High-value products from ex-situ catalytic pyrolysis of polypropylene waste using iron-based catalysts: the influence of support materials

The role of physicochemical marble processing wastewater treatment sludge in the production of new generation pyrolysis char from waste polypropylene

The effects of marble processing wastewater physicochemical treatment sludge (K1) on polypropylene (PP) waste pyrolysis were investigated by lab-scale batch pyrolysis system. PP-K1 proportions and pyrolysis temperature were studied as variables and both were found to have influences onto pyrolysis char, oil/tar, gas fractions distribution, as well as pyrolysis char characteristics (determined via SEM, EDX, FTIR, TGA and XRD analyses). The influence of K1 could be related to its high mineral composition (CaCO3, CaMg(CO3)2 and (Mg0.03Ca0.97)(CO3)) which also detected in the char products. K1 acts as catalyst and remained unchanged in thermochemical reactions below 700°C. The main thermal degradation of PP occurs around 400-470°C, although it starts at about 300-350°C, whereas, K1 resulted in more thermal degradation at 300°C pyrolysis. As K1 dose increased, pyrolysis chars became more thermally stable with the pyrolysis temperature. Diverse types of chars in terms of porosity, thermal strength and chemical structure were produced with PP + K1 as compared to the PP chars. For example, with 10%-20% K1 doses, the chars are in aromatic structure while chars become aliphatic when K1 dosage increased to 30% or above. The structural diversity made these chars new products that can be used as raw material for subsequent purposes. This study provided a basis for the chars' physical and chemical properties which are needed for further research to develop new generation evaluation areas for them. Therefore, a new symbiotic upcycling approach has been presented for PP wastes and marble processing wastewater treatment sludge.

A review on value-addition to plastic waste towards achieving a circular economy

Plastic and mixed plastic waste (PW) has received increased worldwide attention owing to its huge rate of production, high persistency in the environment, and unsustainable waste management practices. Therefore, sustainable PW management and upcycling approaches are imperative to achieve the objectives of the United Nations Sustainable Development Goals. Numerous recent studies have shown the application and feasibility of various PW conversion techniques to produce materials with better economic value. Within this framework, the current review provides an in-depth analysis of cutting-edge thermochemical technologies such as pyrolysis, gasification, carbonization, and photocatalysis that can be used to value plastic and mixed PW in order to produce energy and industrial chemicals. Additionally, a thorough examination of the environmental impacts of contemporary PW upcycling techniques and their commercial feasibility through life cycle assessment (LCA) and techno-economical assessment are provided in this review. Finally, this review emphasizes the opportunities and challenges accompanying with existing PW upcycling techniques and deliver recommendations for future research works.

Plastic wastes-derived N-doped carbon nanotubes for efficient removal of sulfamethoxazole in high salinity wastewater via nonradical peroxymonosulfate activation

Peroxymonosulfate (PMS) catalytic activation is effective to eliminate organic pollutants from water, thus the development of low-cost and efficient catalysts is significant in applications. The resource conversion of plastic wastes (PWs) into carbon nanotubes (CNTs) is a promising candidate for PMS-based advanced oxidation processes (AOPs), and also a sustainable strategy to realize plastic management and reutilization. Herein, cost-effective PWs-derived N-doped CNTs (N-pCNTs) were synthesized, which displayed efficient activity for PMS activation through an electron transfer pathway (ETP) for sulfamethoxazole (SMX) degradation in high salinity water. The pyrrolic N induced the positively charged surface of N-pCNTs, favoring the electrostatic adsorption of PMS and subsequent generation of active PMS* . A galvanic oxidation process was developed to prove the electron-shuttle dominated ETP for SMX oxidation. Combined with theoretical calculations, the efficiency of ETP was determined by the potential difference between HOMO of SMX and LUMO of N-pCNTs. Such oxidation produced low-toxicity intermediates and resulted in selective degradation of specific sulfonamide antibiotics. This work reveals the feasibility of low-cost N-pCNTs catalysts from PWs serving as an appealing candidate for PMS-AOPs in water remediation, providing a new solution to alleviate environmental issues caused by PWs and also advances the understanding of ETP during PMS activation.

