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Wang Y, Chang BP, Veksha A, Kashcheev A, Tok ALY, Lipik V, Yoshiie R, Ueki Y, Naruse I, Lisak G. Processing plastic waste via pyrolysis-thermolysis into hydrogen and solid carbon additive to ethylene-vinyl acetate foam for cushioning applications. JOURNAL OF HAZARDOUS MATERIALS 2024; 464:132996. [PMID: 37988865 DOI: 10.1016/j.jhazmat.2023.132996] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Subscribe] [Scholar Register] [Received: 07/01/2023] [Revised: 11/04/2023] [Accepted: 11/10/2023] [Indexed: 11/23/2023]
Abstract
A strategy for enhancing value creation from pyrolysis gas and oil, derived from plastic waste, through the generation of two additional outputs of solid carbon and hydrogen was investigated. Three types of hard-to-recycle plastic waste (marine plastic litter, household mixed plastics and cosmetic products packaging) were thermally treated in two stages: (i) decomposition of feedstock into gas and oil via pyrolysis at 600 °C; and (ii) thermolytic conversion of the pyrolysis gas and a fraction of oil into hydrogen and solid carbon at 1300 °C separately. The thermolysis of both pyrolysis gas and oil fractions predominantly resulted in the production of solid carbon (39-70 wt% per plastic feedstock and carbon content of 91.3-98.6 wt%) and H2-rich gas (H2 yield of 5.9-10.8 wt% per plastic waste feedstock and H2 content of 71.4-97.2 vol% per gas volume). The incorporation of pyrolysis oil into the thermolysis process could enhance the outputs of solid carbon and hydrogen. Characterizations of solid carbon and hydrogen obtained from pyrolysis gas and oil fractions were further conducted. The observed similar properties of H2 and solid carbon from pyrolysis gas and oil supported the feasibility of introducing all the pyrolytic products together into the thermolysis process without condensation of oil. To enhance the value of these solid carbon derived from plastics for practical usage, we utilized the obtained solid carbon as a reinforcing agent for polymer composite foam development. The solid carbon reinforced composite foam displayed great abrasion resistance (wear loss: 240 mg), compression strength (0.347 MPa), and dynamic impact properties (energy returned: 124 J/m and energy absorbed: 57.3 J/m), emphasizing the viability of solid carbon as a nucleating agent and reinforcing filler in polymer foam for cushioning applications. Overall, the strategy of pyrolysis-thermolysis, which harnesses both pyrolysis gas and oil, unlocks additional value creation by producing two new outputs from plastic waste. Depending on the market prices for solid carbon and hydrogen, this can substantially change the economics of plastic waste management and create new revenue streams, incentivizing plastic waste collection and processing.
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Affiliation(s)
- Yuxin Wang
- Residues and Resource Reclamation Centre (R3C), Nanyang Environment and Water Research Institute, Nanyang Technological University, 637141, Singapore; Department of Mechanical Systems Engineering, Nagoya University, Tokai National Higher Education and Research, 464-8603, Japan
| | - Boon Peng Chang
- School of Materials Science and Engineering, Nanyang Technological University, 50 Nanyang Avenue, 639798, Singapore
| | - Andrei Veksha
- Residues and Resource Reclamation Centre (R3C), Nanyang Environment and Water Research Institute, Nanyang Technological University, 637141, Singapore
| | - Aleksandr Kashcheev
- School of Materials Science and Engineering, Nanyang Technological University, 50 Nanyang Avenue, 639798, Singapore
| | - Alfred Ling Yoong Tok
- School of Materials Science and Engineering, Nanyang Technological University, 50 Nanyang Avenue, 639798, Singapore
| | - Vitali Lipik
- School of Materials Science and Engineering, Nanyang Technological University, 50 Nanyang Avenue, 639798, Singapore
| | - Ryo Yoshiie
- Department of Mechanical Systems Engineering, Nagoya University, Tokai National Higher Education and Research, 464-8603, Japan
| | - Yasuaki Ueki
- Institute of Materials and Systems for Sustainability, Nagoya University, Tokai National Higher Education and Research, 464-8601, Japan
| | - Ichiro Naruse
- Institute of Materials and Systems for Sustainability, Nagoya University, Tokai National Higher Education and Research, 464-8601, Japan
| | - Grzegorz Lisak
- Residues and Resource Reclamation Centre (R3C), Nanyang Environment and Water Research Institute, Nanyang Technological University, 637141, Singapore; School of Civil and Environmental Engineering, Nanyang Technological University, 50 Nanyang Avenue, 639798, Singapore.
