Debrominated high quality oil production by the two-step catalytic pyrolysis of phenolic printed circuit boards (PPCB) using natural clays and HY

Thermal and Catalytic Recycling of Plastics from Waste Electrical and Electronic Equipment-Challenges and Perspectives

The amount of end-of-life electrical and electronic devices has been widely increased, globally. This emphasizes how recycling waste electric and electronic equipment (WEEE) is essential in order to reduce the amount of WEEE that is disposed of directly in the environment. Plastics account for a big percentage in WEEE, almost 20%. As a result, the application of recycling methods on plastics gathered from WEEE is of great importance since, in this way, landfill disposal can be reduced. Nevertheless, despite the advantages, there are a lot of difficulties, such as the variety of different plastics present in the plastic mix and the existence of various additives in the plastic parts, for instance, brominated flame retardants that need special attention during their treatments, which restricts their wide application. Considering all these, this review aims to provide readers with all the current techniques and perspectives that are available for both the thermal and the catalytic recycling of plastics retrieved from WEEE. Apart from the up-to-date information on the recycling methods, in this review, emphasis is also given on the advantages each method offers and also on the difficulties and the limitations that may prevent them from being applied on a large scale. Current challenges are critically examined, including the use of mechanical or thermo-chemical recycling, the treatment of individual polymers or polymer blends and the separation of harmful additives before recycling or not. Finally, emerging technologies are briefly discussed.

Recent Advancements in Pyrolysis of Halogen-Containing Plastics for Resource Recovery and Halogen Upcycling: A State-of-the-Art Review

Plastic waste has emerged as a serious issue due to its impact on environmental degradation and resource scarcity. Plastic recycling, especially of halogen-containing plastics, presents challenges due to potential secondary pollution and lower-value implementations. Chemical recycling via pyrolysis is the most versatile and robust approach for combating plastic waste. In this Review, we present recent advancements in halogen-plastic pyrolysis for resource utilization and the potential pathways from "reducing to recycling to upcycling" halogens. We emphasize the advanced management of halogen-plastics through copyrolysis with solid wastes (waste polymers, biomass, coal, etc.), which is an efficient method for dealing with mixed wastes to obtain high-value products while reducing undesirable substances. Innovations in catalyst design and reaction configurations for catalytic pyrolysis are comprehensively evaluated. In particular, a tandem catalysis system is a promising route for halogen removal and selective conversion of targeted products. Furthermore, we propose novel insights regarding the utilization and upcycling of halogens from halogen-plastics. This includes the preparation of halogen-based sorbents for elemental mercury removal, the halogenation-vaporization process for metal recovery, and the development of halogen-doped functional materials for new materials and energy applications. The reutilization of halogens facilitates the upcycling of halogen-plastics, but many efforts are needed for mutually beneficial outcomes. Overall, future investigations in the development of copyrolysis and catalyst-driven technologies for upcycling halogen-plastics are highlighted.

The fate of bromine during microwave-assisted pyrolysis of waste printed circuit boards

Bromine control is imperative for efficient treatment and products utilization during pyrolysis of waste printed circuit boards (WPCBs). This study investigated Br-species in products from microwave-assisted auger pyrolysis of WPCBs, and discussed synergetic evolution mechanisms, release kinetics and thermodynamics of Br-containing pollutants with different kinds of mineral species (alkaline earth, alkali, and transition metals). Results indicated that heavy Br-containing volatiles release (e.g., brominated phenols) was dominated at 320-520 °C. Brominated phenols released Br* to react with small-molecule groups to form light Br-containing products (e.g., HBr, CH3Br, and CH3CH2Br) at >520 °C. K2CO3 efficiently suppressed Br-containing pollutants emissions (∼50% reduction) and promoted bromine fixation in char (∼33.49% increase). With K2CO3 addition, bromine evolution mechanism is largely dehydrobromination and neutralization reactions when bromine bonds with aliphatic carbon with an adjacent aliphatic hydrogen. Negatively charged oxygen of K2CO3 attacks bromine and causes C-Br scission when bromine bonds with CH3* or aromatic carbon. The chemical reaction models (CRM3-CRM5) are best fitted with bromine evolution and the activation energy of WPCBs-KC reached the lowest (149.83-192.19 kJ/mol). Furthermore, bromine control strategy in WPCBs pyrolysis products toward environmental and economic sustainability were suggested, which created less environmental impact and maximum resource recovery.

