Fuels from Waste Plastics by Thermal and Catalytic Processes: A Review

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.

Pyrolysis study of a waste plastic mixture through different kinetic models using isothermal and nonisothermal mechanism

Pyrolysis can be a convenient way to produce oils and gases simultaneously, as well as hydrocarbons and even crude petrochemicals. It can also be used to produce energy from a waste plastic mixture (WPM). To ascertain the kinetics parameters at the heating rates of 5, 10, 20, and 50 °C min-1, various kinetic models, including (a) model-fitting and (b) model-free, which are further separated into isothermal and non-isothermal categories, have been selected. The apparent activation energy (E a) and pre-exponential factor (A a) were calculated using the Friedman (model-free isothermal), KAS, FWO (model-free non-isothermal), and Coats-Redfern (model-fitting non-isothermal) approaches. The activation energy (E a), pre-exponential component (A a), and overall reaction order (n) were also calculated using a multi-linear regression methodology. In addition, the solid fuel characterization of WPM has been compared with previous literature results, as have the physico-chemical characteristics of pyrolytic oil. Finally, a brief mention of WPM's kinetic process has been included in this work. However, the results indicated two stages of thermal degradation and volatilization of the WPM zone during pyrolysis (410-510 °C, 510-770 °C). In the temperature range of 410-510 °C, 510-770 °C, two-stage thermal degradation zones are used to analyze the kinetic parameters for WPM. The result showed the average activation values obtained by the KAS, FWO, and Friedmam methods were 297.61, 295.25, and 267.26 kJ mol-1. In the case of the Coats-Redfern methods, the lowest activation energy was obtained by the PT1 kinetic model at 22.56 kJ mol-1, and the highest activation energy was found in the D3 kinetic model at 418.80 kJ mol-1 in the temperature zone of 410-510 °C. The temperature zone with the lowest activation energy was found to be between 510 °C and 770 °C.

Oxidative Upcycling of Polyethylene to Long Chain Diacid over Co-MCM-41 Catalyst

Plastic pollution is an emerging global threat due to lack of effective methods for transforming waste plastics into useful resources. Here, we demonstrate a direct oxidative upcycling of polyethylene into high-value and high-volume saturated dicarboxylic acids in high carbon yield of 85.9 % in which the carbon yield of long chain dicarboxylic (C10-C20) acids can reach 58.9% over cobalt-doped MCM-41 molecular sieves, in the absence of any solvent or precious metal catalyst. The distribution of the dicarboxylic acids can be controllably adjusted from short-chain (C4-C10) to long-chain ones (C10-C20) through changing cobalt loading of MCM-41 under nanoconfinement. Highly and sparsely dispersed cobalt along with confined space of mesoporous structure enables complete degradation of polyethylene and high selectivity of dicarboxylic acid in mild condition. So far, this is the first report on highly selective one-step preparation of long chain dicarboxylic acids. The approach provides an attractive solution to tackle plastic pollution and a promising alternative route to long chain diacids.

Mild Catalytic Degradation of Crystalline Polyethylene Units in a Solid State Assisted by Carboxylic Acid Groups

Crystalline polyethylenes bearing carboxylic acid groups in the main chain were successfully degraded with a Ce catalyst and visible light. The reaction proceeds in a crystalline solid state without swelling in acetonitrile or water at a reaction temperature as low as 60 or 80 °C, employing dioxygen in air as the only stoichiometric reactant with nearly quantitative recovery of carbon atoms. Heterogeneous features of the reaction allowed us to reveal a dynamic morphological change of polymer crystals during the degradation.