Simultaneous production of high-valued carbon nanotubes and hydrogen from catalytic pyrolysis of waste plastics: The role of cellulose impurity

Upcycling waste plastics into valuable carbon nanotubes (CNTs) and hydrogen via catalytic pyrolysis is a sustainable strategy to mitigate white pollution. However, real-world plastics are complex and generally contain organic impurities, such as cellulose, which have a non-negligible impact on the catalytic pyrolysis process and product distribution. In this study, cellulose was chosen as a model compound to distinguish the effects of oxygen-containing components on the CNTs and hydrogen production during the catalytic pyrolysis of waste polypropylene. Different amounts of cellulose were mixed with polypropylene to regulate the O/C mass ratio of the feedstock, and the relationship between the O/C mass ratio and the yield of products has been built quantificationally. The results revealed that the relative content of CNTs increased to over 95%, and the stability and purity of carbon deposition increased accordingly when the O/C mass ratio is 0.05. This could be ascribed to the etching effects caused by small amounts of H2O and CO2 on amorphous carbon. However, further increasing the amount of cellulose caused the deactivation of the Fe-Ni catalyst. This not only decreased the carbon yield but had an adverse impact on its morphology and graphitization, leading to the increase of amorphous carbon. This study can provide fundamental guidance for the efficient utilization of waste plastics that take advantage of organic impurities in waste plastic to promote the formation of high-purity CNTs.

Fe-Co Bimetallic Catalysts for Pyrolysis of Disposable Face Masks and Nitrile Gloves: Synthesis and Characterization of N-Doped Carbon Nanotubes

The global spread of severe acute respiratory syndrome coronavirus 2 has led to a widespread surge in the use of disposable medical face masks (DFMs) and waste nitrile gloves (WNGs). To address the immense disruption in waste management systems, the catalytic pyrolysis of DFMs and WNGs was undertaken to yield multiwalled carbon nanotubes. Two MgO-supported bimetallic catalysts, Fe-Co and Fe-Ni, were synthesized for catalytic pyrolysis. The MgO-supported Fe and Co catalysts showed a good yield of N-doped CNTs (N-CNTs) above 33 wt %, while the percentage of WNGs did not exceed 20 wt %. The pyrolysis process resulted in the formation of Fe-Co microspinels, which were subsequently encapsulated within N-CNTs, ultimately yielding FeCo-NCNTs. The synthesized FeCo-NCNTs were approximately 25 nm in diameter and were extended over several micrometers in length. Subsequent evaluations included testing several acid-washed FeCo-NCNTs as catalysts for the oxygen reduction reaction. The FeCo-NCNTs exhibited remarkable catalytic performance, with a half-wave potential at 0.831 V (vs RHE) and exceptional resistance to methanol poisoning. These remarkable findings have the potential to contribute to the sustainable recycling of waste generated during the COVID-19 pandemic and to the utilization of waste-derived materials.

Production of combustible fuels and carbon nanotubes from plastic wastes using an in-situ catalytic microwave pyrolysis process

This study performed in-situ microwave pyrolysis of plastic waste into hydrogen, liquid fuel and carbon nanotubes in the presence of Zeolite Socony Mobil ZSM-5 catalyst. In the presented microwave pyrolysis of plastics, activated carbon was used as a heat susceptor. The microwave power of 1 kW was employed to decompose high-density polyethylene (HDPE) and polypropylene (PP) wastes at moderate temperatures of 400-450 °C. The effect of plastic composition, catalyst loading and plastic type on liquid, gas and solid carbon products was quantified. This in-situ CMP reaction resulted in heavy hydrocarbons, hydrogen gas and carbon nanotubes as a solid residue. A relatively better hydrogen yield of 129.6 mmol/g as a green fuel was possible in this process. FTIR and gas chromatography analysis revealed that liquid product consisted of C₁₃₊ fraction hydrocarbons, such as alkanes, alkanes, and aromatics. TEM micrographs showed tubular-like structural morphology of the solid residue, which was identified as carbon nanotubes (CNTs) during X-ray diffraction analysis. The outer diameter of CNTs ranged from 30 to 93 nm from HDPE, 25-93 nm from PP and 30-54 nm for HDPE-PP mixure. The presented CMP process took just 2-4 min to completely pyrolyze the plastic feedstock into valuable products, leaving no polymeric residue.

