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76 Energy & Fuels 1997, 11, 76-87

Depolymerization-Liquefaction of Plastics and Rubbers.


1. Polyethylene, Polypropylene, and Polybutadiene
Joseph Shabtai,* Xin Xiao, and W. Zmierczak
Department of Chemical and Fuels Engineering, University of Utah,
Salt Lake City, Utah 84112

Received May 20, 1996X

The solid superacid-catalyzed depolymerization-liquefaction (DL) reactions of high-density


polyethylene (HDPE), isotactic polypropylene (PPR), and cis-polybutadiene (PB) samples were
systematically investigated as a function of processing conditions, i.e., temperature (350-450
C), time (0.5-3.0 h), H2 pressure (500-2000 psig), catalyst type and concentration, and the
presence of solvents. Catalysts used included SO42-/Fe2O3, SO42-/ZrO2, and a Pt-modified SO42-/
ZrO2. At temperatures >400 C, with 1-2 wt % of SO42-/Fe2O3 or SO42-/ZrO2 as catalyst, there
is an overlap of catalytic and noncatalytic, viz. thermal DL, reactions. Under such conditions
HDPE yields a liquid product consisting of C5-C30 (mostly C5-C12) normal and branched paraffins,
accompanied by small amounts of cycloparaffins and olefins. Selective catalytic DL of HDPE
was achieved at lower temperature (350 C) in the presence of 17-33 wt % of SO42-/ZrO2 or the
more active Pt/SO42-/ZrO2 catalyst, preferably in the presence of a chemically compatible solvent,
i.e., n-octadecane. Under such conditions the high-yield (>90 wt %) product predominantly
consists of branched paraffins in the gasoline boiling range. PPR, which shows high DL reactivity
due to its multiply branched polymeric chain structure, yields a similar gasoline-like mixture of
C5-C12 branched paraffins as main product. The change in product composition from HDPE
and PPR as a function of temperature and reaction time allows for elucidation of mechanistic
aspects of the stepwise DL reactions of these polymers. For HDPE results are rationalized in
terms of a carbonium ion mechanism involving extensive skeletal isomerization and attendant
-cleavage reactions leading to low branched paraffins as final products. Results obtained
demonstrate that at mild temperatures, under properly designed catalytic conditions, waste HDPE
and PRR feeds could be effectively converted into desirable multibranched paraffins which
represent potential blending components for reformulated, nonaromatic gasolines.

Introduction as a potentially cheap and abundant source for trans-


portation fuels and useful chemicals. Thermodegrada-
In 1993, the total production of plastics in the United
tion of polymers has been investigated extensively since
States was 19.3 million tons.1 A predominant part of
World War II,3-7 but relatively few studies on the
such materials is ultimately disposed as waste. Fur-
catalytic conversion of polymers have been carried out,
ther, about 280 million automotive tires were discarded
especially for production of liquid fuels.
in the United States in 1990.2 As a result, the effective
Considerable research has been carried out aimed at
disposal of waste polymers is now recognized as a major
production of olefins and aromatics through polymer
environmental problem. Plastics and rubbers are un-
pyrolysis at temperatures above 700 C. However,
desirable components for landfilling, since they are not
relatively limited systematic studies have been reported
presently biodegradable. Their destruction by incinera-
on the reactivity of individual polymers and product
tion poses air pollution problems due to the release of
distributions obtained. Recently, there have been some
airborne particles and carbon dioxide into the atmo-
reports on the thermal cracking of plastics to hydrocar-
sphere. An alternative would be true recycling, i.e.,
bon feedstocks. Kastner and Kaminsky8 investigated
conversion into monomers that can be reused. For
the thermolysis of polyolefins in N2 using a fluidized
example, DuPont has commercialized a depolymeriza-
bed reactor. At temperatures below 550 C, good yields
tion process for polyethylene terephthalate (PET) to
of high-boiling waxes and other useful products were
reclaim ethylene glycol and terephthalic acid for reuse
found with low yields of gas and aromatics. Kaminsky
in the production of new PET. However, waste streams
and Rossler9 indicated that, in the temperature range
usually consist of polymer mixtures; furthermore, even
of 650-820 C, pyrolysis of plastic wastes, used tires,
pure polymers do not depolymerize thermally to corre-
and waste oil residues produces olefins and other
sponding monomers with sufficient selectivity. On the
other hand, waste plastics and rubbers can be regarded (3) Jellinek, H. H. G. J. Polym. Sci. 1949, 4, 13.
(4) Madorsky, L. J. Polym. Sci. 1952, 9, 133.
X Abstract published in Advance ACS Abstracts, November 15, 1996. (5) Kuroki, T.; Honda, T.; Sekiguchi, Y.; Ogawa, T.; Sawaguchi, T.;
(1) U.S. EPA. Characterization of Municipal Solid Waste, 1994 Ikemura, T. Nippon Kagaku Kaishi 1977, 894.
Update; U.S. GPO: Washington, DC, 1994. (6) Murata, K.; Sato, K. Kagaku Kogaku Ronbunshu 1981, 7, 64.
(2) Hearing before the Subcommittee on Environment and Labor (7) Lechert, H.; Woebes, V.; Sung, Q.; Kaminsky, W.; Sinn, H. Eur.
and the Subcommittee on Regulation, Business Opportunities, and Pat. Appl. EP 321807, 1989; Appl. DE 3743752, 1987.
Energy of the Committee on Small Business, House of Representatives, (8) Kastner, H.; Kaminsky, W. Hydrocarbon Process. 1995, 109-
April 18, 1990: Scrap Tire Management and Recycling Opportunities, 112.
Serial No. 101-52; U.S. GPO: Washington, DC, 1990. (9) Kaminsky, W.; Rossler, H. CHEMTECH 1992, 108-113.

