Pyrolysis-catalytic upgrading of brominated high impact polystyrene over Fe and Ni modified catalysts: Influence of HZSM-5 and MCM-41 catalysts

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.

Upgrading of solid recovered fuel (SRF) by dechlorination and catalytic pyrolysis over nanocrystalline ZSM-5 zeolite

Globally increasing concern related to municipal solid waste generation is encouraging research efforts on developing alternative routes to valorize mixed refused wastes. In this way, catalytic pyrolysis is emerging as an interesting and efficient technology due to its great flexibility in terms of feedstock. In the current work, upgrading of a Solid Recovered Fuel (SRF) has been investigated by catalytic pyrolysis over nanocrystalline ZSM-5 zeolite (n-ZSM-5), paying special attention to dechlorination effects due to the high Cl content of the raw waste. Thus, pretreatment of the SRF by water washing and mild thermal processing allows for a significant reduction of the Cl concentration. Regarding the catalytic pyrolysis step, the best conditions correspond with a temperature of 400 °C in the catalyst bed and 0.50 catalyst/SRF mass ratio, which lead to ca. 30 wt% oil yield (rich in aromatic hydrocarbons) together with about 40 wt% gas yield (rich in C3-C4 olefins). Accordingly, these products could find use as raw chemicals or for the production of advanced fuels. In addition, zeolite reutilization has been tested for several cycles, denoting a progressive modification of the products distribution because of coke deposition. However, an almost total recovery of the n-ZSM-5 zeolite catalytic performance is achieved after regeneration by air calcination, affording the production of an oil fraction with a Cl content as low as 40 ppm.

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.

Catalytic Pyrolysis of Polystyrene Waste in Hydrocarbon Medium

The fast catalytic pyrolysis of polystyrene in the hydrocarbon medium (light and heavy cycle oil) over zeolite catalysts at 450-550 °C was investigated. The influence of reaction conditions (medium, temperature, vapor residence time, polystyrene concentration) on polymer conversion and product distribution was studied. It was found that the polymer conversion is close to 100%, while ethylbenzene, benzene, and toluene are the main products of its transformation. The maximum yield of ethylbenzene (80%) was achieved at 550 °C, vapor residence time 1-2 s, polystyrene concentration 10%, and heavy cycle oil as the medium. The influence of zeolite topology on product distribution was explored. The possible mechanism of polystyrene pyrolysis was proposed.

First-Generation Organic Reaction Intermediates in Zeolite Chemistry and Catalysis

Zeolite chemistry and catalysis are expected to play a decisive role in the next decade(s) to build a more decentralized renewable feedstock-dependent sustainable society owing to the increased scrutiny over carbon emissions. Therefore, the lack of fundamental and mechanistic understanding of these processes is a critical "technical bottleneck" that must be eliminated to maximize economic value and minimize waste. We have identified, considering this objective, that the chemistry related to the first-generation reaction intermediates (i.e., carbocations, radicals, carbenes, ketenes, and carbanions) in zeolite chemistry and catalysis is highly underdeveloped or undervalued compared to other catalysis streams (e.g., homogeneous catalysis). This limitation can often be attributed to the technological restrictions to detect such "short-lived and highly reactive" intermediates at the interface (gas-solid/solid-liquid); however, the recent rise of sophisticated spectroscopic/analytical techniques (including under in situ/operando conditions) and modern data analysis methods collectively compete to unravel the impact of these organic intermediates. This comprehensive review summarizes the state-of-the-art first-generation organic reaction intermediates in zeolite chemistry and catalysis and evaluates their existing challenges and future prospects, to contribute significantly to the "circular carbon economy" initiatives.

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.

Heterogeneous Diels-Alder tandem catalysis for converting cellulose and polyethylene into BTX

Producing biomass-derived aromatic hydrocarbons via controllable Diels-Alder reactions is a promising approach to recover energy and chemicals from waste streams. A tandem Diels-Alder catalysis consisting of SAPO-34 and Fe/HZSM-5 (stacked catalysis or mixed catalysis) was evaluated for thermochemical conversion of cellulose and polyethylene blends into benzene, toluene, and xylenes (BTX). Aromatization catalyst type significantly affected the activity of tandem catalysis, and the BTX obtained from the HZSM-5 stacked catalysis was ~2.3 times higher than that of the USY stacked one. An introduction of Fe active promoters into HZSM-5 increased the Lewis to Brønsted acid sites molar ratio (L/B) from 0.4 to 4.1. The comparison between Fe/HZSM-5 stacked catalysis and parent HZSM-5 single catalysis indicated that the former was more effective for BTX production, obtaining a nearly two-fold increase in yield with a high selectivity of 82.8%. A close proximity between Fe/HZSM-5 and SAPO-34 in the mixed catalysis increased the BTX enhancement to 1.8. A synergistic effect was provided by the coordination of Lewis and Brønsted acid sites in the Fe/HZSM-5 mixed catalysts for facilitating BTX generation, achieving a maximum of 25.9% at a Fe/HZSM-5 to SAPO-34 mass ratio of 1:1 with a theoretical L/B of 7.2. This work provides a sustainable strategy to produce biomass-derived aromatic hydrocarbons.

