Hydrocracking of a plastic mixture over various micro-mesoporous composite zeolites

Catalyst Accessibility and Acidity in the Hydrocracking of HDPE: A Comparative Study of H-USY, H-ZSM-5, and MCM-41 Modified with Ga and Al

Plastic pollution is a critical environmental issue due to the widespread use of plastic materials and their long degradation time. Hydrocracking (HDC) offers a promising solution to manage plastic waste by converting it into valuable products, namely chemicals or fuels. This work aims to investigates the effect of catalyst accessibility and acidity on the HDC reaction of high density polyethylene (HDPE). Therefore, a variety of materials with significant differences in both textural and acidic properties were tested as catalysts. These include H-USY and H-ZSM.5 zeolites with various Si/Al molar ratios (H-USY: Si/Al = 2.9, 15, 30 and 40; H-ZSM-5: Si/Al = 11.5, 40, 500) and mesostructured MCM-41 materials modified with Ga and Al, also with different Si/metal ratios (Si/Al = 16 and 30; Si/Ga = 63 and 82). Thermogravimetric analysis under hydrogen atmosphere was used as a preliminary screening tool to evaluate the potential of the various catalysts for this application in terms of energy requirements. In addition, batch autoclave reactor experiments (T = 300 °C, PH2 = 20 bar, t = 60 min) were conducted to obtain further information on conversion, product yields and product distribution for the most promising systems. The results show that the catalytic performance in HDPE hydrocracking is determined by a balance between the acidity of the catalyst and its structural accessibility. Accordingly, for catalyst series where the structural and textural properties do not vary with the Si/Al ratio, there is a clear correlation of the HDPE degradation temperature and of the HDPE conversion with the Si/metal ratio (which relates to the acidic properties). In contrast, for catalyst series where the structural and textural properties vary with the Si/Al ratio, no consistent trend is observed and the catalytic performance is determined by a balance between the acidic and textural properties. The product distribution was also found to be influenced by the physical and chemical properties of the catalyst. Catalysts with strong acidity and smaller pores were observed to favor the formation of lighter hydrocarbons. In addition to the textural and acidic properties of the catalyst, the role of coke formation should not be neglected to ensure a comprehensive analysis of the catalytic performance.

Hydrothermal carbonisation of polyvinyl chloride in ethanol-water/water system for solid fuels: Dechlorination, characteristics analysis of hydrochar, and reaction path

Polyvinyl chloride (PVC) waste plastic is a typical solid waste. In this paper, the dechlorination and carbonization behavior of PVC in ethanol-water/water system under different process parameters (temperature, residence time, solid-liquid ratio) was studied, and hydrothermal carbon was characterized by SEM, elemental analysis, TG-DTG, XPS, Py-GC/MS. The results show that temperature is the key to the hydrothermal dechlorination of PVC, and the dechlorination efficiency of PVC is the highest by parameter optimization (220°C-90 min-10% S/D-80% E/D), which can reach 96.33 %. With the removal of Cl, the surface of the PVC matrix changed from full and smooth flocculent to honeycomb with uniform pore size distribution. Thermogravimetric analysis shows that the combustion of hydrochar can be divided into three stages: HCl precipitation and volatile combustion, semi-coke and coke combustion, and fixed carbon combustion. The combustion parameters and kinetic parameters of hydrochar were measured, and it was found that the hydrothermal carbonization of PVC at higher temperatures and ethanol-water ratio could improve the combustion performance of hydrochar. The highest calorific value can reach 36.68 MJ/mol. Py-GC/MS analyzed the distribution of the pyrolysis products, and alkylbenzene and aliphatic were the main products of pyrolysis. The structural analysis of hydrochar showed that C-C and CC accounted for the largest proportion, accompanied by a small amount of C-O and CO and trace C-Cl. The possible reaction mechanism of the hydrothermal carbonization of PVC was analyzed based on the distribution of functional groups and compound composition. This work provides an effective and sustainable method for the recycling of refractory chlorinated plastics.

Visualizing the Structure, Composition and Activity of Single Catalyst Particles for Olefin Polymerization and Polyolefin Decomposition

The structural and morphological characterization of individual catalyst particles for olefin polymerization, as well as for the reverse process of polyolefin decomposition, can provide an improved understanding for how these catalyst materials operate under relevant reaction conditions. In this review, we discuss an emerging analytical toolbox of 2D and 3D chemical imaging techniques that is suitable for investigating the chemistry and reactivity of related catalyst systems. While synchrotron-based X-ray microscopy still provides unparalleled spatial resolutions in 2D and 3D, a number of laboratory-based techniques, most notably focused ion beam-scanning electron microscopy, confocal fluorescence microscopy, infrared photoinduced force microscopy and laboratory-based X-ray nano-computed tomography, have helped to significantly expand the arsenal of analytical tools available to scientists in heterogeneous catalysis and polymer science. In terms of future research, the review outlines the role and impact of in situ and operando (spectro-)microscopy experiments, involving sophisticated reactors as well as online reactant and product analysis, to obtain real-time information on the formation, decomposition, and mobility of polymer phases within single catalyst particles. Furthermore, the potential of fluorescence microscopy, X-ray microscopy and optical microscopy is highlighted for the high-throughput characterization of olefin polymerization and polyolefin decomposition catalysts. By combining these chemical imaging techniques with, for example, chemical staining methodologies, selective probe molecules as well as particle sorting approaches, representative structure-activity relationships can be derived at the level of single catalyst particles.