S0887-0624(96)00076-X CCC: $14.00 1997 American Chemical Society


DL of Plastics and Rubbers Energy & Fuels, Vol. 11, No. 1, 1997 77

hydrocarbons that can be used as petrochemicals. Son- studied the monomer formation from polyisobutylene in
gip et al.10 have indicated that a two-stage process for the presence of a SiO2-Al2O3 catalyst. Isobutylene
pyrolysis of waste polymers followed by reforming of started forming even at 160 C and reached a yield of
the heavy oil pyrolysate is more economical. Solid 22% at 240 C. The authors found that the polymer can
polyethylene was pyrolyzed at 450 C, yielding an oil be converted to the corresponding monomer and oligo-
with a gasoline fraction of 34 wt %, having a research mers having 2-10 monomeric units, but the latter
octane number (RON) value practically equal to zero. cannot be converted to the monomer under the mild
After reforming at 400 C with a REY zeolite catalyst, reaction conditions used. Williams et al.20 studied the
the gasoline yield increased to 48 wt % and the RON influence of temperature and heating rate on product
value of this fraction was 67. Catalysts activities and composition in pyrolysis of scrap automotive tires.
properties were also compared. It was concluded that Pyrolysis between 420 and 720 C resulted in significant
large pore size and strong acidity are necessary for yields of hydrocarbon liquids, solid char, and gases.
effective cracking of polymeric molecules. Scott et al.11 There was, gradually, an increase in aromaticity and
investigated the fast pyrolysis of low-density polyeth- decrease in aliphatic compounds as the temperature was
ylene at 600 C using an activated carbon fluidized bed increased.
reactor. They observed feed conversions of 80% into It should be pointed out that conventional pyrolysis
gaseous and liquid products, the latter having a high of polymers usually results in unsaturated and unstable
aromatic content. Over 60% of the pyrolysis product oils in low yields and of low value that can be used
was a liquid hydrocarbon fraction of relatively low- mainly for direct combustion. Further, most of the
boiling range. Yamamoto and Takamiya12 studied the catalytic studies so far have been conducted under
cracking of polyethylene on SiO2-Al2O3 under N2. In nitrogen at ambient or low pressure. It is also apparent
the absence of a catalyst, the pyrolysis yielded 77.1% of that development of efficient coprocessing of coal and
gas at 600 C. The products were mainly ethylene, waste polymers is being hindered by the lack of detailed
propylene, and 1-butene. With SiO2-Al2O3 as catalyst, fundamental data on the catalytic breakdown reactions
a higher gas yield (87.8%) was obtained even at 450 C. of a variety of plastics and rubbers.
The gas consisted mainly of isobutylene (45.6%). The present research was concerned with a systematic
Uemichi and co-workers13 studied the pyrolysis of investigation of the catalytic depolymerization-lique-
polyolefins to aromatic hydrocarbons under N2 using faction (DL) reactions of three representative com-
activated carbon-supported metal (Pt, Fe, or Mo) cata- mercial polymers, i.e., polyethylene, polypropylene, and
lysts. Polyethylene was converted to C6-C14 aromatics polybutadiene under H2 pressure, using finely dispersed
at 526 C with a selectivity of 60%. Benzene was superacid catalysts, i.e., SO42-/Fe2O3, SO42-/ZrO2, and
produced as the main aromatic component over the Pt- SO42-/Al2O3.21-28 Products were identified by a combi-
containing catalyst, while catalysts containing Fe or Mo nation of GC/MS and FTIR and, in some cases, by
yielded preferentially toluene. The presence of methyl comparison with authentic reference samples. Quan-
branching in polypropylene was found to be unfavorable titative analysis was performed by gas chromatography.
for the formation of aromatics.14 The change in product composition as a function of
Audisio and Silvani15 studied the catalytic degrada- processing variables, i.e., temperature, reaction time,
tion of polypropylene under vacuum (10-1 Torr). Cata- hydrogen pressure, and catalyst type and concentration,
lysts, e.g., Al2O3, SiO2, SiO2-Al2O3, and Y-type zeolites, was studied. The objective was to determine suitable
were screened at 200, 400, and 600 C. The authors conditions for conversion of the above polymers into
concluded that SiO2-Al2O3, HY, and REY were the most high-quality liquid fuels, as well as to obtain data
efficient catalysts for this reaction. Smith16 studied the needed for predictive modeling of waste polymer copro-
catalytic cracking of byproduct (amorphous) polyprop- cessing with coal.
ylene into fuel oil with a SiO2-Al2O3 catalyst. In
another study, Carle and Hann17 mixed up to 2.5% of Experimental Section
amorphous polypropylene into the feed of a fluid cata-
Materials. Samples of high-density polyethylene (HDPE)
lytic cracker. (d, 0.959 g/cm3; average MW, 125 000; Tm, 130 C) and isotactic
Wagener and Puts18 studied the depolymerization of polypropylene (PPR) (d, 0.900 g/cm3; average MW, 250 000;
polybutadiene and polyisoprene using THF or toluene Tm, 189 C) were obtained from Aldrich Chemical Co. A
as solvent and bubbling ethylene gas as an additive. polybutadiene sample (98% cis; d, 0.910 g/cm3; average MW,
Significant amounts of oligomers were formed via an 197 000; softening point, 140-170 C) was provided by Scien-
acyclic diene metathesis mechanism. Nanbu et al.19 tific Polymer Products, Inc.
Catalysts. Four types of solid superacid catalysts were
(10) Songip, A. R.; Masuda, T.; Kuwahara, H.; Hashimoto, K. Appl. employed in the DL studies, i.e., SO42-/Fe2O3, SO42-/ZrO2,
Catal. B: Environ. 1993, 2, 153-164.
(11) Scott, D. S.; Czernik, S. R.; Piskorz, J.; Radlein, D. St. A. G. (20) Williams, P. T.; Besler, S.; Taylor, D. T. Fuel 1990, 69, 1474-
Energy Fuels 1990, 4, 407-411. 1482.
(12) Yamamoto, M.; Takamiya, N. Bull. Sci. Eng. Res. Lab. Waseda (21) Yamaguchi, T.; Jin, T.; Tanabe, K. J. Phys. Chem. 1986, 90,
Univ. 1985, 111, 8-14. 3148.
(13) Uemichi, Y.; Makino, Y.; Kanazuka, T. J. Anal. Appl. Pyrol. (22) Hino, M.; Arata, K. Chem. Lett. 1979, 477.
1989, 14, 331-344. (23) Hino, M.; Arata, K. Chem. Lett. 1979, 1259.
(14) Uemichi, Y.; Makino, Y.; Kanazuka, T. J. Anal. Appl. Pyrol. (24) Wen, M. Y.; Wender, I.; Tierney, J. W. Energy Fuels 1990, 4,
1989, 16, 229-238. 372-379.
(15) Audisio, G.; Silvani, A. J. Anal. Appl. Pyrol. 1984, 7, 83-90. (25) Arata, K.; Hino, M. Appl. Catal. 1990, 59, 197-204.
(16) Smith, V. C. U.S. Pat. 4,151,216, 1979. (26) Garin, F.; Andriamasinoro, D.; Abdulsamad, A.; Sommer, J. J.
(17) Carle, R. A.; Hann, P. D. U.S. Pat. 4,143,086, 1979. Catal. 1991, 131, 199-203.
(18) Wagener, K. B.; Puts, R. D. Polym. Prepr. (Am. Chem. Soc., (27) Zmierczak, W.; Xiao, X.; Shabtai, J. Energy Fuels 1994, 8, 113-
Div. Polym. Chem.) 1991, 32 (1), 379-380. 116.
(19) Nanbu, H.; Ishihara, Y.; Takesue, T.; Ikemura, T. Polym. J. (28) Xiao, X.; Zmierczak, W.; Shabtai, J. Prepr. Pap.sAm. Chem.
1986, 18 (11), 871-875. Soc., Div. Fuel Chem. 1995, 40 (1), 4-8.
78 Energy & Fuels, Vol. 11, No. 1, 1997 Shabtai et al.