The Overlooked Potential of Sulfated Zirconia: Reexamining Solid Superacidity Toward the Controlled Depolymerization of Polyolefins

Closed-loop recycling via an efficient chemical process can help alleviate the global plastic waste crisis. However, conventional depolymerization methods for polyolefins, which compose more than 50% of plastics, demand high temperatures and pressures, employ precious noble metals, and/or yield complex mixtures of products limited to single-use fuels or oils. Superacidic forms of sulfated zirconia (SZrO) with Hammet Acidity Functions (H0) ≤ - 12 (i.e., stronger than 100% H2SO4) are industrially deployed heterogeneous catalysts capable of activating hydrocarbons under mild conditions and are shown to decompose polyolefins at temperatures near 200 °C and ambient pressure. Additionally, confinement of active sites in porous supports is known to radically increase selectivity, coking and sintering resistance, and acid site activity, presenting a possible approach to low-energy polyolefin depolymerization. However, a critical examination of the literature on SZrO led us to a surprising conclusion: despite 40 years of catalytic study, engineering, and industrial use, the surface chemistry of SZrO is poorly understood. Ostensibly spurred by SZrO's impressive catalytic activity, the application-driven study of SZrO has resulted in deleterious ambiguity in requisite synthetic conditions for superacidity and insufficient characterization of acidity, porosity, and active site structure. This ambiguity has produced significant knowledge gaps surrounding the synthesis, structure, and mechanisms of hydrocarbon activation for optimized SZrO, stunting the potential of this catalyst in olefin cracking and other industrially relevant reactions, such as isomerization, esterification, and alkylation. Toward mitigating these long extant issues, we herein identify and highlight these current shortcomings and knowledge gaps, propose explicit guidelines for characterization of and reporting on characterization of solid acidity, and discuss the potential of pore-confined superacids in the efficient and selective depolymerization of polyolefins.

The role of chemical and solvent-based recycling within a sustainable circular economy for plastics

Chemical and solvent-based recycling of plastic waste may help overcome some of the challenges faced by predominantly applied mechanical recycling techniques. This study quantifies the environmental impacts of chemical and solvent-based recycling as a function of varying process parameters and product composition using life cycle assessment. Furthermore, potential benefits and impacts on a system level are determined. To that end, a high-resolution material flow analysis is conducted for the reference system of Switzerland, covering all main plastic types and applications. In a scenario for the year 2040, we employ environmentally beneficial mechanical recycling where possible and convey suitable remaining waste streams to chemical or solvent-based recycling processes. Applying chemical or solvent-based recycling as a complement to maximum mechanical recycling, instead of thermal treatment with energy recovery, may achieve a reduction in the climate change impact of the system ranging from less than 10 % to almost 40 %. For achieving high environmental benefits, proper process choice and configuration are crucial. Dissolution or depolymerization provide higher benefits relative to other chemical recycling processes, but can only treat certain waste streams and require prior sorting into plastic types. Pyrolysis and gasification appeared to only have the ability to achieve substantial benefits over incineration if their output products can substitute high-impact chemicals and provided that efficient heat transfer and recovery is warranted when implemented on a large scale. As industrial-scale plants for chemical or solvent-based plastic recycling are still lacking, the upscaling potential and the environmental benefits achievable in practice are highly uncertain today.

Tandem oxidative and thermal cracking of polypropylene at low temperatures

Polypropylene waste was upcycled into terminal functionalized long-chain chemicals with the aid of anionic surfactants. The reaction only needs to be heated at 80 °C for 5 min by coupling exothermic oxidative cracking with endothermic thermal cracking. This work opens a new way to rapidly convert plastic waste into high-value-added chemicals under mild conditions.

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.

A review on gasification and pyrolysis of waste plastics

Gasification and pyrolysis are thermal processes for converting carbonaceous substances into tar, ash, coke, char, and gas. Pyrolysis produces products such as char, tar, and gas, while gasification transforms carbon-containing products (e.g., the products from pyrolysis) into a primarily gaseous product. The composition of the products and their relative quantities are highly dependent on the configuration of the overall process and on the input fuel. Although in gasification, pyrolysis processes also occur in many cases (yet prior to the gasification processes), gasification is a common description for the overall technology. Pyrolysis, on the other hand, can be used without going through the gasification process. The current study evaluates the most common waste plastics valorization routes for producing gaseous and liquid products, as well as the key process specifications that affected the end final products. The reactor type, temperatures, residence time, pressure, the fluidizing gas type, the flow rate, and catalysts were all investigated in this study. Pyrolysis and waste gasification, on the other hand, are expected to become more common in the future. One explanation for this is that public opinion on the incineration of waste in some countries is a main impediment to the development of new incineration capacity. However, an exceptional capability of gasification and pyrolysis over incineration to conserve waste chemical energy is also essential.