A reusable, impurity-tolerant and noble metal-free catalyst for hydrocracking of waste polyolefins

One-step conversion of low-purity polyolefins to value-added products without pretreatments represents a great opportunity for chemical recycling of waste plastics. However, additives, contaminants, and heteroatom-linking polymers tend to be incompatible with catalysts that break down polyolefins. Here, we disclose a reusable, noble metal-free and impurity-tolerant bifunctional catalyst, MoS_x-Hbeta, for hydroconversion of polyolefins into branched liquid alkanes under mild conditions. The catalyst works for a wide scope of polyolefins, including different kinds of high-molecular weight polyolefins, polyolefins mixed with various heteroatom-linking polymers, contaminated polyolefins, and postconsumer polyolefins with/without cleaning under 250°C and 20 to 30 bar H₂ in 6 to 12 hours. A 96% yield of small alkanes was successfully achieved even at a temperature as low as 180°C. These results demonstrate the great potentials of hydroconversion in practical use of waste plastics as a largely untapped carbon feedstock.

Catalytic cracking of polystyrene pyrolysis oil: Effect of Nb2O5 and NiO/Nb2O5 catalyst on the liquid product composition

The catalytic cracking of polystyrene pyrolysis oil was investigated over a Nb2O5 and a NiO/Nb2O5 catalyst in a fixed bed reactor. First, the pyrolysis of two different polystyrene feedstock (polystyrene foam and polystyrene pellet) was carried out in a semi-batch reactor, and the resulting polystyrene pellets pyrolysis oil was selected for catalytic cracking reaction because of its high liquid yield (85%). Catalytic cracking experiments were then performed at different temperatures (350-500 °C) using Nb2O5 or NiO/Nb2O5 catalyst. Gas chromatography-mass spectrometry analysis of liquid product obtained from the catalytic cracking process showed that the dimers in the pyrolysis oil were converted to monomers during the catalytic cracking process. The catalytic cracking results also showed that the NiO/Nb2O5 catalyst (having slightly higher acidic sites) had slightly higher activity for monomer conversion than the Nb2O5 catalyst (having less acidic sites). X-ray diffraction, transmission electron microscopy, pyridine Fourier transform infrared spectroscopy, NH3 Temperature Programmed Desorption and X-ray photoelectron spectroscopy were used to characterize the catalyst. The highest catalytic cracking activity was observed at 400 °C with the Nb2O5 catalyst with 4% toluene, 6% ethylbenzene, approximately 50% styrene, 13% α-methyl styrene, and only 6% of dimers in the liquid oil. The increase in temperature positively affected the yield of gases during catalytic cracking process.

Transition metal chalcogenide bifunctional catalysts for chemical recycling by plastic hydrocracking: a single-source precursor approach

Sulfided nickel, an established hydrocracking and hydrotreating catalyst for hydrocarbon refining, was synthesized on porous aluminosilicate supports for the hydrocracking of mixed polyolefin waste. Zeolite beta, zeolite 13X, MCM41 and an amorphous silica-alumina catalyst support were impregnated with the single-source precursor (SSP) nickel (II) ethylxanthate for catalyst support screening. Application of this synthesis method to beta-supported nickel (Ni@Beta), as an alternative to wet impregnation using aqueous nickel (II) nitrate, provided catalytic materials with higher conversion to fluid products at the same mild batch reaction conditions of 330°C with appropriate agitation and 20 bar H2 pressure. Mass balance quantification demonstrated that SSP-derived 5wt%Ni@Beta yielded a greater than 95 wt% conversion of a mixed polyolefin feed to fluid products, compared with 39.8 wt% conversion in the case of 5wt%Ni@Beta prepared by wet impregnation. Liquid and gas products were quantitatively analysed by gas chromatography-flame ionization detection (GC-FID) and gas chromatography-mass spectrometry (GC-MS), revealing a strong selectivity to saturated C4 (37.3 wt%), C5 (21.6 wt%) and C6 (12.8 wt%) hydrocarbons in the case of the SSP-derived catalyst.