SO42-/Al2O3, and a Pt-modified SO42-/ZrO2. The method of GC/MS examination and quantitative GC analyses were
preparation and properties of the first two were described in performed directly with samples of the original product, viz.,
detail elsewhere.27,28 SO42-/Al2O3 was prepared according to before the treatment with methanol.
the following procedure: 12.4 g of Al2(SO4)3(14-18)H2O was Product Analysis. Gas and liquid products were identified
dissolved in 44 mL of distilled water, and a 30% aqueous by a combination of GC/MS and FTIR and, in some cases, by
ammonia solution was slowly added with vigorous mixing, comparison with authentic reference samples. A HP 5890
until a pH 8.5 was reached. The precipitate formed was Series II gas chromatograph/HP 5971 mass selective detector
filtered, washed with distilled water, and then dried at 110 (GC/MS) system and a Perkin-Elmer 1600 series FTIR were
C for 2 h. The dry solid was pulverized and calcined at 550 used in the analyses. GC/MS analysis of liquid products was
C for 2 h. A portion of the resulting Al2O3, 2.0 g, was treated performed using a 30 m 0.25 mm i.d. DB-5 capillary column
with 50 mL of a 1.5 M (NH4)2SO4 plus 1.0 M H2SO4 aqueous provided by J&W Scientific.
solution for 1 h with constant stirring. The resulting solid, Quantitative analysis was performed by gas chromatogra-
i.e., SO42-/Al2O3, was then filtered, washed with 100 mL of phy and simulated distillation (SIMD). HP 5880A and Varian
water, dried at 110 C for 2 h, calcined at 600 C for 3 h, and 3700 gas chromatographs equipped with FID detectors were
stored in a desiccator. The Pt/SO42-/ZrO2 catalyst was pre- used in the analysis. Columns used for quantitative analysis
pared by impregnating 20.0 g of SO42-/ZrO2 with 11.0 mL of of gas products were 4 m 0.3 cm o.d. stainless steel packed
an aqueous H2PtCl6 solution, followed by drying at 110 C for with Chromosorb 102. Columns used for quantitative analysis
24 h and subsequent calcination at 550 C for 3 h. The final of liquid products were 4 m 0.3 cm o.d. stainless steel packed
catalyst contained 0.5 wt % of Pt. with 10% OV-17 on Chromosorb W-HP and 30 m 0.25 mm
Reactors. The catalytic DL studies were performed mostly i.d. DB-225 or DB-5 capillary columns provided by J&W
in a 50 mL Microclave reactor (Autoclave Engineers) equipped Scientific. SIMD was performed according to ASTM Methods
with a MagneDrive stirrer, pressure gauge, tachometer, gas D5307 and D2887 except for the following modifications: the
sampling device, vent valves, external electric heating furnace, temperature correlation curve was made using C6-C18 normal
and temperature controller. A 300 mL EZE-seal Autoclave paraffins, and the internal standard was a mixture of about
reactor (Autoclave Engineers) was also employed in some of equal amounts of C7, C8, and C9 normal paraffins. SIMD was
the runs. performed with a 0.5 m 0.3 cm o.d. stainless steel Supelco
Experimental Procedure. In most of the runs a mixture PETROCOL B column.
of the polymer, 5.0-20.0 g, and catalyst, 1-2 wt % (without Mass Balance. The mass balance of the runs was in the
any solvent), was introduced in the autoclave reactor. The range of 90-95% (relative to the feed weight) for polyethylene
latter was closed, purged sequentially with nitrogen and and polypropylene and 80-90% for polybutadiene. Conver-
hydrogen, and then pressurized with hydrogen to a selected sions were determined on the basis of the difference between
initial pressure. The reactor was heated to the desired the weight of the feed used and the solid polymer residue after
temperature in 12-15 min (50 mL Microclave reactor) or 40 reaction. The gas samples consisted mostly of C1-C4 hydro-
min (300 mL autoclave reactor), and stirring (500 rpm) was carbons, accompanied by some C5, C6, and traces of C7, C8
started after the melting or softening point of the polymer was compounds. The liquid samples contained mostly C5-C12
reached. At the end of each experiment, the reactor was components, accompanied by some C13-C30, and traces of C2-
quickly cooled to room temperature with a fan (about 20 min), C4 compounds. The product composition was calculated from
and the liquid product (plus any unconverted solid feed) was GC data (FID detector). The C2-C4 gas components found in
removed from the reactor and weighed. The liquid was the liquid product were added to the gas composition, and the
separated by decantation and filtration. The solid residue was C5-C8 components found in the gaseous product were added
rinsed with n-hexane to remove any liquid product, dried, and to the liquid composition, correspondingly.
weighed. Then the catalyst was separated from the uncon-
verted polymer feed by washing sequentially with n-hexade-
cane (80 C) and n-hexane (room temperature). The solid Results and Discussion
residue was dried and weighed to determine the weight of
recovered catalyst (including coke). Gaseous and some volatile A. DL Reactions of Polyethylene. Results of the
liquid products were collected in a stainless steel trap kept at GC/MS analysis of a typical polyethylene DL product,
liquid nitrogen temperature and weighed. This way, the obtained at 450 C with 0.5 wt % of SO42-/Fe2O3 as
product was separated and the weights of gas, liquid, solid, catalyst, are given in Figure 1. As seen, the liquid
and recovered catalyst were determined. product obtained consists of a mixture of C5-C32 (mostly
In the presence of a solvent and larger amounts of catalyst, C5-C12) normal and branched paraffins, accompanied
the following modified procedure was applied: 5.0 g of polymer, by some amounts of 5- and 6-ring nonsubstituted and
e.g., HDPE, 5.0 g of n-octadecane (mp 30 C), and the desired mono-, di-, and trialkylsubstituted cycloparaffins. The
amount of catalyst (2.0-5.0 g) were charged into the Micro- proportion of cycloparaffins decreases to some extent
clave reactor. The reactor was sealed, purged sequentially with increase in the C number of the product compo-
with N2 and H2, charged with H2 to an initial pressure of 500
nent. In addition to n-paraffins, branched paraffins,
psig, and heated to 350 C. After reaction (60 min), the reactor
was cooled and about 1 mL of the liquid product was sampled
and cycloparaffins, the product contains small amounts
by a pipet for GC/MS and quantitative GC analysis. To of olefins and cycloolefins. An example of the boiling
determine total conversion, the main product in the reactor point distribution of the total liquid product is given in
was removed and subjected to Soxhlet extraction with n- Figure 2.
pentane. Conversion was determined on the basis of the The composition of the DL product from HDPE
insoluble solid residue. After removal of the n-pentane solvent, changes markedly with changes in processing variables,
the main part of the liquid product was collected and analyzed. e.g., temperature and reaction time, as described below.
Products from polybutadiene required special treatment Table 1 summarizes data on the change in product
because of their high viscosity at partial conversions. After
composition as a function of increase in reaction tem-
the removal of gas products, 20 mL of methanol was added
to the product. The reactor was then sealed, purged with perature, between 420 and 465 C, keeping other
nitrogen, heated to 200 C with continuous stirring, and then processing conditions constant, i.e., catalyst, SO42-/ZrO2,
cooled. The methanolic solution was subjected to GC analysis, 2.0 wt %; H2 pressure, 1500 psig; reaction time, 2.0 h.
whereas the solid residue was used to determine the total As seen, under such conditions the feed conversion is
conversion. To avoid the loss of volatile product components, very high and increases from 82.5 wt % at 420 C to
DL of Plastics and Rubbers Energy & Fuels, Vol. 11, No. 1, 1997 79