Co-pyrolysis of paper-laminated phenolic printed circuit boards and calcium-based additives in fixed and fluidized bed reactors

This study compares the impact of the calcium-based additives and the pyrolyzer on the recovery and the halide content of the oil produced from the pyrolysis of paper-laminated phenolic resin printed circuit boards (FR2-PCB). The preliminary experiments showed that the maximum liquid recovery (40.6%) was achieved in a fluidized bed pyrolyzer containing a 50:50 mixture of CaO and Ca(OH)2 operating at T = 620 °C and PCB-to-additive ratio (FR2/A) = 5.4 g/g for 22 min. Extra tests were then carried out under these conditions in fixed and fluidized bed pyrolyzers to separately explore the impact of CaO, Ca(OH)2, and CaO + Ca(OH)2 on the liquid recovery (LR) and the halogen content of the non-solid products. In the fluidized bed, LR in the presence of CaO, Ca(OH)2, and CaO + Ca(OH)2 was 34.5%, 41.2%, and 38.9 wt%, respectively. The fraction of phenolic compounds in the pyrolysis oil ranged from 86% to 93%, about 1-3% higher than the corresponding values in the fixed bed. Using additives led to lower halide content in the pyrolysis oil of the fluidized bed than that of the fixed bed. However, the opposite trend was observed in the absence of additives. Regardless of the type of pyrolyzer, Ca(OH)2 was more successful than CaO in increasing LR, whereas CaO was more effective than Ca(OH)2 in pyrolysis oil dechlorination. Co-pyrolysis of FR2-PCB and CaO + Ca(OH)2 in a fluidized bed reactor was identified as a practical approach to enhance the recovery of pyrolysis oil comprising only 5% of the original halogen content of the feedstock.

Debromination with Bromine Recovery from Pyrolysis of Waste Printed Circuit Boards Offers Economic and Environmental Benefits

Bromine is an important resource that is widely used in medical, automotive, and electronic industries. Waste electronic products containing brominated flame retardants can cause serious secondary pollution, which is why catalytic cracking, adsorption, fixation, separation, and purification have gained significant attention. However, the bromine resources have not been effectively reutilized. The application of advanced pyrolysis technology could help solve this problem via converting bromine pollution into bromine resources. Coupled debromination and bromide reutilization during pyrolysis is an important field of research in the future. This prospective paper presents new insights in terms of the reorganization of different elements and adjustment of bromine phase transition. Furthermore, we proposed some research directions for efficient and environmentally friendly debromination and reutilization of bromine: 1) precise synergistic pyrolysis should be further explored for efficient debromination, such as using persistent free radicals in biomass, polymer hydrogen supply, and metal catalysis, 2) rematching of Br elements and nonmetal elements (C/H/O) will be a promising direction for synthesizing functionalized adsorption materials, 3) oriented control of the bromide migration path should be further studied to obtain different forms of bromine resources, and 4) advanced pyrolysis equipment should be well developed.

Removal of polybrominated diphenyl ethers in high impact polystyrene (HIPS) from waste TV sets

Most studies have shown that improper disposal of e-waste can accelerate the release of high concentrations of polybrominated diphenyl ethers (PBDEs), and this situation causes environmental pollution and human health risks. The recycling technology of waste electronic plastics based on solvent processes can reduce environmental pollution and health risks from PBDEs. In this study, high impact polystyrene (HIPS) from waste TV sets was taken as the research object, and d-limonene and n-propanol were used as solvent and precipitant, respectively. We studied the relationship between the precipitation conditions and the size of precipitate particles, and the effect laws of precipitation conditions on the removal percentage of PBDEs were discussed. Transferring behavior of PBDEs during precipitation was investigated, and the parameters suitable for removing PBDEs from HIPS solution were confirmed. Results showed that lower HIPS concentration in d-limonene, lower precipitation temperature, higher mass ratio of n-propanol to HIPS solution, and greater stirring speed were conducive to form smaller and more uniform precipitate particles. All conditions (concentration, temperature, mass ratio, and stirring rate) that could increase the solubility of PBDEs in the mixed solvent of limonene and n-propanol or decrease the swelling degree of HIPS precipitate particles, or reduce the size of particles could improve the removal percentage of PBDEs. The investigated results indicated that insoluble PBDEs (e.g., decabromodiphenyl ether) transferred into the HIPS precipitate mainly through the generated crystals and then precipitated together with the HIPS particles, and soluble PBDEs (e.g., octabromodiphenyl ether) migrated into the precipitate by the solution entrained. The precipitate particles, which measured approximately 1.0 mm (on average), were obtained when the solution containing 10% of HIPS from waste TV shell was precipitated by adding n-propanol equivalent to twice the mass of the solution at 40 °C and 3000 r/min stirring speed. The total concentration of PBDEs in the precipitate particles (dried) was reduced to 2369 mg/kg, and 88.06% of the PBDEs in the original plastic solution was successfully removed by this process.

