Valorization of the plastic residue from a WEEE treatment plant by pyrolysis

Influence of Feedstock Particle Size on the Certain Determination of Chlorine and Bromine in Pyrolysis Oils from Waste Electrical and Electronic Equipment Plastics

Rejected streams emerging from waste sorting and recycling plants are still capable of being valorized by unconventional recycling routes. This is the case of the plastic-rich fraction generated after the treatment of waste electrical and electronic equipment (WEEE). However, the material complexity of this stream supposes a handicap when it comes to obtaining repetitive results in laboratory-scale recycling processes. This work aims to highlight the influence that the pretreatment (mainly particle size reduction) of a real WEEE plastic-rich stream has on the variability of the concentration of halogens (representative pollutants) in the oils obtained from its recycling via pyrolysis. The pretreatment steps were based on the standards of the European Committee for Standardization (ECN) for the analysis of waste samples. Four samples were studied: the WEEE plastics as received; two milled samples (2 and 1 mm particle size) derived from the original one; and a simulated sample composed of virgin polymers. All the samples were treated under the same conditions: 500 °C reaction temperature, 15 °C min-1 heating rate, 30 min dwell time, and a 1 L min-1 nitrogen purge flow. The oils obtained in, at least, two pyrolysis tests performed on the same sample were deeply characterized, and the results were compared. The oils derived from the "as-received" sample showed an unacceptable relative standard deviation (RSD, ∼42%) in the chlorine concentration. The sample milled to 2 mm reduced the RSD on the concentration of chlorine in the oils down to 8%, while no enhancement in the results was observed for the further milled sample. The other two major pyrolysis fractions were also characterized, showing an overall enhancement in the RSD of the analysis of the main components of the gases, while no improvement in the solids pollutants' characterization was achieved.

Effect of Feed Mass, Reactor Temperature, and Time on the Yield of Waste Polypropylene Pyrolysis Oil Produced via a Fixed-Bed Reactor

This paper presents the results of investigations into the pyrolysis of waste polypropylene in a laboratory fixed-bed batch reactor. The experiments were designed and verified in such a way as to allow the application of the response surface methodology (RSM) in the development of an empirical mathematical model that quantifies the impacts mentioned above. The influence of the mass of the raw material (50, 100, and 150 g) together with the reactor temperature (450, 475, and 500 °C) and the reaction time (45, 50 and 75 min) was examined. It has been shown that the mass of the raw material, i.e., the filling volume of the reactor, has a significant influence on the pyrolysis oil yield. This influence exceeds the influence of reactor temperature and reaction time. This was explained by observing the temperature change inside the reactor at three different spots at the bottom, middle, and top of the reactor. The recorded temperature diagrams show that, with greater masses of feedstock, local overheating occurs in the middle part of the reactor, which leads to the overcracking of volatile products and, from there, to an increased formation of non-condensable gases, i.e., a reduced yield of pyrolytic oil.

A Preliminary Study on the Use of Highly Aromatic Pyrolysis Oils Coming from Plastic Waste as Alternative Liquid Fuels

In this work, the low-temperature pyrolysis of a real plastic mixture sample collected at a WEEE-authorised recycling facility has been investigated. The sample was pyrolysed in a batch reactor in different temperature and residence time conditions and auto-generated pressure by following a factorial design, with the objective of maximising the liquid (oil) fraction. Furthermore, the main polymers constituting the real sample were also pyrolysed in order to understand their role in the generation of oil. The pyrolysis oils were characterised and compared with commercial fuel oil number 6. The results showed that in comparison to commercial fuel oil, pyrolysis oils coming from WEEE plastic waste had similar heating values, were lighter and less viscous and presented similar toxicity profiles in fumes of combustion.