Figure 1. GC/MS analysis of the liquid product from DL of HDPE (450 C, 2.0 h, 1200 psig of H2, SO42-/Fe2O3).

Figure 2. Boiling point distribution of the liquid product from DL of HDPE by simulated distillation (450 C, 2.0 h, 1200 psig
of H2, SO42-/Fe2O3).

100 wt % at 450-465 C. At 420 C the product is shows that higher molecular weight liquids (C13+)
predominantly liquid. With increase in temperature, steeply decrease (from 54.0 wt % at 420 C to 11.7 wt %
however, the yield of liquid products gradually decreases at 465 C), as expected for these intermediate depolym-
(from 92.8 wt % at 420 C to 60.2 wt % at 465 C), while erization products, while the C5-C12 fraction passes
that of C1-C4 gaseous products correspondingly in- through a maximum and then declines. The compo-
creases (from 7.2 wt % at 420 C to 39.8 wt % at 465 nents of the predominant gasoline-range (C5-C12) frac-
C). The changes in the composition of gaseous (C1- tion (Table 1) either increase (C5 and C6 hydrocarbons)
C4) and liquid (C5-C12 and C13+) product fractions as a or pass through a maximum and then slightly decrease
function of temperature are plotted in Figures 3 and 4, (C7-C12 hydrocarbons) with increase in temperature.
respectively. As seen from Figure 3, C3 and C4 hydro- The above trends clearly demonstrate the gradual
carbons predominate in the gaseous product in the breakdown of the polyethylene polymeric chains. Table
entire temperature range studied. Further, Figure 4 2 and Figure 5 show that the same trends, although in
80 Energy & Fuels, Vol. 11, No. 1, 1997 Shabtai et al.

Table 1. Composition of Products from DL of HDPE as a


Function of Reaction Temperaturea
temp
420 C 435 C 450 C 465 C
convrn,b wt % 82.5 98.9 100 100
product distrbn,c wt %
gas (C1-C4) 7.2 11.9 21.6 39.8
liquid 92.8 88.1 78.4 60.2
gasoline boiling range,c wt %
C5-C12 42.7 58.0 63.0 53.2
liquid product distrbn,d wt %
C5H12e (+C5H10)e 4.6 7.5 10.6 19.1
C6H14 (+C6H12) 5.5 8.7 11.8 17.4
C7H16 (+C7H14) 6.8 10.2 13.0 14.3
C8H18 (+C8H16) 7.3 10.8 13.5 12.2
C9H20 (+C9H18) 6.3 9.0 11.1 9.3
C10H22 (+C10H20) 5.9 7.9 8.7 7.5
C11H24 (+C11H22) 5.0 6.3 6.6 5.0
C12H26 (+C12H24) 4.6 5.4 5.0 3.5
C13+ 54.0 34.2 19.7 11.7
a In each run were used 10.0 g of polyethylene feed and 0.20 g

of SO42-/ZrO2 catalyst; initial H2 pressure was 1500 psig, and


reaction time was 2.0 h. b Weight percent of feed converted into
products. c Calculated in weight percent of total product. d Weight
percent of liquid product. e All fractions of a given C number
consist of mixtures of normal and branched paraffins, accompanied
by some cycloparaffins and trace amounts of olefins.

Figure 4. Change in product composition from DL of HDPE


as a function of reaction temperature (1500 psig of H2, 2 h,
SO42-/ZrO2).