An integrated utilization strategy of printed circuit boards and waste tire by fast co-pyrolysis: Value-added products recovery and heteroatoms transformation

Fast co-pyrolysis has been suggested as a promising technique to solve the environmental issues and simultaneously recover value-added products from polymer wastes. However, to date, no studies have focused on fast co-pyrolysis of printed circuit boards (PCB) and waste tire (WT). Therefore, we comprehensively investigated the fast co-pyrolysis of PCB and WT using pyrolysis-gas chromatography/mass spectrometry. The results show that an increase in temperature during fast pyrolysis improved the interactions between the PCB and WT pyrolyzates, increasing the formation of aliphatic and aromatic compounds. The formation of p-cymene was greatly induced by the isomerization and dehydrogenation reactions of D-limonene. Co-pyrolysis reduced the formation of brominated phenols and benzothiazole from PCB and WT pyrolysis, respectively, whereas promoted the interactions between Br- and S/N-containing radicals, concentrating them into heavy compounds. Increasing the temperature enhanced the release of heteroatom compounds. The findings suggest that debromination of PCB achieved via dehydrogenation of WT pyrolysis provoked secondary reactions of olefins and interactions of heteroatom radicals. The major products were accurately predicted by different fitting models using response surface methodology, indicating the synergistic interactions during co-pyrolysis. The results were beneficial for optimizing the experimental parameters to obtain the maximum yield of desired products.

Novel trends in the thermo-chemical recycling of plastics from WEEE containing brominated flame retardants

The amount of plastics from waste electric and electronic equipment (WEEE) has enormously increased nowadays, due to the rapid expansion and consumption of electronic devices and their short lifespan. This, in combination with their non-biodegradability, led to the need to explore environmentally friendly solutions for their safe disposal. One main obstacle when recycling plastics from WEEE is that they usually comprise harmful additives such as brominated flame retardants (BFRs) that need to be removed before or during their recycling. This paper reviews existing techniques for the recycling of plastics from WEEE and focuses specifically on the advantages, disadvantages, and challenges of pyrolysis as an environmentally friendly method for the production of value-added materials (monomers, hydrocarbons, phenols, etc.). Current technological trends available for the recycling of plastics containing brominated flame retardants are reviewed in an attempt to provide insights for future research on the sustainable management of plastics from WEEE. Emphasis is given on conventional pyrolysis, where a pretreatment step for the debromination of products is applied. This is required since brominated compounds treated at high temperatures may result in the production of harmful to health compounds such as dioxins. All current pretreatment methods (solvent extraction, supercritical fluid technology, etc.) are presented and compared in detail. Co-pyrolysis is also investigated, as it seems to be a very interesting approach, since no catalysts or solvents are used, and at the same time, more plastic wastes can be consumed as feedstock. Furthermore, catalytic pyrolysis along with key parameters, such as the type of the catalyst or pyrolysis temperature, are fully analyzed. Catalysts affect the products' distribution and enhance the removal of bromine from pyrolysis oils. Finally, an emerging technique, that of microwave-assisted pyrolysis, is also highlighted, as it offers many advantages over conventional pyrolysis. Of course, there are some impediments, such as the operational costs or other difficulties as regards the industrial implementation of the mentioned techniques that need to be overcome through future works.