A Comprehensive Review on the Thermal Stability Assessment of Polymers and Composites for Aeronautics and Space Applications

This review article provides an exhaustive survey on experimental investigations regarding the thermal stability assessment of polymers and polymer-based composites intended for applications in the aeronautical and space fields. This review aims to: (1) come up with a systematic and critical overview of the state-of-the-art knowledge and research on the thermal stability of various polymers and composites, such as polyimides, epoxy composites, and carbon-filled composites; (2) identify the key factors, mechanisms, methods, and challenges that affect the thermal stability of polymers and composites, such as the temperature, radiation, oxygen, and degradation; (3) highlight the current and potential applications, benefits, limitations, and opportunities of polymers and composites with high thermal stability, such as thermal control, structural reinforcement, protection, and energy conversion; (4) give a glimpse of future research directions by providing indications for improving the thermal stability of polymers and composites, such as novel materials, hybrid composites, smart materials, and advanced processing methods. In this context, thermal analysis plays a crucial role in the development of polyimide-based materials for the radiation shielding of space solar cells or spacecraft components. The main strategies that have been explored to improve the processability, optical transparency, and radiation resistance of polyimide-based materials without compromising their thermal stability are highlighted. The combination of different types of polyimides, such as linear and hyperbranched, as well as the incorporation of bulky pendant groups, are reported as routes for improving the mechanical behavior and optical transparency while retaining the thermal stability and radiation shielding properties. Furthermore, the thermal stability of polymer/carbon nanocomposites is discussed with particular reference to the role of the filler in radiation monitoring systems and electromagnetic interference shielding in the space environment. Finally, the thermal stability of epoxy-based composites and how it is influenced by the type and content of epoxy resin, curing agent, degree of cross-linking, and the addition of fillers or modifiers are critically reviewed. Some studies have reported that incorporating mesoporous silica micro-filler or microencapsulated phase change materials (MPCM) into epoxy resin can enhance its thermal stability and mechanical properties. The mesoporous silica composite exhibited the highest glass transition temperature and activation energy for thermal degradation among all the epoxy-silica nano/micro-composites. Indeed, an average activation energy value of 148.86 kJ/mol was recorded for the thermal degradation of unfilled epoxy resin. The maximum activation energy range was instead recorded for composites loaded with mesoporous microsilica. The EMC-5p50 sample showed the highest mean value of 217.6 kJ/mol. This remarkable enhancement was ascribed to the polymer invading the silica pores and forging formidable interfacial bonds.

Removal of Bromine from Polymer Blends with a Composition Simulating That Found in Waste Electric and Electronic Equipment through a Facile and Environmentally Friendly Method

The increasing volume of plastics from waste electric and electronic equipment (WEEE) nowadays is of major concern since the various toxic compounds that are formed during their handling enhance the difficulties in recycling them. To overcome these problems, this work examines solvent extraction as a pretreatment method, prior to thermochemical recycling by pyrolysis. The aim is to remove bromine from some polymeric blends, with a composition that simulates WEEE, in the presence of tetrabromobisphenol A (TBBPA). Various solvents-isopropanol, ethanol and butanol-as well as several extraction times, were investigated in order to find the optimal choice. Before and after the pretreatment, blends were analysed by X-ray fluorescence (XRF) to estimate the total bromine content. Blends were pyrolyzed before and after the soxhlet extraction in order to evaluate the derived products. FTIR measurements of the polymeric blends before and after the soxhlet extraction showed that their structure was maintained. From the results obtained, it was indicated that the reduction of bromine was achieved in all cases tested and it was ~34% for blend I and ~46% and 42% for blend II when applying a 6 h soxhlet with isopropanol and ethanol, respectively. When using butanol bromine was completely eliminated, since the reduction reached almost 100%. The latter finding is of great importance, since the complete removal of bromine enables the recycling of pure plastics. Therefore, the main contribution of this work to the advancement of knowledge lies in the use of a solvent (i.e., butanol) which is environmentally friendly and with a high dissolving capacity in brominated compounds, which can be used in a pretreatment stage of plastic wastes before it is recycled by pyrolysis.