Table 2. Composition of Products from DL of HDPE as a


Function of Reaction Timea
reaction time
0.5 h 1.0 h 2.0 h 3.0 h
convrn,b wt % 99.4 99.9 100 100
product distrbn,c wt %
gas (C1-C4) 12.5 17.9 22.9 29.3
liquid 87.5 82.1 77.1 70.7
gasoline boiling range,c wt %
C5-C12 52.2 57.9 58.7 55.4
liquid product distrbn,d wt %
C5H12e (+C5H10)e 6.5 8.9 10.1 11.7
C6H14 (+C6H12) 7.2 9.3 10.9 12.5
C7H16 (+C7H14) 7.7 10.5 12.5 13.6
C8H18 (+C8H16) 8.1 11.1 13.1 12.0
C9H20 (+C9H18) 8.7 10.3 10.1 9.7
C10H22 (+C10H20) 7.9 8.1 8.4 8.2
C11H24 (+C11H22) 7.1 6.7 6.3 6.1
C12H26 (+C12H24) 6.4 5.6 4.7 4.5
C13+ 40.4 29.5 23.9 21.7
a In each run were used 10.0 g of polyethylene feed and 0.10 g

of SO42-/ZrO2 catalyst; reaction temperature was 450 C and initial


H2 pressure was 1500 psig. b Weight percent of feed converted into
products. c Calculated in weight percnet of total product. d Weight
percent of liquid product. e All fractions of a given C number
Figure 3. Change in gas product composition from DL of
consist of mixtures of normal and branched paraffins, accompanied
HDPE as a function of reaction temperature (1500 psig of H2,
by some cycloparaffins and trace amounts of olefins.
2 h, SO42-/ZrO2).

a less pronounced manner, are observed for a series of above 1500 psig, the concentrations of the gasoline and
runs on the change of product composition as a function C13+ fractions remained essentially unchanged.
of reaction time between 0.5 and 3.0 h. It should be A comparison of HDPE conversions in the presence
noted that in this series of runs the catalyst concentra- of different superacid catalysts indicated that the DL
tion was reduced from 2.0 wt % (Table 1, footnote a) to activities of the latter were in the order SO42-/ZrO2 >
1.0 wt % (Table 2, footnote a). SO42-/Al2O3 > SO42-/Fe2O3. This was in agreement
The effect of H2 pressure, in the range of 500-2000 with a previous study on the relative acidities and
psig, upon the product composition was relatively dealkylation activities of these superacid catalysts.27,28
weaker in comparison with the temperature and time B. DL Reactions of Polypropylene. Table 3
effects. Increase in H2 pressure from 500 to 1500 psig summarizes results obtained on the change in product
resulted in some increase in the yield of the gasoline composition from SO42-/ZrO2-catalyzed DL of PPR as a
(C5-C12) fraction and a corresponding decrease in the function of reaction temperature between 380 and 450
yield of the C13+ fraction. However, at H2 pressures C, with other processing conditions kept constant
DL of Plastics and Rubbers Energy & Fuels, Vol. 11, No. 1, 1997 81

Figure 5. Change in product composition from DL of HDPE Figure 6. Change in product composition from DL of PPR as
as a function of reaction time (1500 psig of H2, 450 C, SO42-/ a function of reaction temperature (1500 psig of H2, 2 h, SO42-/
ZrO2). ZrO2).
(footnote a). It is found that at 380-400 C the total Figure 8 summarize the change in DL product composi-
conversion of the PPR feed is markedly higher than that tion as a function of reaction time between 0.5 and 3.0
of HDPE (<20 wt %), and it increases with increase in h (410 C). The general trends, although less pro-
temperature (from 79.8 wt % at 380 C to 100 wt % at nounced, are similar with those found for the above-
400 C). The yield of the predominantly liquid product described temperature effect.
decreases gradually with increase in temperature (from Compositional changes within the gasoline-range
95.1 wt % at 380 C to 56.8 wt % at 450 C), whereas fraction from PPR as a function of temperature are
that of C1-C4 gaseous products correspondingly in- plotted in Figure 9. It is found that the lower boiling
creases. The predominant gasoline-range (C5-C12) frac- C5-C9 hydrocarbon components increase with increase
tion increases with temperature up to a maximum of in temperature from 380 to 450 C, whereas C10-C12
67 wt % at 410 C and then slightly decreases. These components pass through a maximum and then decline.
trends are plotted in Figure 6. The GC/MS profile of These trends, together with the observed parallel de-
the predominant C5-C12 fraction is given in Figure 7. cline of C13+ components, are consistent with the
As seen, the fraction consists mainly of C5-C12 branched anticipated gradual depolymerization of oligomeric hy-
paraffins accompanied by minor amounts of correspond- drocarbon intermediates.
ing branched olefins and polymethyl-substituted naph- Compositional changes in the C1-C4 gas product from
thenes, e.g., 1,3,5-trimethylcyclohexane. Table 4 and PPR as a function of temperature are given in Figure
Table 3. Composition of Products from DL of PPR as a Function of Reaction Temperaturea
temp
380 C 390 C 400 C 410 C 420 C 450 C
convrn,b wt % 79.8 97.0 99.8 100 100 100
product distrbn,c wt %
gas (C1-C4) 4.9 6.5 10.7 14.9 21.7 43.3
liquid 95.1 93.5 89.3 85.2 78.3 56.8
gasoline boiling range,c wt %
C5-C12 55.3 64.0 66.3 66.6 64.1 52.3
liquid product distrbn,d wt %
C5H12e (+C5H10)e 5.0 6.7 8.2 9.8 11.4 17.5
C6H14 (+C6H12) 6.3 7.9 9.4 10.7 12.2 18.0
C7H16 (+C7H14) 5.8 7.3 7.9 8.4 9.1 12.4
C8H18 (+C8H16) 6.9 8.4 9.3 9.8 10.7 12.3
C9H20 (+C9H18) 12.1 14.1 14.9 15.4 15.6 15.5
C10H22 (+C10H20) 6.7 7.6 8.3 8.4 8.2 7.0
C11H24 (+C11H22) 6.8 7.1 6.9 6.7 6.5 4.2
C12H26 (+C12H24) 8.6 9.5 9.3 9.0 8.2 5.3
C13+ 41.9 31.5 25.7 21.8 18.1 7.9
a In each run were used 10.0 g of polypropylene feed and 0.10 g of SO 2-/ZrO catalyst; initial H pressure was 1500 psig and reaction
4 2 2
time was 2.0 h. b Weight percent of feed converted into products. c Calculated in weight percent of total product. d Weight percent of
liquid product. e All fractions of a given C number consist of mixtures of branched paraffins, accompanied by small amount of cycloparaffins
and trace amounts of olefins.
82 Energy & Fuels, Vol. 11, No. 1, 1997 Shabtai et al.

Figure 7. GC/MS analysis of liquid product (gasoline-range fraction) from DL of PPR (410 C, 2.0 h, 1500 psig of H2, SO42-/
Fe2O3).