Catalytic effect and mechanism of in-situ metals on pyrolysis of FR4 printed circuit boards: Insights from kinetics and products

Pyrolysis is a promising method for the recovery of waste printed circuit boards (WPCBs), but few researches have noticed the influence of in-situ metals. This study conducted a series of comparisons between metal-free leftover pieces (LP) and intact boards (IB), including pyrolysis characteristics, volatile emission, kinetics, and thermodynamic parameters. The thermo-gravimetry (TG) analyses indicated that both the samples presented predominant mass loss in narrow temperature intervals, and characteristic pyrolysis temperatures of IB were approximately 15 °C lower than those of LP. Dominant constituents in evolved gases were detected by Fourier-transform infrared spectrometry as CO₂, phenol, bromophenol, ethers, ketones, and aldehydes, and metals accelerated the generation of light hydrocarbons and aromatic compounds. The activation energy and thermodynamic parameters were calculated and compared, and the results verified the presence of in-situ metals led to a lower energy barrier and higher reaction extent. Moreover, conversion behaviors of Cu, Fe, Sn, and Pb manifested the formation of metal bromides and implied the reduction of brominated volatiles. The obtained results confirmed the catalytic effect of in-situ metals on PCBs pyrolysis and their bromine fixation abilities. This study contributes to fundamental knowledge that can be used to guide the pyrolysis of WPCBs.

Chemical Recycling of WEEE Plastics—Production of High Purity Monocyclic Aromatic Chemicals

More than 200 kg real waste electrical and electronic equipment (WEEE) shredder residues from a German dismantling plant were treated at 650 °C in a demonstration scale thermochemical conversion plant. The focus within this work was the generation, purification, and analysis of pyrolysis oil. Subsequent filtration and fractional distillation were combined to yield basic chemicals in high purity. By means of fractional distillation, pure monocyclic aromatic fractions containing benzene, toluene, ethylbenzene, and xylene (BTEX aromatics) as well as styrene and α-methyl styrene were isolated for chemical recycling. Mass balances were determined, and gas chromatography–mass spectrometry (GC-MS) as well as energy dispersive X-ray fluorescence (EDXRF) measurements provided data on the purity and halogen content of each fraction. This work shows that thermochemical conversion and the subsequent refining by fractional distillation is capable of recycling WEEE shredder residues, producing pure BTEX and other monocyclic aromatic fractions. A significant decrease of halogen content (up to 99%) was achieved with the applied methods.

Catalytic effect and mechanism of coexisting copper on conversion of organics during pyrolysis of waste printed circuit boards

Pyrolysis is a promising technology for recycling organic materials from waste printed circuit boards (WPCBs). Nevertheless, the generated organic bromides are toxic and urgently needed to be removed. The coexisting copper (Cu) of WPCBs has potential performance on debromination. However, the catalytic effect and mechanism of Cu on pyrolysis process and products were still unclear. To clarify the in-situ catalysis of Cu, the analysis on kinetics and pyrolysis products was performed. The results showed that Cu can change the mechanism function of pyrolysis, which reduced the apparent activation energy (Ea). The mechanism function of Cu-coated WPCBs was obtained by Šesták-Berggren model and expressed as: dαdt=1.65×10⁷×1-α^-1.30α^6.09-ln1-α^-6.03exp⁡-202.45KJ/molRT. Product analysis suggested that Cu promoted the conversion of organic bromides to Br₂ and HBr. During the process of pyrolysis, bromide atoms interacted with Cu to form coordination compound, which can weaken the strength of C-Br bond and generate bromide free radical (Br*). Besides, Cu can promote the conversion of aromatic-Br to Br₂ as the catalyst for Ullmann cross-coupling reaction. Therefore, the presence of Cu was beneficial to pyrolysis. This work provided the theoretical basis for the improvement and application of pyrolysis technology.