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.

Influence of the Synergistic Effect of Multi-Walled Carbon Nanotubes and Carbon Fibers in the Rubber Matrix on the Friction and Wear of Metals during the Mixing Process

As a piece of high-intensity running equipment, the wear of an internal mixer determines the quality of rubber and its life. In general, the wear of an internal mixer is caused by the friction between the rubber and metal during the mixing process, and the most severe wear position is the end face of the equipment. In this paper, a mixture of multi-walled carbon nanotubes (MWCNTs) and carbon fibers (CFs) are added to rubber by mechanical compounding to obtain MWCNT/CF/carbon black (CB) composites. By investigating the synergistic mechanism of MWCNTs and CFs, we analyze the effect of the MWCNT/CF ratio on the frictional wear of metal on the end face of the internal mixer. At the microscopic level, MWCNTs and CFs form a spatial meshwork with CB particles through synergistic interactions. The CB particles can be adsorbed on the spatial meshwork to promote the dispersion of CB particles. In addition, the formation of oil film can be slowed down due to the spatial meshwork, which could hinder the spillage of aromatic oil. Meanwhile, the spatial meshwork serves as a physical isolation layer between the rubber and metal to reduce friction. Therefore, it dramatically impacts the dispersion degree of CB particles, the friction coefficient, the roughness of the surface, and the wear of metal. It shows that the synergistic effect of MWCNT/CF and CB particles is best when the CF content of the rubber matrix is 5 phr, showing the most stable spatial network structure, the best dispersion of CB particles, and minor wear on the end face of the internal mixer.

Scaling of catalytic cracking fluidized bed downer reactor based on CFD simulations-Part II: effect of reactor scale

The practical realization of the scaling up of gas–solid multiphase flow reactors with chemical reactions is hindered by chaotic flow behaviors and complex heat and mass transfers in the reactor. In addition, a law to scale up complex reaction mechanisms in multiphase flow systems has been rarely proposed in the existing literature. Thus, this study aims to investigate the scaling up of the catalytic cracking fluidized bed downer reactor based on the similitude method of chemical reaction performance. Three downer reactor scales with a height of 5, 15, and 30 m, were investigated. To anticipate the behavior of reactive flow, a Eulerian–Eulerian CFD model, two-fluid model, was constructed, which was combined with the kinetic theory of granular flow. A four-lump kinetic model was chosen to represent the mechanism of the catalytic cracking reaction of heavy oil from the pyrolysis of waste plastic. The CFD model accurately predicted the species composition distribution. The scaling law based on the geometric similarity, kinematic similarity, and chemical reaction similarity, was proposed. The catalytic cracking performance similarity of the downer reactor was obtained. With variances in the range of 10% and mean relative absolute error less than 5%, the axial and lateral distributions of chemical performance (heavy oil conversion, gasoline mass fraction, and gasoline selectivity) were found to be extremely similar.

The modified scaling law based on the similitude method for a catalytic cracking downer reactor was proposed for various reactor scales. An excellent similarity of chemical performance of complex catalytic cracking was obtained.