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Okoye CO, Zhang Z, Zhang D. Carbon black preparation by partial oxidation of spent tyre pyrolysis oil - Influence of temperature, residence time and oxygen to feed ratio. WASTE MANAGEMENT (NEW YORK, N.Y.) 2024; 174:273-281. [PMID: 38071867 DOI: 10.1016/j.wasman.2023.11.040] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Subscribe] [Scholar Register] [Received: 08/21/2023] [Revised: 11/07/2023] [Accepted: 11/29/2023] [Indexed: 01/16/2024]
Abstract
Preparation of carbon black (CB) by partial oxidation of the spent tyre pyrolysis oil (STPO) and its heavy residue fraction (HRF) was systematically studied using a lab-scale drop tube furnace. The effect of furnace operating temperature (T: 1100 to 1400 °C), residence time (tr: 5 to 60 s) and oxygen to feed ratio (O/F: 174 to 732) on the yield and quality of CB was examined using the response surface methodology (RSM). T was shown to have the most significant influence on CB yield and properties. While the CB yield was also influenced by tr, the quality was more sensitively dependent on T and O/F. The predicted optimal tr and O/F were approximately the same for both feedstocks (60 s and 174, respectively). However, T was higher for the HRF feedstock (1368 °C) than the STPO feedstock (1331 °C) due to the abundance of more viscous heavy hydrocarbons in HRF. Validation experiments under the aforementioned conditions demonstrated the models' ability to predict responses accurately. The CB from both feedstocks had low contents of ash (<0.03%), volatiles (∼0.5%), sulphur (<0.7%), and high carbon (≥95%). The BET surface area and average primary particle size for CB from STPO and HRF were comparable to those of commercial CBs from fossil fuel feedstock. The CB from HRF had a higher carboxyl oxygen functional group (18%) compared to the CB from STPO (∼13%) and commercial CB (<5%).
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Affiliation(s)
- Chiemeka Onyeka Okoye
- Centre for Energy (M473), The University of Western Australia, 35 Stirling Highway, Crawley, WA 6009, Australia.
| | - Zhezi Zhang
- Centre for Energy (M473), The University of Western Australia, 35 Stirling Highway, Crawley, WA 6009, Australia
| | - Dongke Zhang
- Centre for Energy (M473), The University of Western Australia, 35 Stirling Highway, Crawley, WA 6009, Australia
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Veksha A, Wang Y, Foo JW, Naruse I, Lisak G. Defossilization and decarbonization of hydrogen production using plastic waste: Temperature and feedstock effects during thermolysis stage. JOURNAL OF HAZARDOUS MATERIALS 2023; 452:131270. [PMID: 36989781 DOI: 10.1016/j.jhazmat.2023.131270] [Citation(s) in RCA: 3] [Impact Index Per Article: 3.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Subscribe] [Scholar Register] [Received: 01/16/2023] [Revised: 03/16/2023] [Accepted: 03/21/2023] [Indexed: 06/19/2023]
Abstract
The replacement of natural gas with plastic-derived pyrolysis gas can defossilize H2 production, while subsequent capture, utilization and storage of carbon in a solid form can decarbonize the process. The objective of this study was to investigate H2 production from three types of plastics using a process comprising pyrolysis (600 °C) and thermolysis stages (1200-1500 °C). Depending on the plastic feedstock and thermolysis temperature, the laboratory-scale setup generated 1000-1350 mL/min product gas with H2 purity of 74.3-94.2 vol%. The recovery of 5-9 wt% molecular H2 per mass of plastics was achieved. Other products included solid residue (0.1-12 wt%) and oil (8-52 wt%) from the pyrolysis reactor, solid carbon (36-53 wt%) and gas impurities (2-16 wt%) from the thermolysis reactor. The purity of H2 gas was detrimentally influenced by polyethylene terephthalate in the feedstock due to the dilution of gas by CO. The decomposition of methane containing in the pyrolysis gas was the limiting reaction step during H2 production and improved at higher thermolysis temperature. Three solid carbon structures were formed during the thermolysis stage regardless of the plastic type: carbon black aggregates, carbon black aggregates coated with a layer of pyrolytic carbon and a carbon film on the inner reactor wall. Among the three types of carbon, the highest valorization potential was identified for carbon black aggregates. Plastic feedstock composition had little if any effect on carbon black properties, while high thermolysis temperature (1500 °C) reduced the particle sizes and increased the surface area of aggregates.
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Affiliation(s)
- Andrei Veksha
- Residues and Resource Reclamation Centre (R3C), Nanyang Environment and Water Research Institute, Nanyang Technological University, 637141, Singapore.
| | - Yuxin Wang
- Residues and Resource Reclamation Centre (R3C), Nanyang Environment and Water Research Institute, Nanyang Technological University, 637141, Singapore; Department of Mechanical Systems Engineering, Nagoya University, Tokai National Higher Education and Research, 464-8603, Japan
| | - Jun Wei Foo
- Residues and Resource Reclamation Centre (R3C), Nanyang Environment and Water Research Institute, Nanyang Technological University, 637141, Singapore
| | - Ichiro Naruse
- Institute of Materials and Systems for Sustainability, Nagoya University, Tokai National Higher Education and Research, 464-8601, Japan
| | - Grzegorz Lisak
- Residues and Resource Reclamation Centre (R3C), Nanyang Environment and Water Research Institute, Nanyang Technological University, 637141, Singapore; School of Civil and Environmental Engineering, Nanyang Technological University, 50 Nanyang Avenue, 639798, Singapore.
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