Pyrolysis of end-of-life polystyrene in a pilot-scale reactor: Maximizing styrene production

Synergistic interaction between scrap tyre and plastics for the production of sulphur-free, light oil from fast co-pyrolysis

Fast co-pyrolysis offers a sustainable solution for upcycling polymer waste, including scrap tyre and plastics. Previous studies primarily focused on slow heating rates, neglecting synergistic mechanisms and sulphur transformation in co-pyrolysis with tyre. This research explored fast co-pyrolysis of scrap tyre with polypropylene (PP), low-density polyethylene (LDPE), and polystyrene (PS) to understand synergistic effects and sulphur transformation mechanisms. A pronounced synergy was observed between scrap tyre and plastics, with the nature of the synergy being plastic-type dependent. Remarkably, blending 75 wt% PS or LDPE with tyre effectively eliminated sulphur-bearing compounds in the liquid product. This reduction in sulphur content can substantially mitigate the release of hazardous materials into the environment, emphasizing the environmental significance of co-pyrolysis. The synergy between PP or LDPE and tyre amplified the production of lighter hydrocarbons, while PS's interaction led to the creation of monocyclic aromatics. These findings offer insights into the intricate chemistry of scrap tyre and plastic interactions and highlight the potential of co-pyrolysis in waste management. By converting potential pollutants into valuable products, this method can significantly reduce the release of hazardous materials into the environment.

Polystyrene Waste Thermochemical Hydrogenation to Ethylbenzene by a N-Bridged Co, Ni Dual-Atom Catalyst

Recycling waste plastics requires the degradation of plastics into small molecules. However, various products are widely distributed using traditional methods of depolymerizing polystyrene (PS) such as catalytic pyrolysis and hydrogenolysis. Here, we creatively report a N-bridged Co, Ni dual-atom (Co-N-Ni) catalyst for the targeted conversion of waste PS plastics to ethylbenzene via a pressurized tandem fixed-bed reactor where hydropyrolysis is coupled with downstream vapor-phase hydrotreatment. The Co-N-Ni catalyst achieves 95 wt % PS conversion with 92 wt % ethylbenzene yield, significantly superior to the corresponding single-atom catalysts, and enables degradation of real PS plastics. Theoretical calculations and experimental results demonstrate that the d-band center of metal atoms is well regulated in the Co-N-Ni catalyst. The Co site activates the C═C bond more easily, while the Ni site spatially optimizes the adsorption configuration of the styrene molecule due to the electronic interaction. This Co-N-Ni catalyst in the tandem reactor also shows excellent durability and provides a new direction for real plastic degradation.

Thermal pyrolysis of waste versus virgin polyolefin feedstocks: The role of pressure, temperature and waste composition

Due to the complexity and diversity of polyolefinic plastic waste streams and the inherent non-selective nature of the pyrolysis chemistry, the chemical decomposition of plastic waste is still not fully understood. Accurate data of feedstock and products that also consider impurities is, in this context, quite scarce. Therefore this work focuses on the thermochemical recycling via pyrolysis of different virgin and contaminated waste-derived polyolefin feedstocks (i.e., low-density polyethylene (LDPE), polypropylene (PP) as main components), along with an investigation of the decomposition mechanisms based on the detailed composition of the pyrolysis oils. Crucial in this work is the detailed chemical analysis of the resulting pyrolysis oils by comprehensive two-dimensional gas chromatography (GC × GC) and ICP-OES, among others. Different feedstocks were pyrolyzed at a temperature range of 430-490 °C and at pressures between 0.1 and 2 bar in a continuous pilot-scale pyrolysis unit. At the lowest pressure, the pyrolysis oil yield of the studied polyolefins reached up to 95 wt%. The pyrolysis oil consists of primarily α-olefins (37-42 %) and n-paraffins (32-35 %) for LDPE pyrolysis, while isoolefins (mostly C₉ and C₁₅) and diolefins accounted for 84-91 % of the PP-based pyrolysis oils. The post-consumer waste feedstocks led to significantly less pyrolysis oil yields and more char formation compared to their virgin equivalents. It was found that plastic aging, polyvinyl chloride (PVC) (3 wt%), and metal contamination were the main causes of char formation during the pyrolysis of polyolefin waste (4.9 wt%).