Table 4. Composition of Products from DL of PPR as a


Function of Reaction Timea
reaction time
0.5 h 1.0 h 2.0 h 3.0 h
convrn,b wt % 87.1 97.8 99.9 100
product distrbn,c wt %
gas (C1-C4) 6.7 7.8 11.1 14.1
liquid 93.3 92.2 88.9 85.9
gasoline boiling range,c wt %
C5-C12 59.8 66.2 68.0 66.2
liquid product distrbn,d wt %
C5H12e (+C5H10)e 5.8 6.1 6.6 6.9
C6H14 (+C6H12) 10.3 12.7 13.5 13.7
C7H16 (+C7H14) 8.4 9.5 9.8 9.8
C8H18 (+C8H16) 7.4 8.5 9.9 10.1
C9H20 (+C9H18) 13.0 14.6 14.9 14.7
C10H22 (+C10H20) 6.8 7.6 8.1 8.6
C11H24 (+C11H22) 5.3 5.3 6.1 5.8
C12H26 (+C12H24) 7.1 7.5 7.6 7.6
C13+ 35.9 28.2 23.5 22.9
a In each run were used 10.0 g of polypropylene feed and 0.10

g of SO42-/ZrO2 catalyst; reaction temperature was 410 C and


initial H2 pressure was 1500 psig. b Weight percent of feed
converted into products. c Calculated in weight percent of total
product. d Weight percent of liquid product. e All fractions of a
given C number consist of mixtures of branched paraffins, ac-
companied by small amount of cycloparaffins and trace amounts
of olefins.
Figure 8. Change in product composition from DL of PPR as
10. As in the case of HDPE (Figure 3) C3-C4 hydro- a function of reaction time (1500 psig of H2, 410 C, SO42-/
carbons are formed in markedly higher yields than C1- ZrO2).
C2 products. However, whereas C4 products are more
abundant than C3 hydrocarbons from polyethylene, a exhibits low DL reactivity at temperatures <400 C. At
higher yield of C3 hydrocarbons, corresponding to the temperatures <130 C, i.e., in the solid state, this is
propylene monomer, is found from polypropylene de- probably due to the presence of nonreactive crystallites29
composition, especially at 450 C (Figure 10). in this polymer, while in the molten state (Tm 130
C. Catalytic and Solvent Effects. The above C), at temperatures <400 C, the polymeric chains
results were obtained with very small amounts (0.5- apparently remain associated to a significant extent by
2.0 wt %) of finely dispersed superacid catalysts. The nonbonding interactions, thereby inhibiting free access
purpose was to identify an inexpensive superacid as a
(29) Schmidt-Rohr, K.; Spiess, H. W. Multidimensional Solid-State
disposable catalyst in coprocessing of waste polymers NMR and Polymers; Academic Press: San Diego, CA, 1994; pp 171-
with coal. Further, it was indicated that polyethylene 174 and references cited therein.
DL of Plastics and Rubbers Energy & Fuels, Vol. 11, No. 1, 1997 83

overlap of catalytic and thermal reactions. The catalytic


effects under such conditions were relatively weak and
were reflected in somewhat better yields and product
distribution (higher concentration of lower boiling com-
ponents) in the presence as compared with in the
absence of the small amounts of superacid catalysts
used. To determine in a more precise manner these and
other effects, a series of specifically designed experi-
ments were performed in which (1) the catalyst/
polyethylene feed ratios were markedly increased (1:5
or 1:2 by weight), thereby simulating or approaching
typical ratios used in FCC flow reactors;30 (2) the
conventional superacid catalysts were replaced with a
Pt-modified catalyst, i.e., Pt/SO42-/ZrO2, which is mark-
edly more resistant to deactivation; (3) a chemically
compatible solvent, i.e., n-octadecane, was added to the
polyethylene feed to untangle the polymeric chains
during reaction and make them accessible to the dis-
persed catalyst; and (4) the reaction temperature was
reduced to 350 C, at which thermal, noncatalytic
decomposition of polyethylene is essentially excluded.
It should be noted that nonmodified SO42-/ZrO2 catalyst
is resistant to deactivation at high hydrogen pressures
(g500 psig)26 and that this resistance as well as the
isomerization activity of the catalyst is markedly in-
creased by modification with Pt.31 Results obtained
from comparative DL runs with and without catalysts,
as well as with and without n-octadecane as solvent,
are summarized in Table 5.
As seen, with about 17-33 wt % of Pt/SO42-/ZrO2 as
Figure 9. Change in composition of the gasoline (C5-C12) catalyst and in the presence of n-C18H38 as solvent,
fraction from DL of PPR as a function of reaction temperature polyethylene (PE) undergoes almost complete DL at 350
(1500 psig of H2, 2 h, SO42-/ZrO2).
C (runs DL-1 and DL-2). In contrast, there is es-
sentially no reaction of this polymer in the absence of
the catalyst under otherwise identical processing condi-
tions (run DL-5). With the nonmodified SO42-/ZrO2 as
catalyst (runs DL-3 and DL-4) there is considerable
reaction, but the total conversion is markedly lower. A
high activity of Pt/SO42-/ZrO2, in concentrations of 17-
33 wt % (relative to the feed), is exhibited even in the
absence of the solvent (runs DL-6 and DL-7). However,
the nonmodified SO42-/ZrO2 catalyst shows sharply
lower activity under such conditions (run DL-8). As
expected, in the absence of both a catalyst and the
solvent, PE undergoes no reaction whatsoever at 350
C (run DL-9).
The GC/MS profile of the liquid product from run
DL-2 (350 C; 17 wt % of Pt/SO42-/ZrO2, n-C18H38
solvent) is given in Figure 11. As seen, the product
consists predominantly of C5-C12 branched paraffins
accompanied by very small amounts of n-paraffins.
Although partial catalytic hydrocracking of the n-C18H38
solvent contributes to the liquid product, it is found, as
shown in Figure 12, that the GC/MS profile of the liquid
product from PE only, viz. in the absence of this solvent
(run DL-7), is essentially identical. The predominance
of isoparaffins in the DL product (Figures 11 and 12)
indicates that in the presence of sufficient catalyst
Figure 10. Change in gas product composition from DL of concentrations, preferably in the presence of an n-
polypropylene as a function of reaction temperature (1500 psig
paraffinic solvent, PE undergoes in-depth depolymeri-
of H2, 2 h, SO42-/ZrO2).
zation, accompanied by extensive hydroisomerization,
of the catalyst to potentially reactive sites in the chains.
On the basis of the composition of products (Table 1 and (30) Gary, J. H. Petroleum Refining: Technology and Economics,
Figure 1), it is indicated that at higher temperatures, 2nd ed.; Dekker: New York, 1984; p 101.
(31) Tanabe, K.; Yamaguchi, T. In Successful Design of Catalysts;
i.e. >400 C, DL of polyethylene in the presence of small Inui, T., Ed.; Elsevier Science Publishers: Amsterdam, 1988; pp 99-
amounts (1-2 wt %) of superacid catalysts involves an 110.
84 Energy & Fuels, Vol. 11, No. 1, 1997 Shabtai et al.

