Recycling of plastic waste using flash pyrolysis – Effect of mixture composition

Recent advances in liquid fuel production from plastic waste via pyrolysis: Emphasis on polyolefins and polystyrene

The management of plastic waste (PW) has become an indispensable worldwide issue because of the enhanced accumulation and environmental impacts of these waste materials. Thermo-catalytic pyrolysis has been proposed as an emerging technology for the valorization of PW into value-added liquid fuels. This review provides a comprehensive investigation of the latest advances in thermo-catalytic pyrolysis of PW for liquid fuel generation, by emphasizing polyethylene, polypropylene, and polystyrene. To this end, the current strategies of PW management are summarized. The various parameters affecting the thermal pyrolysis of PW (e.g., temperature, residence time, heating rate, pyrolysis medium, and plastic type) are discussed, highlighting their significant influence on feed reactivity, product yield, and carbon number distribution of the pyrolysis process. Optimizing these parameters in the pyrolysis process can ensure highly efficient energy recovery from PW. In comparison with non-catalytic PW pyrolysis, catalytic pyrolysis of PW is considered by discussing mechanisms, reaction pathways, and the performance of various catalysts. It is established that the introduction of either acid or base catalysts shifts PW pyrolysis from the conventional free radical mechanism towards the carbonium ion mechanism, altering its kinetics and pathways. This review also provides an overview of PW pyrolysis practicality for scaling up by describing techno-economic challenges and opportunities, environmental considerations, and presenting future outlooks in this field. Overall, via investigation of the recent research findings, this paper offers valuable insights into the potential of thermo-catalytic pyrolysis as an emerging strategy for PW management and the production of liquid fuels, while also highlighting avenues for further exploration and development.

Production of light olefins and monocyclic aromatic hydrocarbons from the pyrolysis of waste plastic straws over high-silica zeolite-based catalysts

Owing to the ever-increasing generation of plastic waste, the need to develop environmentally friendly disposal methods has increased. This study explored the potential of waste plastic straw to generate valuable light olefins and monocyclic aromatic hydrocarbons (MAHs) via catalytic pyrolysis using high-silica zeolite-based catalysts. HZSM-5 (SiO2/Al2O3:200) exhibited superior performance, yielding more light olefins (49.8 wt%) and a higher MAH content than Hbeta (300). This was attributed to the increased acidity and proper shape selectivity. HZSM-5 displayed better coking resistance (0.7 wt%) than Hbeta (4.4 wt%) by impeding secondary reactions, limiting coke precursor formation. The use of HZSM-5 (80) resulted in higher MAHs and lower light olefins than HZSM-5 (200) because of its higher acidity. Incorporation of Co into HZSM-5 (200) marginally lowered light olefin yield (to 44.0 wt%) while notably enhancing MAH production and boosting propene selectivity within the olefin composition. These observations are attributed to the well-balanced coexistence of Lewis and Brønsted acid sites, which stimulated the carbonium ion mechanism and induced H-transfer, cyclization, Diels-alder, and dehydrogenation reactions. The catalytic pyrolysis of plastic straw over high-silica and metal-loaded HZSM-5 catalysts has been suggested as an efficient and sustainable method for transforming plastic waste materials into valuable light olefins and MAHs.

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.

A Thermo-Catalytic Pyrolysis of Polystyrene Waste Review: A Systematic, Statistical, and Bibliometric Approach

Global polystyrene (PS) production has been influenced by the lightness and heat resistance this material offers in different applications, such as construction and packaging. However, population growth and the lack of PS recycling lead to a large waste generation, affecting the environment. Pyrolysis has been recognized as an effective recycling method, converting PS waste into valuable products in the chemical industry. The present work addresses a systematic, bibliometric, and statistical analysis of results carried out from 2015 to 2022, making an extensive critique of the most influential operation parameters in the thermo-catalytic pyrolysis of PS and its waste. The systematic study showed that the conversion of PS into a liquid with high aromatic content (84.75% of styrene) can be achieved by pyrolysis. Discussion of PS as fuel is described compared to commercial fuels. In addition, PS favors the production of liquid fuel when subjected to co-pyrolysis with biomass, improving its properties such as viscosity and energy content. A statistical analysis of the data compilation was also discussed, evaluating the influence of temperature, reactor design, and catalysts on product yield.