Bridging Plastic Recycling and Organic Catalysis: Photocatalytic Deconstruction of Polystyrene via a C–H Oxidation Pathway

Chemical recycling of synthetic polymers represents a promising strategy to deconstruct plastic waste and make valuable products. Inspired by small-molecule C–H bond activation, a visible-light-driven reaction is developed to deconstruct polystyrene (PS) into ∼40% benzoic acid as well as ∼20% other monomeric aromatic products at 50 °C and ambient pressure. The practicality of this strategy is demonstrated by deconstruction of real-world PS foam on a gram scale. The reaction is proposed to proceed via a C–H bond oxidation pathway, which is supported by theoretical calculations and experimental results. Fluorescence quenching experiments also support efficient electron transfer between the photocatalyst and the polymer substrate, providing further evidence for the proposed mechanism. This study introduces concepts from small-molecule catalysis to polymer deconstruction and provides a promising method to tackle the global crisis of plastic pollution.

Fungal Enzymes Involved in Plastics Biodegradation

Plastic pollution is a growing environmental problem, in part due to the extremely stable and durable nature of this polymer. As recycling does not provide a complete solution, research has been focusing on alternative ways of degrading plastic. Fungi provide a wide array of enzymes specialized in the degradation of recalcitrant substances and are very promising candidates in the field of plastic degradation. This review examines the present literature for different fungal enzymes involved in plastic degradation, describing their characteristics, efficacy and biotechnological applications. Fungal laccases and peroxidases, generally used by fungi to degrade lignin, show good results in degrading polyethylene (PE) and polyvinyl chloride (PVC), while esterases such as cutinases and lipases were successfully used to degrade polyethylene terephthalate (PET) and polyurethane (PUR). Good results were also obtained on PUR by fungal proteases and ureases. All these enzymes were isolated from many different fungi, from both Basidiomycetes and Ascomycetes, and have shown remarkable efficiency in plastic biodegradation under laboratory conditions. Therefore, future research should focus on the interactions between the genes, proteins, metabolites and environmental conditions involved in the processes. Further steps such as the improvement in catalytic efficiency and genetic engineering could lead these enzymes to become biotechnological applications in the field of plastic degradation.

Pyrolysis Characteristics of Hailar Lignite in the Presence of Polyvinyl Chloride: Products Distribution and Chlorine Migration

This study investigated the effects of polyvinyl chloride (PVC) addition on low-rank coal’s pyrolysis characteristics, especially the products distribution and chlorine migration. Hailar lignite (HLE) with different industrial, pure, PVC-content additions were prepared (the mass percentage of PVC addition was from 5% to 25%), and the co-pyrolysis characteristics of HLE and PVC were performed on a fixed-bed reactor and thermogravimetric analyzer. The chars were characterized with X-ray diffraction (XRD), X-ray fluorescence (XRF), and Fourier-transform infrared (FT-IR) spectroscopy analysis. The gas and tar compositions were analyzed by using gas chromatography (GC) and a gas chromatography–mass spectrometry (GC–MS) system, respectively. The results indicate that the addition of PVC can increase the release amounts of CH4, C2H4, and C2H6, simultaneously reducing the release amount of CO2 and CO; the quality of pyrolysis tar was also improved, especially the alkane content in tar, which increased by 6.9%. The migration of chlorine in PVC was analyzed with the different PVC additions and terminal pyrolysis temperatures. It showed that the content of chlorine in the gas phase first increased with the increasing pyrolysis temperature, but at the terminal temperature of 600 °C, the chlorine in the gas phase began to decrease. The results of the co-pyrolysis char characterization show that the content of the alkali metal oxide gradually decreases in the char, and metal chloride appears during the pyrolysis process. In the co-pyrolysis reaction of coal and PVC, chlorine was fixed in the char, thereby reducing the distribution of chlorine in the gas phase. This also proves that the PVC pyrolysis process, with the participation of low-rank coal, can enrich chlorine into the solid phase, thus reducing the emission of chlorine in the gas phase.

