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EP-4735543-A1 - COATING COMPOSITIONS CONTAINING CHAR AND METHODS OF USE THEREOF

EP4735543A1EP 4735543 A1EP4735543 A1EP 4735543A1EP-4735543-A1

Abstract

Provided here are coating compositions containing a solvent, a binder, and char particles and methods of forming a thermal protective coating on a surface using these coating compositions.

Inventors

  • CUOQ, FABRICE

Assignees

  • SABIC Global Technologies B.V.

Dates

Publication Date
20260506
Application Date
20240630

Claims (15)

  1. 1. A coating composition comprising a solvent, a binder, and char particles.
  2. 2. The coating composition of claim 1 , wherein the char particles are a byproduct of processing of mixed plastic waste.
  3. 3. The coating composition of claim 1, wherein the char particles are a byproduct of processing of biomass.
  4. 4. The coating composition of claim 1, wherein the char particles are a byproduct of fast pyrolysis of mixed plastic waste, or biomass, or a combination thereof.
  5. 5. The coating composition of claim 1, wherein the char particles are less than 20 pm in size.
  6. 6. The coating composition of claim 1, wherein the char particles are less than 10 pm in size.
  7. 7. A method of forming a thermal protective coating, the method comprising: selecting a coating composition containing a solvent, a binder, and char particles; applying the coating composition to a surface; and drying the coating composition to form a thermal protective coating on the surface.
  8. 8. The method of claim 7, further comprising: processing of mixed plastic waste, or biomass, or a combination thereof to produce a pyoil and the char particles.
  9. 9. The method of claim 7, further comprising: supplying the char particles to a milling process to produce char particles of a predetermined size.
  10. 10. The method of claim 9, wherein the predetermined size is less than 20 pm in size.
  11. 11. The method of claim 9, wherein the predetermined size is less than 10 pm in size.
  12. 12. The method of claim 7, wherein the thermal protective coating on the surface has a thickness ranging from 100 pm to 10 mm.
  13. 13. The method of claim 7, wherein the thermal protective coating on the surface has a thickness ranging from 10 mm to 5 cm.
  14. 14. The method of claim 7, wherein thermal conductivity of the surface decreases by about twenty percent upon forming the thermal protective coating.
  15. 15. The method of claim 7, wherein thermal conductivity of the surface decreases by about forty percent upon forming the thermal protective coating.

Description

COATING COMPOSITIONS CONTAINING CHAR AND METHODS OF USE THEREOF Inventor: Fabrice Cuoq Cross-Reference to Related Applications [0001] This application claims the benefit of and priority to U.S. Provisional Application No. 63/511,256, filed on June 30, 2023, which is incorporated herein by reference in its entirety. Technical Field [0002] The disclosure relates to coating compositions containing char, particularly thermal protective coatings, and methods of use of these compositions. Background [0003] Char is formed during the pyrolysis of biomass or mixed plastic waste. The inorganic mineral content present in the biomass or mixed plastic waste feedstock can be primarily retained in the char formed during the pyrolysis process. Char particles greater than 10 micrometers (pm) are removed during pyrolysis by processes, such as hot gas filtration and cyclone separation. Particulate solids less than 10 pm in size still remain in the pyoil. Char particles need to be removed if the pyoil is to be converted into gasoline or diesel fuel. Removal of char particles in the micron size range improves properties of the pyoil for downstream processing into other chemicals and fuels. Processing of char is expensive, and occurs either via incineration or landfilling — both of are not environmentally friendly processes. Summary [0004] Applicant has recognized ways to recycle the char formed during the production of pyoil. Provided here are coating compositions containing char and methods of use thereof. Embodiments include a coating composition containing a solvent, a binder, and char particles. In certain embodiments, the char particles are a byproduct of processing of mixed plastic waste, or biomass, or a combination thereof. In certain embodiments, the char particles are a byproduct of fast pyrolysis of mixed plastic waste, or biomass, or a combination thereof. Embodiments include methods of forming a thermal protective coating containing char particles. One such method includes the steps of selecting a coating composition containing a solvent, a binder, and char particles, applying the coating composition to a surface, and drying the coating composition to form a thermal protective coating on the surface. The method can further include the step of processing of mixed plastic waste, or biomass, or a combination thereof to produce a pyoil and the char particles. The method can further include the step of supplying the char particles to a milling process to produce char particles of a predetermined size. The predetermined size may be less than about 20 pm in size. The thermal protective coating on the surface may have a thickness ranging from about 100 pm to about 10 mm. The thermal protective coating on the surface may have a thickness ranging from about 10 mm to about 5 cm. In certain embodiments, the thermal conductivity of the surface decreases by about twenty percent or by about forty percent. [0005] The details of one or more embodiments are set forth in the description below. Other features, objects, and advantages of the embodiments will be apparent from the description and the claims. Detailed Description [0006] Char is a waste product from pyrolysis of biomass or mixed plastic waste or a combination thereof. One of the common sources of char is from a fast pyrolysis process. In this process, mixed plastic waste, or biomass, or a combination thereof is processed to produce pyoil and char. Char has varying ash content dependent on the feedstock. Further processing of char is expensive and occurs either via incineration or landfilling. These processes are not environmentally friendly or sustainable processes. Therefore, an alternative use of the char is relevant to economics and environmental, social, and governance (ESG) characteristics of a pyrolysis plant. Embodiments described herein include coating compositions containing char. The thermal properties of char are harnessed when char is used to increase the insulative properties of a coating. A coating is a composition applied to a surface of an article to deliver a specific performance. Examples of the performance of a coating composition include color retention, flexibility and elasticity, insulation, waterproofing, water- shedding, permeability, corrosion containment and prevention, and anti-microbial defense. Provided here are coating compositions that deliver substantial thermal insulation. [0007] Insulating coatings are normally produced by using aerogel as an insulating film. Aerogel is however relatively expensive. Provided here are coating compositions containing char as a filler to provide thermal insulation properties to the coating. [0008] Embodiments include a coating composition containing a solvent, a binder, and char particles. In certain embodiments, the char particles are a byproduct of processing of mixed plastic waste, or biomass, or a combination thereof. Char has insulating properties. For example, the specific heat capacity at 20 degree