Recent Advances in the Chemobiological Upcycling of Polyethylene Terephthalate (PET) into Value-Added Chemicals

Polyethylene terephthalate (PET) is a plastic material commonly applied to beverage packaging used in everyday life. Owing to PET's versatility and ease of use, its consumption has continuously increased, resulting in considerable waste generation. Several physical and chemical recycling processes have been developed to address this problem. Recently, biological upcycling is being actively studied and has come to be regarded as a powerful technology for overcoming the economic issues associated with conventional recycling methods. For upcycling, PET should be degraded into small molecules, such as terephthalic acid and ethylene glycol, which are utilized as substrates for bioconversion, through various degradation processes, including gasification, pyrolysis, and chemical/biological depolymerization. Furthermore, biological upcycling methods have been applied to biosynthesize value-added chemicals, such as adipic acid, muconic acid, catechol, vanillin, and glycolic acid. In this review, we introduce and discuss various degradation methods that yield substrates for bioconversion and biological upcycling processes to produce value-added biochemicals. These technologies encourage a circular economy, which reduces the amount of waste released into the environment.

Selection of Conditions in PVB Polymer Dissolution Process for Laminated Glass Recycling Applications

Polyvinyl(butyral) (PVB) post-production waste collected from the windshields of end-of-life vehicles and post-consumer building laminated glass are valuable polymeric materials that can be reused. Every year, large amounts of PVB waste are still being buried in landfills owing to a lack of appropriate recycling techniques. Before reuse, PVB should be thoroughly cleaned of solid contaminants such as glass dust, fused heating wires, and other waste polymers, metals, and ceramics. This can be done by polymer dissolution and filtration. In this study, we propose the purification of PVB from contamination by dissolving the post-consumer polymeric materials into single and binary organic solvents. As part of the experimental work, measurements and optimization of the dissolution time of PVB were performed. PVB dissolves faster when a binary solvent (2-propanol + ethyl acetate) than pure 2-propanol is used. From the point of view of the practical application of PVB solutions, measurements of density and dynamic viscosity as a function of PVB concentration and temperature were performed. The PVB solutions obtained in this work can be widely used as glues for glass, ceramics, metal, impregnating, and insulating materials or as paint additives that are entirely transparent for visible light and to block UV rays.

Effects of Heating Rate and Temperature on the Thermal Pyrolysis of Expanded Polystyrene Post-Industrial Waste

The use of plastic as material in various applications has been essential in the evolution of the technology industry and human society since 1950. Therefore, their production and waste generation are high due to population growth. Pyrolysis is an effective recycling method for treating plastic waste because it can recover valuable products for the chemical and petrochemical industry. This work addresses the thermal pyrolysis of expanded polystyrene (EPS) post-industrial waste in a semi-batch reactor. The influence of reaction temperature (350-500 °C) and heating rate (4-40 °C min^-1) on the liquid conversion yields and physicochemical properties was studied based on a multilevel factorial statistical analysis. In addition, the analysis of the obtaining of mono-aromatics such as styrene, toluene, benzene, ethylbenzene, and α-methyl styrene was performed. Hydrocarbon liquid yields of 76.5-93% were achieved at reaction temperatures between 350 and 450 °C, respectively. Styrene yields reached up to 72% at 450 °C and a heating rate of 25 °C min^-1. Finally, the potential application of the products obtained is discussed by proposing the minimization of EPS waste via pyrolysis.

Effect of aluminum leaching pretreatment on catalytic pyrolysis of metallised food packaging plastics and its linear and nonlinear kinetic behaviour