Direct Gas-Phase Derivatization by Employing Tandem μ-Reactor-Gas Chromatography/Mass Spectrometry: Case Study of Trifluoroacetylation of 4,4'-Methylenedianiline

Pyrolysis-gas chromatography/mass spectrometry (Py-GC/MS) is a promising technique allowing the rapid characterization of the polymer structure and additives of microgram-scale plastics. However, the Py-GC/MS analysis of polymers with urethane bonds is challenging because they produce highly reactive pyrolyzates such as amines and isocyanates polymerizing in the GC column, which limits the efforts to elucidate the pyrolysis mechanism and plastic characterization by online GC analysis. Herein, a novel pyrolysis-gas-phase derivatization-GC/MS (Py-GPD-GC/MS) technique was developed, allowing the pyrolysis of polymers and the subsequent direct gas-phase derivatization of pyrolyzates, employing a modified tandem μ-reactor-GC/MS system. This work conducted the gas-phase trifluoroacetylation of 4,4'-methylenedianiline (MDA), which is one of the major polyurethane (PU) pyrolyzates, using N-methyl-bis-trifluoroacetamide (MBTFA) as a derivatization agent. The trifluoroacetylation gas-phase reaction was monitored by in situ GC/MS analysis and the effects of derivatization conditions were investigated. The highest MDA conversion observed was 65.6 area %. Furthermore, the sequential PU pyrolysis and direct trifluoroacetylation of PU pyrolyzates in the first μ-reactor and second μ-reactor, respectively, were successfully operated, achieving the inhibited polymerization and detection of trifluoroacetylated derivatives. Thus, the Py-GPD-GC/MS method has a significant potential to be applied for other combinations of pyrolyzates and derivatization reactions, enabling deeper characterization of plastics producing highly reactive pyrolyzates that cannot be accurately analyzed by conventional Py-GC/MS analysis.

In-situ debromination mechanism based on self-activation and catalysis of Ca(OH)2 during pyrolysis of waste printed circuit boards

Completely and deeply removed bromide from waste printed circuit boards (WPCBs) is necessary due to their toxicity and carcinogenicity. To achieve this purpose, calcium hydroxide (Ca(OH)₂) as a debromination agent was added during pyrolysis process of WPCBs. The results showed that hydrogen bromide (HBr), 4-bromophenol, 2-bromophenol and 2,4-dibromophenol were the main bromide species in pyrolysis products. The Ca(OH)₂ plays a significant role for removing HBr and organic bromide, but not affects products yield. Optimal removal efficiency for 4-bromophenol, 2-bromophenol and 2,4-dibromophenol reached 87.5 %, 74.6 % and 54.5 %, respectively. And debromination efficiency was related to the steric hindrance caused by bromide atoms. The Ca(OH)₂ can be activated by captured HBr and its thermal decomposition. And the newly-generated calcium bromide and calcium oxide significantly facilitate debromination due to their high surface energy and reactivity. The debromination mechanism was clarified by experiments coupled with computational chemistry: the coordination of bromide and calcium to form [Ph-Br···Ca²⁺] or [Ph-Br···Ca_atom]. Then, electrons were delivered form bromide atom to Ca²⁺ or Ca_atom, which resulted in the stretch and weaken the C-Br bond. Hence, the C-Br bond was more easily to break. This work can provide support for designing novel and efficient debromination agents applied for high-temperature system.

Converting polycarbonate and polystyrene plastic wastes intoaromatic hydrocarbons via catalytic fast co-pyrolysis

Thermochemical conversion of plastic wastes is a promising approach to produce alternative energy-based fuels. Herein, we conducted catalytic fast co-pyrolysis of polycarbonate (PC) and polystyrene (PS) to generate aromatic hydrocarbons using HZSM-5 (Zeolite Socony Mobil-5, hydrogen, Aluminosilicate) as a catalyst. The results indicated that employing HZSM-5 in the catalytic conversion of PC facilitated the synthesis of aromatic hydrocarbons in comparison to the non-catalytic run. A competitive reaction between aromatic hydrocarbons and aromatic oxygenates was observed within the studied temperature region, and catalytic degradation temperature of 700 °C maximized the competing reaction towards the formation of targeted aromatic hydrocarbons at the expense of phenolic products. Catalyst type also played a vital role in the catalytic decomposition of PC wastes, and HZSM-5 with different Si/Al molar ratios produced more aromatic hydrocarbons than HY (Zeolite Y, hydrogen, Faujasite). Regarding the effect of Si/Al molar ration in HZSM-5 on the distribution of monocyclic aromatic hydrocarbons (MAHs), a Si/Al molar ratio of 38 maximized benzene formation with an advanced factor of 5.1. Catalytic fast co-pyrolysis of PC with hydrogen-rich plastic wastes including polypropylene (PP), polyethylene (PE), and polystyrene (PS) favored the production of MAHs, and PS was the most effective hydrogen donor with a ∼2.5-fold increase. The additive effect of MAHs increased at first and then decreased when the PC percentage was elevated from 30 % to 90 %, achieving the maximum value of 32.4 % at 70 % PC.