Table 5. Catalyst and Solvent Effects in DL of HDPEa


run no.
DL-1 DL-2 DL-3 DL-4 DL-5 DL-6 DL-7 DL-8 DL-9
catalyst Pt/SO42-/ZrO2 Pt/SO42-/ZrO2 SO42-/ZrO2 SO42-/ZrO2 no Pt/SO42-/ZrO2 Pt/SO42-/ZrO2 SO42-/ZrO2 no
catalyst catalyst
solventb n-C18H38 n-C18H38 n-C18H38 n-C18H38 n-C18H38 none none none none
catalyst/feed 1:2 1:5 1:2 1:5 1:2 1:5 1:5
wt ratioa
H2 pressure, 750 750 820 820 900 700 700 780 820
psigc
total convrn,d,e 92.5 88.9 77.5 45.0 <2.0 64.7 55.1 30.0 <0.5
wt %
a In each run were used 10.0 g of HDPE feed and a calculated amount (2.0 or 5.0 g) of catalyst; reaction temperature was 350 C and

reaction time was 1.0 h. b In runs with n-C18H38, 5.0 g of this solvent and 5.0 g of HDPE feed were used for reaction. c Reaction pressure;
initial H2 pressure in all runs was 500 psig. d Total HDPE conversion into liquid and gaseous products, as determined by the weight of
unreacted HDPE residue (see Experimental Section). e Based on runs without solvent (DL-6 to DL-8), C1-C4 gases formed from HDPE
represent only 4-7 wt % of the total products.

Figure 11. GC/MS analysis of the liquid product from DL of HDPE (350 C, 1.0 h, 20% Pt/SO42-/ZrO2, 500 psig of H2, n-octadecane
as solvent).

even at 350 C. This is quite different from the paraffins and alkyl-substituted naphthenes; (2) benzene
composition of products from PE at elevated tempera- and (C1-C6) alkylbenzenes; (3) tetralins and indanes;
ture (450 C) in the presence of small amounts (1-2 wt and (4) bicyclic arenes. Results on the change in product
%) of nonmodified SO42-/ZrO2, which is characterized composition from DL of this polymer as a function of
by significant concentration of n-paraffinic components reaction temperature (350-430 C), using SO42-/ZrO2
(Figure 1). The results obtained provide the basis for as catalyst, are summarized in Table 6. As seen, C5-
bona fide catalytic conversion of waste PE into gasoline- C10 paraffins and naphthenes are major components
range isoparaffins, as potential high-grade fuel compo- (45 wt %) at 350 C but decrease moderately with
nents. increase in temperature. Alkylbenzenes are also im-
It should be noted that, compared to HDPE, PPR portant components (21.7 wt % at 350 C) but gradually
shows markedly higher depolymerization reactivity even decrease with increase in temperature up to 415 C,
in the presence of small amounts, e.g., 1 wt %, of probably as a result of acid-catalyzed intramolecular
superacid catalysts (Table 3). This higher reactivity can cyclization reactions of (C3-C6) alkylbenzenes to yield
be ascribed to the presence of multiple tertiary carbons indanes and tetralins. Consistent with that is the
in the branched polypropylene chains, with consequent observed gradual increase in the concentration of the
fast formation of tertiary carbonium ions and attendant latter types of compounds in the same temperature
cleavage reactions leading to isoparaffinic products (vide range, i.e., from 350 to 415 C. Bicyclic arenes, in
infra). particular alkylnaphthalenes, increase slightly with
D. DL Reactions of Polybutadiene. Figure 13 temperature, probably as a result of dehydrogenation
provides the GC/MS analysis of the liquid product reactions of tetralins and alkylindanes above 400 C.
obtained by DL of a polybutadiene sample (average MW E. Mechanistic Aspects of DL Reactions. The
197 000) at 415 C with 1.0 wt % of SO42-/ZrO2 as change in product composition from DL of polyethylene
catalyst. As seen, the product consists of a mixture of and polypropylene as a function of temperature and
the following main types of compounds: (1) C5-C12 reaction time (sections A and B above), coupled with the
DL of Plastics and Rubbers Energy & Fuels, Vol. 11, No. 1, 1997 85

Figure 12. GC/MS analysis of the liquid product from DL of HDPE (350 C, 1.0 h, 20% Pt/SO42-/ZrO2, 500 psig of H2, no solvent).

Figure 13. GC/MS analysis of the liquid product from DL of cis-polybutadiene, MW 197 000 (415 C, 2.0 h, 1500 psig of H2,
SO42-/ZrO2).

data on the observed catalytic effects (Table 5), can be and results in regeneration of the acidic catalyst.32
rationalized in terms of stepwise cleavage reactions of Branched olefins produced by -cleavage reactions
these polymers by a carbonium ion mechanism. undergo to a major extent hydrogenation to the corre-
The high reactivity of polypropylene can be ascribed sponding paraffins. Such reactions involve fast proto-
to the presence of multiple tertiary carbons in the nation of the olefinic intermediate to yield a carbonium
polymeric chains and the consequent fast formation of ion which in turn, by metathesis with hydrogen, yields
tertiary carbonium ions in the presence of strongly the skeletally analogous paraffin. Limited hydrogena-
acidic catalysts. Such carbonium ions undergo -cleav- tion of olefins has been previously found even in
age reactions to yield lower branched paraffins and noncatalytic hydropyrolysis proceeding by a free radical
olefins by a sequence proposed in Figure 14. Lower
molecular weight carbonium ions yield corresponding (32) Shabtai, J.; Ramakrishnan, R.; Oblad, A. G. Thermal Hydro-
carbon Chemistry; Advances in Chemistry Series 183; Oblad, A. G.,
branched paraffins by metathesis with molecular hy- Davis, H. G., Eddouger, R. T., Eds.; American Chemical Society:
drogen, a reaction that involves a low activation energy Washington, DC, 1979; pp 297-328.
86 Energy & Fuels, Vol. 11, No. 1, 1997 Shabtai et al.