This research aims to study the effect of aluminum (Al) leaching pre-treatment on the catalytic pyrolysis of metallised food packaging plastics waste (MFPW). The experiments started with removal of Al from MFPW using leaching process to prepare Al-free mixed plastic waste (MPW). The catalytic pyrolysis of MPW over ZSM-5 zeolite catalyst was carried out using thermogravimetric (TG) analysis coupled with FTIR, while GC-MS was used to observe the compounds of the volatile products. The catalytic pyrolysis kinetic behaviour of MPW was studied using the linear and nonlinear isoconversional approaches. The elemental and proximate results showed that MPW is very rich in carbon elements (79 %) and volatile content (99 %). The TG results showed that MPW and ZSM/MPW were fully decomposed in the range of 376-496 °C without any presence of char. Based on TG-FTIR analysis, methane and carboxylic acid residue were the main groups of the synthesized volatile products, whereas nitrous oxide, 1-Butanol, 1-Propene, acetic acid, and formic acid were the major GC compounds. In case of ZSM/MPW, carbon dioxide and acetic acid were the major GC compounds at 5-25 °C/min, triphenylphosphine oxide and Phosphine oxide at 30 °C/min. The kinetic analysis showed that when the activation energies are located in the range 287-297 kJ/mol (MPW) and 153-187 kJ/mol (ZSM/MPW) and KAS, Vyazovkin, and Cai methods are the most suitable models to study pyrolysis kinetic of MPW with R² > 89. Based on that, leaching and catalytic pyrolysis processes are a highly suggested technology that can be used to convert MFPW into high-added energy and chemical products.

Variation behavior of organic compounds in melamine-urea-formaldehyde impregnated bond paper in different pyrolysis stages

Melamine-urea-formaldehyde impregnated bond paper (MUF) is widely used as panel coating and decorative raw paper. Inappropriate treatment of MUF may lead to environmental pollution. In this study, routine MUF and MUF treated with additional titanium (MUF-T) were subjected to fast pyrolysis, and the product properties at different temperatures were investigated. The pyrolysis temperature was selected considering the reaction stages determined by Gaussian curve-fitting on thermogravimetric analysis curves. It was found that the presence of additional titanium changed the decomposition order of the organic components at 220 °C. Urea-formaldehyde in MUF could be decomposed at 220 °C, which had little effect on other components (melamine and cellulose). However, in terms of MUF-T, the decomposition temperature of urea-formaldehyde was postponed to 244 °C, which means that the pyrolysis strategy needs to choose a temperature higher than 244 °C. The volatiles in MUF-T are more easily converted to bio-gas or bio-oil than those in MUF. However, only CH₄ was observed in the bio-gas generated of MUF-T at 220 °C, indicating that titanium did not catalyze the fracture of oxygen-containing functional groups at low temperatures. Titanium condensed at 550 °C, and the utilization of bio-char may face a problem of titanium particle shedding.

Synergetic biofuel production from co-pyrolysis of food and plastic waste: reaction kinetics and product behavior

This study aimed to develop a process for producing bio-oil, char, and value-added chemicals from food waste and plastic waste blend using co-pyrolysis under controlled conditions. The food waste (rice, vegetables, and fish) was blended in definite ratios (70:30, 60:40, and 50:50 w/w) with polyethylene terephthalate (PET). Experiments were conducted at various temperatures (250, 300, and 350 °C) and reaction times (30, 60, 90, and 120 min). A kinetic analysis was performed to fit experimental data, and reaction kinetics were observed to follow Arrhenius behavior. Maximum yields of bio-oil and bio-char, 66 and 40 wt% respectively, were attained at 350 °C, with yields being strongly influenced by variations in temperature and weakly affected by variations in reaction time. Co-pyrolysis promoted the formation of carboxylic acid, hydrocarbons, and furan derivatives. Formation of carboxylic acid could be increased by increasing the ratio of plastic waste. A maximum carboxylic acid content of 42.01% was achieved at 50% of plastic waste. Meanwhile, a maximum aliphatic hydrocarbon content of 44.6% was obtained with a ratio of 70:30 of food waste to plastic waste at 350 °C. Overall, pyrolysis of food and plastic waste produced value-added compounds that can be used as biofuels and for a variety of other applications.

