing nickel oxides) can be used as catalysts. Smuda has demonstrated that microwave or radiofrequency irradiation of a mixture of such ores with a carbon source initiates reduction of the oxide to metal. With this approach, poisoning the active sites of the catalyst will not be critical for the process since there will be a constant supply and generation of active catalyst with the feed material. In addition to well-known catalytic properties of nickel in organic reactions, it was also shown that Ni on carbon and other supports, catalyzes hydrodechlorination and dehydrochlorination of chlorinated organic waste streams [22-24],... 

The Smuda process also uses new cracking catalysts based on cobalt resinates which are cobalt salts of resin acids (mainly abietic acid) such as cobalt abietate and cobalt linoleate (these are commonly referred to as driers in the coatings industry) and preferably with admixtures of heavy metal silicates. Smuda has also explored the use of manganese resinate deposited on an aluminium oxide support to maximize active surface area [23]. 

Due to the sensitivity of the catalyst, the Smuda process requires that the plastic feedstock be pre-processed and cleaned by mechanical processing (i.e. other than washing). In this way dirt, food impurities, etc. can be removed before they deactivate the catalyst [24]. 

Smuda A process for pyrolyzing waste plastics (preferably polyolefins) with the production of diesel fuel and gasoline. A disposable catalyst is used, preferably nickel silicate. Developed by H.W. Smuda (also spelled Zmuda). A large plant has operated in Zabrze, Poland, since 1997. 

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