A carbothermic hybrid synthesized using waste halogenated plastic in sub/supercritical CO2 and its application for lithium recovery

Facile fabrication of porous carbon materials from waste halogenated plastic is highly attractive but frequently hampered due to potential release of halogenated organic pollutants. In this study, a novel type of carbon hybrid was tentatively synthesized from a real-world halogenated plastic as an inexpensive carbon source by sub/supercritical carbon dioxide carbonization technique. It was found that halogen-free carbon carrier was advantageously synthesized through carbonization of halogenated plastic without using catalysts due to zip depolymerization, random chain cracking and free radical reactions induced by sub/supercritical carbon dioxide technique. Exhibiting with more abundant functional groups including C-O, CO groups than pyrolytic carbon carrier, the derived carbon carrier demonstrated excellent performance in selective recovery of lithium from cathode powder with highest recovery efficiency of 93.6%. Mechanism study indicated that cathode powder was transformed into low-valence states of transition metals/metal oxides and released lithium as lithium carbonate due to collapse of oxygen framework via carbothermic reduction. This work provides an applicable and green process for synthesis of alternative carbon carrier from waste halogenated plastic and its application as carbothermic reductant in lithium recovery.

Catalytic Pyrolysis of Plastic Waste and Molecular Symmetry Effects: A Review

The present review addresses the latest findings and limitations in catalytic pyrolysis for the processing of plastic waste into valuable fuels. Compared to thermal degradation of plastics, catalytic pyrolysis provides better results in regards to the quality of the obtained liquid hydrocarbon fuel. Different types of catalysts can be used in order to improve the thermal degradation of plastics. Some of the most used catalysts are different types of zeolites (HUSY, HZSM-5, Hβ), Fluid Catalytic Cracking (FCC), silica-alumina catalysts, or natural clays. There is a need to find affordable and effective catalysts in the aim of achieving commercialization of catalytic pyrolysis of plastic waste. Therefore, this study summarizes and presents the most significant results found in the literature in regards to catalytic pyrolysis. This paper also investigates the symmetry effects of molecules on the pyrolysis process.

On the implementation of the circular economy route for E-waste management: A critical review and an analysis for the case of the state of Kuwait

Electronic waste (e-waste) has become one of the major causes of environmental concerns due to its large volume, high generation rate and toxic environmental burdens. Recent estimates put e-waste generation at about 54 million tonnes per annum with figures reaching approximately 75 million tonnes per annum by 2030. In this manuscript, the state-of-the-art technologies and techniques for segregation, recovery and recycling of e-waste with a special focus on the valorisation aspects of e-plastics and e-metals which are critically reviewed. A history and insight into environmental aspects and regulation/legislations are presented including those that could be adopted in the near future for e-waste management. The prospects of implementing such technologies in the State of Kuwait for the recovery of materials and energy from e-waste where infrastructure is lacking still for waste management are presented through Material Flow Analysis. The information showed that Kuwait has a major problem in waste accumulation. It is estimated that e-waste in Kuwait (with no accumulation or backlog) is generated at a rate of 67,000 tpa, and the imports of broadcasting electronics generate some 19,428 tonnes. After reviewing economic factors of potential recovered plastics, iron and glass from broadcasting devices in Kuwait as e-waste, a total revenue of $399,729 per annum is estimated from their valorisation. This revenue will open the prospect of ventures for other e-waste and fuel recovery options as well as environmental benefits and the move to a circular economy.

Effect of Zeolite Catalyst on the Pyrolysis Kinetics of Multi-Layered Plastic Food Packaging

Pyrolysis is gaining more significance as a technology used to produce alternative fuels and chemicals. This study dealt with the catalytic pyrolysis of a realistic waste mixture of multi-layered plastic food packaging. The thermal behavior, kinetic parameters, and kinetic model of multi-layered plastic food packaging pyrolysis were determined to show its potential for process scale-up. In particular, we aimed to evaluate the effect of a ZSM-5 zeolite catalyst, modified with iron(III) oxide. The pyrolysis process on this decagonal structure was investigated using thermogravimetric analysis under nitrogen flow at four heating rates ranging between 40 and 600 °C. The kinetic study was conducted using the model-free isoconversional Friedman method as well as advanced statistical analysis to determine the reaction mechanism of the process. The thermal decomposition occurred in the range of 350–510 °C, with a mass loss greater than 90%. The kinetic study revealed a complex pyrolysis process, which consisted of three decomposition stages, diffusion, and Avrami-Erofeev reaction types. The activation energy values determined by the Friedman method rose with the degree of conversion, from 127 kJ mol−1 at 0.01 to 219 kJ mol−1 at 0.95. The doping of the catalyst lowered the activation energy of the reaction by 44% and 8% in the first and second stages, respectively, and increased the acidity of the zeolites, thus enhancing the reactivity on the surface of the catalysts. Lower activation energy meant less energy was required to heat the pyrolysis reactor since the onset temperature of sample decomposition was reduced.