Catalytic routes towards polystyrene recycling

Polystyrene (PS) is one of the most popular plastics due to its versatility, which renders it useful for a large variety of applications, including laboratory equipment, insulation and food packaging. However, its recycling is still a challenge, as both mechanical and chemical (thermal) recycling strategies are often cost-prohibitive in comparison to current disposal methods. Therefore, catalytic depolymerization of PS represents the best alternative to overcome these economical drawbacks, since the presence of a catalyst can improve product selectivity for chemical recycling and upcycling of PS. This minireview focuses on the catalytic processes for the production of styrene and other valuable aromatics from PS waste, and it aims to lay the ground for PS recyclability and long-term sustainable PS production.

Machine-Learning-Based Predictions of Polymer and Postconsumer Recycled Polymer Properties: A Comprehensive Review

There has been a tremendous increase in demand for virgin and postconsumer recycled (PCR) polymers due to their wide range of chemical and physical characteristics. Despite the numerous potential benefits of using a data-driven approach to polymer design, major hurdles exist in the development of polymer informatics due to the complicated hierarchical polymer structures. In this review, a brief introduction on virgin polymer structure, PCR polymers, compatibilization of polymers to be recycled, and their characterization using sensor array technologies as well as factors affecting the polymer properties are provided. Machine-learning (ML) algorithms are gaining attention as cost-effective scalable solutions to exploit the physical and chemical structures of polymers. The basic steps for applying ML in polymer science such as fingerprinting, algorithms, open-source databases, representations, and polymer design are detailed in this review. Further, a state-of-the-art review of the prediction of various polymer material properties using ML is reviewed. Finally, we discuss open-ended research questions on ML application to PCR polymers as well as potential challenges in the prediction of their properties using artificial intelligence for more efficient and targeted PCR polymer discovery and development.

Maximizing olefin production via steam cracking of distilled pyrolysis oils from difficult-to-recycle municipal plastic waste and marine litter

Plastic waste is steadily polluting oceans and environments. Even if collected, most waste is still predominantly incinerated for energy recovery at the cost of CO₂. Chemical recycling can contribute to the transition towards a circular economy with pyrolysis combined with steam cracking being the favored recycling option for the time being. However, today, the high variety and contamination of real waste remains the biggest challenge. This is especially relevant for waste fractions which are difficult or even impossible to recycle mechanically such as highly mixed municipal plastic waste or marine litter. In this work, we studied the detailed composition and the steam cracking performance of distilled pyrolysis oil fractions in the naphtha-range of two highly relevant waste fractions: mixed municipal plastic waste (MPW) considered unsuitable for mechanical recycling and marine litter (ML) collected from the sea bottom. Advanced analytical techniques including comprehensive two-dimensional gas chromatography (GC × GC) coupled with various detectors and inductively coupled plasma - mass spectrometry (ICP-MS) were applied to characterize the feedstocks and to understand how their properties affect the steam cracking performance. Both waste-derived naphtha fractions were rich in olefins and aromatics (~70% in MPW naphtha and ~51% in ML naphtha) next to traces of nitrogen, oxygen, chlorine and metals. ICP-MS analyses showed that sodium, potassium, silicon and iron were the most crucial metals that should be removed in further upgrading steps. Steam cracking of the waste-derived naphtha fractions resulted in lower light olefin yields compared to fossil naphtha used as benchmark, due to secondary reactions of aromatics and olefins. Coke formation of ML naphtha was slightly increased compared to fossil naphtha (+ ~50%), while that of MPW naphtha was more than ~180% higher. It was concluded that mild upgrading of the waste-derived naphtha fractions or dilution with fossil feedstocks is sufficient to provide feedstocks suitable for industrial steam cracking.