The Use of Heterogeneous Catalysis in the Chemical Valorization of Plastic Waste

Plastic solid waste (PSW) is an ever-growing environmental challenge for our society, as it not only ends up in landfills but also in waterways and oceans and is consequently entering the food chain. A key strategy to overcome this problem while also preserving carbon resources is to use PSW as a feedstock, evolving towards a circular economy. To implement this, mechanical as well as chemical recycling technologies must be developed. Indeed, owing to the high volume of PSW generated each year, mechanical recycling alone is not adequate for addressing this global challenge. Because of this, chemical recycling via thermal and heterogeneous catalytic conversion has received growing attention. This process has the potential to take PSW and convert it into usable monomers, fuels, synthesis gas, and adsorbents under more sustainable conditions than thermal degradation. This Review highlights the recent research advances in catalytic technologies for PSW conversion and valorization.

Catalytic performance and debromination of Fe-Ni bimetallic MCM-41 catalyst for the two-stage pyrolysis of waste computer casing plastic

A computer casing plastic waste containing brominated flame retardants (BFRs) was pyrolyzed in a two-stage vertical quartz tube reactor using iron and nickel metals modified MCM-41 catalysts. Various catalysts with different ratios of Fe and Ni were prepared and utilized to study their catalytic performance. At the presence of 20%Ni/MCM-41 catalyst, the pyrolytic yield of oil and gas reached maximum values of 49.9 wt% and 13.8 wt% respectively. The co-existence of Fe and Ni showed synergistic effect on oil composition by promoting the formation of valuable single ring hydrocarbons. With regard to the 15%Fe-5%Ni/MCM-41, 10%Fe-10%Ni/MCM-41 and 5%Fe-15%Ni/MCM-41 catalysts, the production of single ring hydrocarbons were 64.58%, 65.93% and 64.74% respectively. The bimetallic catalysts also exhibited remarkable effect on eliminating bromine from pyrolytic oil. At the presence of Fe-Ni/MCM-41, the bromine in pyrolytic oil was reduced to below 4 wt% compared with 10 wt% without catalyst. Higher amounts of Fe in the catalyst is beneficial for the debromination efficiency. The debromination process by the Fe-Ni/MCM-41 may be realized by these different mechanisms: catalytic cracking of organobromines, reaction of loaded metal oxides with HBr/SbBr₃, and deposition of organobromines on the surface of catalyst.

Microwave-assisted catalytic upgrading of co-pyrolysis vapor using HZSM-5 and MCM-41 for bio-oil production: Co-feeding of soapstock and straw in a downdraft reactor

Microwave-assisted co-pyrolysis of low hydrogen-to-carbon and high hydrogen-to-carbon effective ratio materials with the aid of HZSM-5 and MCM-41 is a promising technique to improve the bio-oil quality. The low content of hydrocarbons and short life cycle of catalyst limit the application of pyrolysis technology in biomass energy conversion. The effects of catalytic temperature, and HZSM-5-to-MCM-41, feedstock-to-catalyst, and straw-to-soapstock ratios on the yield and composition of bio-oil were studied in this work. The quality of bio-oil during biomass pyrolysis can be improved by adjusting the operating conditions. The optimal catalytic temperature, and ratios of HZSM-5-to-MCM-41, feedstock-to-catalyst, and straw-to-soapstock were 400 °C, 1:1, 2:1, and 1:2, respectively. The addition of MCM-41 was beneficial in prolonging the life of HZSM-5 since the macromolecular compounds cracked when MCM-41 was added which restrain the generation of coke. The co-pyrolysis of soapstock with straw advanced the deoxygenation of oxygen-containing compounds especially phenol from straw during pyrolysis.

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.

Beneficial use of ultrasound irradiation in synthesis of beta-clinoptilolite composite used in heavy oil upgrading process

A novel beta–clinoptilolite composite was prepared from beta zeolite and alkaline treated clinoptilolite by employing conventional and sonicated mixing procedures. Parent and prepared catalysts were characterized by XRD, FE-SEM, N₂ adsorption–desorption and NH₃-TPD analyses. Prepared composite of beta zeolite and treated clinoptilolite exhibited improved structural properties especially upon sonicated mixing procedure. Employing ultrasound irradiation notably improved beta distribution in the composite and increased mesoporous volume and specific surface area from 0.245 cm³ g⁻¹ and 171.3 m² g⁻¹ in conventionally mixed composite to 0.353 cm³ g⁻¹ and 232.9 m² g⁻¹ in sonicated sample. Catalytic performance of prepared composite was evaluated in heavy oil upgrading process in a continuous fixed bed apparatus. Liquid product was specified by conducting SIMDIS-GC and GC/MS analyses. Spent catalysts were characterized by TGA, FTIR and XRD. Beta–clinoptilolite composite containing only 30 wt% of beta zeolite, exhibited similar performance to beta zeolite catalyst by resulting 75.3% viscosity reduction while producing lower amount of coke. Amount of light hydrocarbons produced over beta–clinoptilolite composite was 33.51 wt% while beta zeolite catalyst produced 35.58 wt% light hydrocarbons in upgrading process. Ultrasound irradiated composite showed more stable structure in catalytic cracking procedure compared to conventionally mixed composite. After 5 h time on stream, relative crystallinity of clinoptilolite phase in the conventionally mixed composite was reduced by 34.5% while sonicated sample remarkably preserved its structure during the reaction and only 1% reduction occurred for this sample.

Beta–clinoptilolite composite synthesized in the presence of ultrasound irradiation exhibited high stability in heavy oil upgrading process while producing equal amount of light fuels and lower amount of coke compared to beta zeolite catalyst.