Recycled (Bio)Plastics and (Bio)Plastic Composites: A Trade Opportunity in a Green Future

Today’s world is at the point where almost everyone realizes the usefulness of going green. Due to so-called global warming, there is an urgent need to find solutions to help the Earth and move towards a green future. Many worldwide events are focusing on the global technologies in plastics, bioplastic production, the recycling industry, and waste management where the goal is to turn plastic waste into a trade opportunity among the industrialists and manufacturers. The present work aims to review the recycling process via analyzing the recycling of thermoplastic, thermoset polymers, biopolymers, and their complex composite systems, such as fiber-reinforced polymers and nanocomposites. Moreover, it will be highlighted how the frame of the waste management, increasing the materials specificity, cleanliness, and a low level of collected material contamination will increase the potential recycling of plastics and bioplastics-based materials. At the same time, to have a real and approachable trade opportunity in recycling, it needs to implement an integrated single market for secondary raw materials.

Oil Production by Pyrolysis of Real Plastic Waste

The aim of this paper is for the production of oils processed in refineries to come from the pyrolysis of real waste from the high plastic content rejected by the recycling industry of the Basque Country (Spain). Concretely, the rejected waste streams were collected from (1) a light packaging waste sorting plant, (2) the paper recycling industry, and (3) a waste treatment plant of electrical and electronic equipment (WEEE). The influence of pre-treatments (mechanical separation operations) and temperature on the yield and quality of the liquid fraction were evaluated. In order to study the pre-treatment effect, the samples were pyrolyzed at 460 °C for 1 h. As pre-treatments concentrate on the suitable fraction for pyrolysis and reduce the undesirable materials (metals, PVC, PET, inorganics, cellulosic materials), they improve the yield to liquid products and considerably reduce the halogen content. The sample with the highest polyolefin content achieved the highest liquid yield (70.6 wt.% at 460 °C) and the lowest chlorine content (160 ppm) among the investigated samples and, therefore, was the most suitable liquid to use as refinery feedstock. The effect of temperature on the pyrolysis of this sample was studied in the range of 430–490 °C. As the temperature increased the liquid yield increased and solid yield decreased, indicating that the conversion was maximized. At 490 °C, the pyrolysis oil with the highest calorific value (44.3 MJ kg⁻¹) and paraffinic content (65% area), the lowest chlorine content (128 ppm) and more than 50 wt.% of diesel was obtained.

How to enhance the environmental sustainability of WEEE plastics management: An LCA study

A new management scheme of plastics from waste of electrical and electronic equipment (WEEE), which includes novel treatments of sorting, dissolution/precipitation, extrusion, catalytic pyrolysis, and plastic upgrading, is proposed. Its environmental performances are quantified by an attributional Life Cycle Assessment and compared with those of European currently adopted schemes, which include conventional mechanical recycling and thermal treatments as well as improper options of dumping and open burning, largely applied to WEEE plastics exported to developing countries. The proposed innovative scheme greatly enhances the environmental sustainability of WEEE plastics management, by increasing the annual amounts of polymers sent to recycling (from 390 kt/y up to 530 kt/y), decreasing residues to be sent to combustion (from 360 kt/y up to 60 kt/y), and reducing the potential impacts of all the midpoint categories under analysis (up to 580% for that of Global Warming). These results are mainly related to the adoption of a dissolution/precipitation process, which allows recovering target polymers such as ABS, HIPS and PC, with improvements in terms of Global Warming, Non-Carcinogens, and Carcinogens equal to 246%, 69% and 35%, even when the stages of polymer upgrading and catalytic pyrolysis are not included in the analysis. The sensitivity analysis shows that advantages of the new approach substantially disappear if the awful contributions of exportation outside Europe are taken into account. This clearly indicates that the first step to enhance the sustainability of WEEE plastics management is a strong limitation of improper treatments applied to exported wastes.