Table 6. Composition of Products from DL of cis-Polybutadiene as a Function of Reaction Temperaturea


temp
350 C 375 C 400 C 415 C 430 C
convrn,b wt % 12.6 24.6 72.9 98.5 100
product distrbn,c wt %
C1-C4 gases 2.5 2.8 2.9 4.4 5.9
liquid products 95.9 93.5 91.3 87.7 84.0
coke plus losses 1.6 3.7 5.8 7.9 10.1
liquid product distrbn, wt %
C5-C10 paraffinsd and 45.0 32.8 29.9 26.9 25.8
cycloparaffinse
benzene and 21.7 20.5 20.4 17.9 17.5
alkylbenzenesf
tetralins and indansg 14.9 19.1 21.6 22.5 21.0
bicyclic arenesh 18.5 27.6 28.1 32.7 35.7
aIn each run were used 5.0 g of polybutadiene feed and 0.05 g of SO 2-/ZrO catalyst; initial H pressure was 1500 psig and reaction
4 2 2
time was 1.0 h. b Weight percent of feed converted into products. c Calculated in weight percent of total product. d C5-C10 paraffins and
small amount of olefins. Cyclopentane, cyclohexane, and (C1-C4) alkyl-substituted derivatives. f (C1-C6) alkyl-substituted benzenes.
e
g Tetralin, indan, and (C -C ) alkyl-substituted derivatives. h (C -C ) alkyl-substituted naphthalenes and (C -C ) alkyl-substituted
1 2 1 3 1 2
biphenyls.

Figure 14. Proposed mechanistic scheme for acid-catalyzed


polypropylene DL.

mechanism.32 The latter involves addition of a hydro-


gen atom to the olefin to form a radical which by
metathesis with molecular hydrogen yields the paraf-
finic product. It should be noted that at temperatures
>400 C and in the absence of sufficient amounts of
catalyst there is probably an overlap of catalytic and
purely thermal PE depolymerization. The latter could
proceed by a radical mechanism resulting in markedly Figure 15. Example of proposed mechanistic sequences for
lower formation of isoparaffinic products. conversion of PE into branched paraffins.
The formation of branched paraffins as main products
from PE indicates that the DL reactions of this straight- of isomeric methylpentadecanes, dimethyltetradecanes,
chain polymer in the presence of superacid catalysts and multiply branched hexadecanes with a selectivity
(Table 5) involve extensive skeletal rearrangement of of >95 wt %.33,34 Further, skeletal isomerization was
intermediate cleavage products. Highly selective hy- found to represent a necessary step preceding the
droisomerization of n-paraffins to branched paraffins, catalytic cracking of n-paraffinic feeds.35 By analogy,
in the presence of strongly acidic Y-type zeolites, was as indicated in Figure 15, straight-chain fragments from
previously observed.33-35 For example, in the presence PE can undergo extensive branching by multiple hy-
of a PtCaY zeolite catalyst at 210 C and 1000 psig of dride and methide (or higher alkide) 1,2-shifts, prior to
H2 pressure, n-hexadecane was converted into a mixture subsequent cleavage and associated reactions leading
to lower branched paraffins. Initiation of the reaction
(33) Coppola, E. N. M.S. Thesis, University of Utah, 1987. involves formation of a secondary carbonium ion, which
(34) Coppola, E. N.; Oblad, A. G.; Shabtai, J. Prepr.sAm. Chem. is somewhat slower compared to the initial formation
Soc., Div. Pet. Chem. 1987, 32 (2), 559.
(35) Schultz, H. F.; Weitkamp, J. H. Ind. Eng. Chem. Prod. Res. Dev. of tertiary carbonium ions from polypropylene (Figure
1972, 11, 46. 14). -Cleavage yields an olefin and a lower carbonium
DL of Plastics and Rubbers Energy & Fuels, Vol. 11, No. 1, 1997 87

ion in which the charge is delocalized along the chain Conclusions


by fast hydride shifts. Multiple methide (or higher
alkide) shifts result in extensive branching of the chain It was demonstrated that the DL of HDPE and PPR
prior to -cleavage reactions, leading to lower branched is a gradual breakdown process, which can be conve-
paraffins. Olefins produced by -cleavage undergo niently controlled to produce C5-C12 hydrocarbons as
protonation to yield carbonium ions which undergo the predominant products. For HDPE, a highly selective
same types of skeletal rearrangement and attendant catalytic DL procedure for production of C5-C12 branched
cleavage reactions. paraffins was achieved by using a relatively low tem-
DL reactions of polybutadiene, unlike those of poly- perature and applying a high Pt/SO42-/ZrO2 catalyst/
ethylene and polypropylene, yield cyclic compounds as feed ratio, preferably in the presence of a chemically
predominant products (Figure 13 and Table 6). Forma- compatible n-paraffinic solvent. For PPR, processing
tion of the latter can be tentatively explained on the conditions for selective conversion of the polymer into
basis of previous studies of the thermal reactions of
a gasoline-like product, consisting of C5-C12 branched
butadiene.36,37 Monomeric butadiene, and possibly also
paraffins, were likewise identified.
some higher dienes, derived by initial depolymerization,
can undergo fast Diels-Alder cyclodimerization to form The results obtained provide fundamental data and
4-vinylcyclohexene (and alkyl-substituted derivatives), possible processing concepts for conversion of HDPE,
which by a sequence of rearrangement and hydrogen PPR, and other polyolefins into desirable isoparaffinic
transfer reactions yield a full range of alkylbenzenes and products representing potential blending components for
alkyl-substituted naphthenes.36,37 Some bicyclic arenes reformulated, nonaromatic gasolines.
can be produced by secondary Diels-Alder additions of
butadiene to unsaturated monocyclic intermediates and/
or intramolecular cyclizations of alkyl- or alkenylben- Acknowledgment. We thank the U.S. Department
zenes.36,37 of Energy for financial support through the Consortium
for Fossil Fuel Liquefaction Science (DE-FC22-
(36) Gil-Av, E.; Shabtai, J.; Steckel, F. Ind. Eng. Chem. 1960, 52, 93PC93053).
31.
(37) Shabtai, J.; Gil-Av, E. Tetrahedron 1962, 18, 87-94. EF960076+

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