Production of bio-oil with reduced polycyclic aromatic hydrocarbons via continuous pyrolysis of biobutanol process derived waste lignin

The fast pyrolysis of waste lignin derived from biobutanol production process was performed to determine the optimal pyrolysis conditions and pyrolysis product properties. Four types of pyrolysis reactors, e.g.: micro-scale pyrolyzer-gas chromatography/mass spectrometry, lab and bench scale fixed bed (FB) reactors, and bench scale rotary kiln (RK) reactor, were employed to compare the pyrolysis reaction conditions and product properties obtained from different reactors. The yields of char, oil, and gas obtained from lab scale and bench scale reactor were almost similar compared to FB reactor. RK reactor produced desirable bio-oil with much reduced yield of poly aromatic hydrocarbons (cancer precursor) due to its higher cracking reaction efficiency. In addition, char agglomeration and foaming of lignin pyrolysis were greatly restricted by using RK reactor compared to the FB reactor.

Fractionation of biomass and plastic wastes to value-added products via stepwise pyrolysis: a state-of-art review

Pyrolysis has been considered as a promising thermochemical process that can convert biomass in nonoxidizing atmospheres to value-added liquid bio-oil, solid biochar, and noncondensable gas products. Fast pyrolysis has a better economic return because of the valuable biofuel production (e.g. bio-oil, syngas). Because of the complexity and heterogeneity of the feedstocks, the one-step pyrolysis often leads to the mixed, acidic, and highly oxygenated liquid products. Moreover, the downstream processes (e.g. deoxygenation) for the desired fuels require high costs on energy and catalysts consumption. Stepwise pyrolysis is defined as a temperature-programmed pyrolysis that can separately obtain the products from each temperature step. It is a feasible approach to accomplish the fractionation by optimizing the pyrolysis process based on the decomposition temperature ranges and products among the biomass constituents. In recent years, the stepwise pyrolysis technology has gained attentions in thermochemical conversion of complex organic solid wastes. Through the stepwise pyrolysis of a real waste, oxygenated and acidic products were concentrated in the first-step liquid product, whereas the second-step product normally contained a high portion of hydrocarbon with low acidity. The stepwise pyrolysis of biomass, plastics, and their mixtures is comprehensively reviewed with the objective of fully understanding the related mechanisms, influence factors, and challenges.

Effect of steam-iron reaction on product characteristics and debromination during pyrolysis of epoxy-printed circuit boards

In this work, the effect of steam and Fe powders on the pyrolysis of epoxy-printed circuit boards (e-PCBs) is in the focus of interest. It was found that higher yields of oil and gas were obtained at 600 °C in steam atmosphere than these obtained in N₂ atmosphere. Due to the interactions of Fe powders and steam, the highest yield of H₂ was obtained at 600 °C, accounting for 12.2 mmol g^-1. In terms of the oil products, a high amount of phenol was produced in steam atmosphere, whereas an increased yield of single ring aromatic compounds was obtained, due to the dehydroxylation reactions promoted by steam-iron reaction. In steam atmosphere, the amount of organobromine compounds was greatly reduced. Fe powders removed most of organobromine compounds and HBr from oils. However, the bromine fixing ability of Fe powders was declined at 700 °C, leading to an increase in the content of inorganic bromine in liquid products. The characterization of spent Fe powders showed that the oxidation reactions of Fe powders with steam proceeded during the experiment, whereas the reduction reactions could be promoted at higher temperatures.

Hydrogen and steam injected tandem μ-reactor GC/FID system: phenol recovery from bisphenol A and alkylphenols using Ni/Y zeolite

Hydrogen and steam injected tandem μ-reactor-GC/FID system achieved online quantification of products from hydrogenation and dealkylation of bisphenol A and alkylphenols using Ni/Y zeolite.