Detection of Brominated Plastics from E-Waste by Short-Wave Infrared Spectroscopy

In this work, the application of Short-Wave Infrared (SWIR: 1000–2500 nm) spectroscopy was evaluated to identify plastic waste containing brominated flame retardants (BFRs) using two different technologies: a portable spectroradiometer, providing spectra of single spots, and a hyperspectral imaging (HSI) platform, acquiring spectral images. X-ray Fluorescence (XRF) analysis was preliminarily performed on plastic scraps to analyze their bromine content. Chemometric methods were then applied to identify brominated plastics and polymer types. Principal Component Analysis (PCA) was carried out to explore collected data and define the best preprocessing strategies, followed by Partial Least Squares—Discriminant Analysis (PLS-DA), used as a classification method. Plastic fragments were classified into “High Br content” (Br > 2000 mg/kg) and “Low Br content” (Br < 2000 mg/kg). The identified polymers were acrylonitrile butadiene styrene (ABS) and polystyrene (PS). Correct recognition of 89–90%, independently from the applied technique, was achieved for brominated plastics, whereas a correct recognition ranging from 81 to 89% for polymer type was reached. The study demonstrated as a systematic utilization of both the approaches at the industrial level and/or at laboratory scale for quality control can be envisaged especially considering their ease of use and the short detection response.

Characterization and Use of Char Produced from Pyrolysis of Post-Consumer Mixed Plastic Waste

In this work, the pyrolysis of post-consumer mixed plastic waste (polypropylene (PP), polystyrene (PS) and polyethylene film (PE)) is carried out. The solid product of the pyrolysis is characterized and tested for its use as adsorbent of lead present in aqueous media. The pyrolysis temperature has a great influence on the solid product yield, decreasing when the temperature increases. The highest yield to solid product obtained is from the pyrolysis of film at lower temperature (450 °C), reaching almost 14%. The results of product solid characterization reveal that the carbon, hydrogen and nitrogen content decreases with increasing pyrolysis temperature. Furthermore, both the ash and the volatile content are related to the pyrolysis temperature. The ash content is higher when the pyrolysis temperature is higher, while when the temperature increases, a solid product with lower volatile content is obtained. In respect to specific surface area, a higher pyrolysis temperature improves the properties of the solid product as an adsorbent. The adsorption capacity increases as the pyrolysis temperature increases, with the highest value of 7.91 mg/g for the solid obtained in the pyrolysis at 550 °C. In addition, adsorption capacity increases as the initial concentration of lead rises, reaching a maximum value close to 26 mg/g for an initial concentration of 40 mg/L. The Sips model is the one that best reproduces the experimental results of the adsorption process equilibrium study.

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 Pyrolysis of a Residual Plastic Waste Using Zeolites Produced by Coal Fly Ash

The plastic film residue (PFR) of a plastic waste recycling process was selected as pyrolysis feed. Both thermal and catalytic pyrolysis experiments were performed and coal fly ash (CFA) and X zeolites synthesized from CFA (X/CFA) were used as pyrolysis catalysts. The main goal is to study the effect of low-cost catalysts on yields and quality of pyrolysis oils. NaX/CFA, obtained using the fusion/hydrothermal method, underwent ion exchange followed by calcination in order to produce HX/CFA. Firstly, thermogravimetry and differential scanning calorimetry (TG and DSC, respectively) analyses evaluated the effect of catalysts on the PFR degradation temperature and the process energy demand. Subsequently, pyrolysis was carried out in a bench scale reactor adopting the liquid-phase contact mode. HX/CFA and NaX/CFA reduced the degradation temperature of PFR from 753 to 680 and 744 K, respectively, while the degradation energy from 2.27 to 1.47 and 2.07 MJkg−1, respectively. Pyrolysis runs showed that the highest oil yield (44 wt %) was obtained by HX/CFA, while the main products obtained by thermal pyrolysis were wax and tar. Furthermore, up to 70% of HX/CFA oil was composed by gasoline range hydrocarbons. Finally, the produced gases showed a combustion energy up to 8 times higher than the pyrolysis energy needs.