Current Trends in Waste Plastics’ Liquefaction into Fuel Fraction: A Review

Polymers and plastics are crucial materials in many sectors of our economy, due to their numerous advantages. They also have some disadvantages, among the most important are problems with the recycling and disposal of used plastics. The recovery of waste plastics is increasing every year, but over 27% of plastics are landfilled. The rest is recycled, where, unfortunately, incineration is still the most common management method. From an economic perspective, waste management methods that lead to added-value products are most preferred—as in the case of material and chemical recycling. Since chemical recycling can be used for difficult wastes (poorly selected, contaminated), it seems to be the most effective way of managing these materials. Moreover, as a result this of kind of recycling, it is possible to obtain commercially valuable products, such as fractions for fuel composition and monomers for the reproduction of polymers. This review focuses on various liquefaction technologies as a prospective recycling method for three types of plastic waste: PE, PP and PS.

Degradation of sulfonated polyethylene by a bio-photo-fenton approach using glucose oxidase immobilized on titanium dioxide

Polyethylene (PE) plastics are highly recalcitrant and resistant to photo-oxidative degradation due to its chemically inert backbone structure. We applied two novel reactions such as, Bio-Fenton reaction using glucose oxidase (GOx) enzyme alone and Bio-Photo-Fenton reaction using GOx immobilized on TiO₂ nanoparticles (TiO₂-GOx) under UV radiation, for (bio)degradation of pre-activated PE with sulfonation (SPE). From both the reactions, GC-MS analyses identified small organic acids such as, acetic acid and butanoic acid as a major metabolites released from SPE. In the presence of UV radiation, 21 fold and 17 fold higher amounts of acetic acid (4.78 mM) and butanoic acid (0.17 mM) were released from SPE after 6 h of reaction using TiO₂-GOx than free GOx, which released 0.22 mM and 0.01 mM of acetic acid and butanoic acid, respectively. Our results suggest that (bio)degradation and valorization of naturally weathered and oxidized PE using combined reactions of biochemistry, photochemistry and Fenton chemistry could be possible.

Catalytic Pyrolysis of Polyethylene for the Selective Production of Monocyclic Aromatics over the Zinc-Loaded ZSM-5 Catalyst

The transformation of waste plastics into value-added aromatics could incentivize better waste plastic management. The reported studies had low selectivity for monocyclic aromatics because more polycyclic aromatic hydrocarbons and carbon residues were generated. The effects of temperature, pressure, and catalyst on monocyclic aromatic selectivity were explored using a central composite design (CCD) followed by the response surface methodology (RSM) at a high ramp rate of 15 °C/min. The liquid product yield and selectivity to aromatic hydrocarbons were enhanced by regulating the acidic properties of the catalyst and processing parameters. The proportion of monocyclic aromatics in the liquid product was up to 90%, and the yield of monocyclic aromatics based on the reactant mass was 51% at the optimized condition. The carbon deposit production was low (only approximately 1%), which allowed higher liquid yields. In addition, the coupling mechanism of multiple factors on the depolymerization/aromatization reactions was proposed. This conversion of polyethylene into high-yield monocyclic aromatics provides a viable plastic recycling approach.

Rubberized Geopolymer Composites: Value-Added Applications

The discovery of an innovative class of inorganic polymers has brought forth a revolution in the history of construction technology. Now, no energy-intensive reactions at elevated temperatures are essential, as found in the case of contemporary cement production. In addition to their attributes of low energy and a mitigated carbon footprint, geopolymeric composites can incorporate diversely originated and profound wastes in their manufacturing. As of today, profoundly accessible landfills of rubber tyre waste negatively impact the environment, water, and soil, with many health hazards. Their nonbiodegradable complex chemical structure supports recycling, and toxic gases are emitted by burning them, leading to aesthetic issues. These, altogether, create great concern for well-thought-out disposal methods. One of the achievable solutions is processing this waste into alternative aggregates to thus generate increased economic value whilst reducing primary aggregate consumption through the incorporation of these vast automobile solid wastes in the manufacturing of geopolymer construction composites, e.g., binders, mortar, concrete, etc., produced through the process of geopolymerization as a replacement for natural aggregates, providing relief to the crisis of the degradation of restricted natural aggregate resources. Currently, tyre rubber is one of the most outstanding materials, extensively employed in scores of engineering applications. This manuscript presents a state-of-the-art review of value-added applications in the context of rubberized geopolymer building composites and a review of past investigations. More significantly, this paper reviews rubberized geopolymer composites for their value-added applications.