Current Prospects for Plastic Waste Treatment

The excessive amount of global plastic produced over the past century, together with poor waste management, has raised concerns about environmental sustainability. Plastic recycling has become a practical approach for diminishing plastic waste and maintaining sustainability among plastic waste management methods. Chemical and mechanical recycling are the typical approaches to recycling plastic waste, with a simple process, low cost, environmentally friendly process, and potential profitability. Several plastic materials, such as polypropylene, polystyrene, polyvinyl chloride, high-density polyethylene, low-density polyethylene, and polyurethanes, can be recycled with chemical and mechanical recycling approaches. Nevertheless, due to plastic waste’s varying physical and chemical properties, plastic waste separation becomes a challenge. Hence, a reliable and effective plastic waste separation technology is critical for increasing plastic waste’s value and recycling rate. Integrating recycling and plastic waste separation technologies would be an efficient method for reducing the accumulation of environmental contaminants produced by plastic waste, especially in industrial uses. This review addresses recent advances in plastic waste recycling technology, mainly with chemical recycling. The article also discusses the current recycling technology for various plastic materials.

Recent Advances in the Decontamination and Upgrading of Waste Plastic Pyrolysis Products: An Overview

Extensive research on the production of energy and valuable materials from plastic waste using pyrolysis has been widely conducted during recent years. Succeeding in demonstrating the sustainability of this technology economically and technologically at an industrial scale is a great challenge. In most cases, crude pyrolysis products cannot be used directly for several reasons, including the presence of contaminants. This is confirmed by recent studies, using advanced characterization techniques such as two-dimensional gas chromatography. Thus, to overcome these limitations, post-treatment methods, such as dechlorination, distillation, catalytic upgrading and hydroprocessing, are required. Moreover, the integration of pyrolysis units into conventional refineries is only possible if the waste plastic is pre-treated, which involves sorting, washing and dehalogenation. The different studies examined in this review showed that the distillation of plastic pyrolysis oil allows the control of the carbon distribution of different fractions. The hydroprocessing of pyrolytic oil gives promising results in terms of reducing contaminants, such as chlorine, by one order of magnitude. Recent developments in plastic waste and pyrolysis product characterization methods are also reported in this review. The application of pyrolysis for energy generation or added-value material production determines the economic sustainability of the process.

Assessing the feasibility of chemical recycling via steam cracking of untreated plastic waste pyrolysis oils: Feedstock impurities, product yields and coke formation

Chemical recycling of plastic waste to base chemicals via pyrolysis and subsequent steam cracking of pyrolysis oils shows great potential to overcome the limitations in present means of plastic waste recycling. In this scenario, the largest concern is the feasibility. Are plastic waste pyrolysis products acceptable steam cracking feedstocks in terms of composition, product yields and coke formation? In this work, steam cracking of two post-consumer plastic waste pyrolysis oils blended with fossil naphtha was performed in a continuous bench-scale unit without prior treatment. Product yields and radiant coil coke formation were benchmarked to fossil naphtha as an industrial feedstock. Additionally, the plastic waste pyrolysis oils were thoroughly characterized. Analyses included two dimensional gas chromatography coupled to a flame ionization detector for the detailed hydrocarbon composition as well as specific analyses for heteroatoms, halogens and metals. It was found that both pyrolysis oils are rich in olefins (∼48 wt%) and that the main impurities are nitrogen, oxygen, chlorine, bromine, aluminum, calcium and sodium. Steam cracking of the plastic waste derived feedstocks led to ethylene yields of ∼23 wt% at a coil outlet temperature of 820 °C and ∼28 wt% at 850 °C, exceeding the ethylene yield of pure naphtha at both conditions (∼22 wt% and ∼27 wt%, respectively). High amounts of heavy products were formed when steam cracking both pyrolysis oils, respectively. Furthermore, a substantial coking tendency was observed for the more contaminated pyrolysis oil, indicating that next to unsaturated hydrocarbons, contaminants are a strong driver for coke formation.