Controlling Diels-Alder reactions in catalytic pyrolysis of sawdust and polypropylene by coupling CO2 atmosphere and Fe-modified zeolite for enhanced light aromatics production

Producing value-added light aromatics (BTEX) from solid waste streams holds excellent promise for resource recovery. Here we present a thermochemical conversion approach that enhanced BTEX production by coupling CO₂ atmosphere and Fe-modified HZSM-5 zeolite to facilitate the Diels-Alder reactions in catalytic pyrolysis of sawdust and polypropylene. The Diels-Alder reactions between sawdust-derived furans and polypropylene-derived olefins could be controlled by tuning CO₂ concentration and Fe loading amount. Sufficient CO₂ (≥50%) with moderate Fe loading (10 wt%) were observed to produce more BTEX and fewer heavy fractions (C₉⁺aromatics). To deepen the mechanistic understanding, quantification of polycyclic aromatic hydrocarbons (PAHs) and catalyst coke was further conducted. The co-use of CO₂ atmosphere and Fe modification suppressed the appearance of low-, medium-, and high-membered ring PAHs by over 40%, decreased pyrolysis oil toxicity from 42.1 to 12.8 μg/g_oil TEQ, and transformed coke from "hard" to "soft". Based on the characterization of CO₂ adsorption behavior, it was deduced that the introduced CO₂ was activated by loaded Fe and reacted in situ with H₂ generated during aromatization to expedite H-transfer. Meanwhile, BTEX recondensation was prevented through the Boudouard reactions of CO₂ and water-gas reactions between the resulting water and carbon deposits. These synergistically enhanced the production of BTEX and suppressed the formation of heavy species, including PAHs and catalyst coke.

Mechanism of microwave-assisted iron-based catalyst pyrolysis of discarded COVID-19 masks

Inexpensive iron-based catalysts are the most promising catalysts for microwave pyrolysis of waste plastics, especially a large number of disposable medical masks (DMMs) with biological hazards produced by spread of COVID-19. However, most synthesized iron-based catalysts have very low microwave heating efficiency due to the enrichment state of iron. Here, we prepared FeAlOx catalysts using the microwave heating method and found that the microwave heating efficiency of amorphous iron and hematite is very low, indeed, these materials can hardly initiate pyrolysis at room temperature, which limits the application of iron-based catalysts in microwave pyrolysis. By contrast, a mixture of DMMs and low-valent iron oxides produced by hydrogen reduction at 500 °C can be heated by microwaves to temperatures above 900 °C under the same conditions. When the hydrogen reduction temperature was incerased to 800 °C, the content of metallic iron in the catalyst gradually increased from 0.34 to 21.43%, which enhanced the microwave response ability of the catalyst, and decreased the gas content in the pyrolysis product from 78.91 to 70.93 wt%; corresponding hydrogen yield also decreased from 29.03 to 25.02 mmolH₂·g^-1_DMMs. Moreover, the morphology of the deposited solid carbon gradually changed from multi-walled CNTs to bamboo-like CNTs. This study clarifies the pyrolysis mechanism of microwave-assisted iron catalysts and lays a theoretical foundation for their application in microwave pyrolysis.

Thermochemical Conversion of Plastic Waste into Fuels, Chemicals, and Value-Added Materials: A Critical Review and Outlooks

Plastic waste is an emerging environmental issue for our society. Critical action to tackle this problem is to upcycle plastic waste as valuable feedstock. Thermochemical conversion of plastic waste has received growing attention. Although thermochemical conversion is promising for handling mixed plastic waste, it typically occurs at high temperatures (300-800 °C). Catalysts can play a critical role in improving the energy efficiency of thermochemical conversion, promoting targeted reactions, and improving product selectivity. This Review aims to summarize the state-of-the-art of catalytic thermochemical conversions of various types of plastic waste. First, general trends and recent development of catalytic thermochemical conversions including pyrolysis, gasification, hydrothermal processes, and chemolysis of plastic waste into fuels, chemicals, and value-added materials were reviewed. Second, the status quo for the commercial implementation of thermochemical conversion of plastic waste was summarized. Finally, the current challenges and future perspectives of catalytic thermochemical conversion of plastic waste including the design of sustainable and robust catalysts were discussed.