Production and Analysis of the Physicochemical Properties of the Pyrolytic Oil Obtained from Pyrolysis of Different Thermoplastics and Plastic Mixtures

The constant search for the proper management of non-degradable waste in conjunction with the circular economy makes the thermal pyrolysis of plastics an important technique for obtaining products with industrial interest. The present study aims to produce pyrolytic oil from thermoplastics and their different mixtures in order to determine the best performance between these and different mixtures, as well as to characterize the liquid fraction obtained to analyze its use based on said properties. This was carried out in a batch type reactor at a temperature of 400 °C for both individual plastics and their mixtures, from which the yields of the different fractions are obtained. The liquid fraction of interest is characterized by gas chromatography and its properties are characterized by ASTM standards. The product of the pyrolysis of mixtures of 75% polystyrene and 25% polypropylene presents a yield of 82%, being the highest, with a viscosity of 1.12 cSt and a calorific power of 42.5 MJ/kg, which has a composition of compounds of carbon chains ranging between C6 and C20, for which it is proposed as a good additive agent to conventional fuels for industrial use.

Pyrolysis Combined with the Dry Reforming of Waste Plastics as a Potential Method for Resource Recovery—A Review of Process Parameters and Catalysts

Emissions of greenhouse gases and growing amounts of waste plastic are serious environmental threats that need urgent attention. The current methods dedicated to waste plastic recycling are still insufficient and it is necessary to search for new technologies for waste plastic management. The pyrolysis-catalytic dry reforming (PCDR) of waste plastic is a promising pro-environmental way employed for the reduction of both CO2 and waste plastic remains. PCDR allows for resource recovery, converting carbon dioxide and waste plastics into synthetic gas. The development and optimization of this technology for the high yield of high-quality synthesis gas generation requires the full understanding of the complex influence of the process parameters on efficiency and selectivity. In this regard, this review summarizes the recent findings in the field. The effect of process parameters as well as the type of catalyst and feedstock are reviewed and discussed.

Determination of the Thermodynamic Parameters of the Pyrolysis Process of Post-Consumption Thermoplastics by Non-Isothermal Thermogravimetric Analysis

Currently, the pyrolysis process is an important technology for the final treatment of plastic waste worldwide. For this reason, knowing in detail the chemical process and the thermodynamics that accompany cracking reactions is of utmost importance. The present study aims to determine the thermodynamic parameters of the degradation process of conventional thermoplastics (polystyrene (PS), polyethylene terephthalate (PET), high-density polyethylene (HDPE), polypropylene (PP) and polyvinyl chloride (PVC)) from the study of their chemical kinetics by thermogravimetric analysis (TG). Non-isothermal thermogravimetry was performed at three heating rates from room temperature to 550 °C with an inert nitrogen atmosphere with a flow of 20 mL min⁻¹. Once the TG data is obtained, an analysis is carried out with the isoconversional models of Friedman (FR), Kissinger–Akahira–Sunose (KAS), and Flynn–Wall–Ozawa (FWO) in order to determine the one that best fits the experimental data, and with this, the calculation of the activation energy and the pre-exponential factor is performed. The validation of the model was carried out using the correlation factor, determining that the KAS model is the one that best adjusts for the post-consumer thermoplastic degradation process at the three heating rates. With the use of the kinetic parameters, the variation of the Gibbs free energy is determined in each of the cases, where it is necessary that for structures containing aromatic groups a lower energy is presented, which implies a relative ease of degradation compared to the linear structures.

Progress on Catalyst Development for the Steam Reforming of Biomass and Waste Plastics Pyrolysis Volatiles: A Review

In recent decades, the production of H₂ from biomass, waste plastics, and their mixtures has attracted increasing attention in the literature in order to overcome the environmental problems associated with global warming and CO₂ emissions caused by conventional H₂ production processes. In this regard, the strategy based on pyrolysis and in-line catalytic reforming allows for obtaining high H₂ production from a wide variety of feedstocks. In addition, it provides several advantages compared to other thermochemical routes such as steam gasification, making it suitable for its further industrial implementation. This review analyzes the fundamental aspects involving the process of pyrolysis-reforming of biomass and waste plastics. However, the optimum design of transition metal based reforming catalysts is the bottleneck in the development of the process and final H₂ production. Accordingly, this review focuses especially on the influence the catalytic materials (support, promoters, and active phase), synthesis methods, and pyrolysis-reforming conditions have on the process performance. The results reported in the literature for the steam reforming of the volatiles derived from biomass, plastic wastes, and biomass/plastics mixtures on different metal based catalysts have been compared and analyzed in terms of H₂ production.