Hydrocarbon Fractions from Thermolysis of Waste Plastics as Components of Engine Fuels

Plastics are one of the basic construction materials with a wide range of various applications. One of their disadvantages is the problem of managing the waste they generate. Chemical recycling offers the possibility of liquefying polymeric waste and using it as fuel components. Existing technologies giving good quality products are expensive. The HT technology developed and described by the authors is cheaper and enables a high quality product to be obtained. The authors have shown that the quality of the received fuel components is influenced not only by the polymer waste processing technology, but also by the feedstock composition. The presented thermolysis technology not only enables more advanced recycling, but also gives the possibility of partial improvement of the product quality. A product with the best physico-chemical properties was obtained from a blend of PE:PP:PS used in the ratio 60:30:10. It was proved that diesel and petrol blends composed of a 5% v/v share of petrol and diesel fractions, obtained from thermolysis of plastics, meet the normative requirements of fuel quality standards.

Local Induction Heating Capabilities of Zeolites Charged with Metal and Oxide MNPs for Application in HDPE Hydrocracking: A Proof of Concept

Zeolites are widely used in high-temperature oil refining processes such as fluid catalytic cracking (FCC), hydrocracking, and aromatization. Significant energy cost are associated with these processes due to the high temperatures required. The induction heating promoted by magnetic nanoparticles (MNPs) under radio frequency fields could contribute to solving this problem by providing a supplementary amount of heat in a nano-localized way, just at the active centre site where the catalytic process takes place. In this study, the potential of such a complementary route to reducing energetic requirements is evaluated. The catalytic cracking reaction under a hydrogen atmosphere (hydrocracking) applied to the conversion of plastics was taken as an application example. Thus, a commercial zeolite catalyst (H-USY) was impregnated with three different magnetic nanoparticles: nickel (Ni), cobalt (Co), maghemite (γ-Fe₂O₃), and their combinations and subjected to electromagnetic fields. Temperature increases of approximately 80 °C were measured for H-USY zeolite impregnated with γ-Fe₂O₃ and Ni-γ-Fe₂O₃ due to the heat released under the radio frequency fields. The potential of the resulting MNPs derived catalyst for HDPE (high-density polyethylene) conversion was also evaluated by thermogravimetric analysis (TGA) under hydrogen atmosphere. This study is a proof of concept to show that induction heating could be used in combination with traditional resistive heating as an additional energy supplier, thereby providing an interesting alternative in line with a greener technology.

Direct conversion of cellulose to ethyl levulinate catalysed by modified fibrous mesoporous silica nanospheres in a co-solvent system

A KCC-1/Al–SO₃H catalyst with Si/Al = 5 was prepared to directly catalyse the synthesis of ethyl levulinate from cellulose in an ethanol/toluene co-solvent system. A reaction yield of 28.8 mol% was achieved after 6 h at 200 °C.

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.

Impervious and influence in the liquid fuel production from municipal plastic waste through thermo-chemical biomass conversion technologies - A review

Plastic waste is an environmental burden substance, which poses a high threat to the society during disposal. Rather than disposal, recycling of this waste to liquid fuel gains importance owing to its high utility. Among various techniques, thermo-chemical recycling techniques hold more benefits in generating high value added liquid fuels. In this review, the details of municipal plastic waste generation are provided with a brief description of the plastic waste management option and importance of recycling is explained. The overview of the thermo-chemical treatment focusing on the pyrolysis, gasification and hydrocracking process was elaborated. Catalysts mediated pyrolysis have wide-open their prospective for the generation of bio-oil, hydrocarbons, syngas and deterioration of undesired substances. Generally, advance development of enthusiastic catalysts for the synthesis of bio-oil would be vital for scaling up the pyrolysis process to succeed in commercial manufacture of biofuels from waste plastics. Overall rate treatment depends on operating parameter which determines the process efficiency and product yield. Hence, critical assessment of various parameter that has remarkable effect in the thermo-chemical treatment process was documented in detail. Moreover, endorsements of liquid fuel production, economic viability, and energy requirement of the treatment process, were delivered to attain effectual plastic wastes management.

Technologies for chemical recycling of household plastics - A technical review and TRL assessment

Chemical recycling is considered an attractive technological pathway for reducing waste and greenhouse gas emissions, as well as promoting circular economy. In the EU, readiness to develop a full commercial plant is becoming increasingly important given the ambitious goal to recycle all plastics by 2030. Household packaging streams tend to be of lower quality and lower recycling performance compared to industrial and commercial waste streams, thus requiring particular attention. This paper assesses chemical recycling technologies available and identifies the most suitable for recycling of household plastic waste. We identify eight different technologies and compare them in terms of process temperature, sensitivity to feedstock contamination and level of polymer breakdown, three critical factors affecting the cost and attractiveness of a chemical process. In addition, we carry out a Technology Readiness Level (TRL) assessment for eight technologies based on the stage of their present development. The review is based on peer-reviewed scientific papers and information collected from technology developers and providers, as well as interviews with experts. Our analysis outlines advantages and disadvantages of technologies available for chemical plastic recycling and their TRL. The chemical recycling technologies with the highest TRL are pyrolysis, catalytic cracking and conventional gasification. However, the economic feasibility of these technologies is difficult to assess due to the low number of projects in operation and scarcity of data available for comparison. The results of this analysis provide timely information as policy makers and developers set targets for recycling, and contemplate investments on research and chemical plastic recovering plants.