The Chemical Recycling of Polyesters for a Circular Plastics Economy: Challenges and Emerging Opportunities

Whilst plastics have played an instrumental role in human development, growing environmental concerns have led to increasing public scrutiny and demands for outright bans. This has stimulated considerable research into renewable alternatives, and more recently, the development of alternative waste management strategies. Herein, the aim was to highlight recent developments in the catalytic chemical recycling of two commercial polyesters, namely poly(lactic acid) (PLA) and poly(ethylene terephthalate) (PET). The concept of chemical recycling is first introduced, and associated opportunities/challenges are discussed within the context of the governing depolymerisation thermodynamics. Chemical recycling methods for PLA and PET are then discussed, with a particular focus on upcycling and the use of metal-based catalysts. Finally, the attention shifts to the emergence of new materials with the potential to modernise the plastics economy. Emerging opportunities and challenges are discussed within the context of industrial feasibility.

High quality liquid fuel production from waste plastics via two-step cracking route in a bottom-up approach using bi-functional Fe/HZSM-5 catalyst

Plastic waste is a serious menace to the world due to its fastest growth rate of ~ 5% per annum and requires efficient technologies for its safe disposal. Plastic liquefaction producing liquid hydrocarbons is an effective way to dispose waste plastics in an eco-friendly manner. In present study, high quality liquid fuel is produced from waste plastics via two-step bottom-up cracking approach. A comparative analysis of liquid products obtained in thermal and catalytic cracking performed at relatively lower temperature (350 °C) with minimal catalyst to plastic feed ratio (1:30) has been studied. Catalytic cracking via two-step bottom-up route provides higher fraction of fuel range hydrocarbons in comparison to the thermal cracking. Catalytic cracking is performed using two different catalysts; HZSM-5 and 5%Fe/HZSM-5 in which later results in higher liquid yield (76 wt%) than former (60 wt%) having comparable fuel characteristics. GC-MS results confirm that liquid product obtained via catalytic cracking contains higher fraction of fuel range hydrocarbons (C₆-C₂₀); 66.39% for 5%Fe/HZSM-5 and 47.33% for HZSM-5 which is comparatively higher than that obtained in thermal cracking (27.39%). FT-IR, ¹H and ¹³C NMR spectroscopic studies confirm that liquid hydrocarbons obtained via catalytic cracking have comparable chemical characteristics with fuel range hydrocarbons. Physiochemical properties of catalysts are studied using XRD, XPS, BET, FE-SEM, HR-TEM, NH₃-TPD and H₂-TPR techniques and correlated with activity results. Analysis of commercial diesel fuel is also incorporated to compare the fuel characteristics of liquid products.

Plastic Waste Conversion over a Refinery Waste Catalyst

Polypropylene (PP) makes up a large share of our plastic waste. We investigated the conversion of PP over the industrial Fluid Catalytic Cracking catalyst (FCC-cat) used to produce gasoline from crude oil fractions. We studied transport limitations arising from the larger size of polymers compared to the crude oil-based feedstock by testing the components of this catalyst separately. Infrared spectroscopy and confocal fluorescence microscopy revealed the role of the FCC matrix in aromatization, and the zeolite Y domains in coking. An equilibrium catalyst (ECAT), discarded during FCC operation as waste, produced the same aromatics content as a fresh FCC-cat, while coking decreased significantly, likely due to the reduced accessibility and activity of the zeolite domains and an enhanced cracking activity of the matrix due to metal deposits present in ECAT. This mechanistic understanding provides handles for further improving the catalyst composition towards higher aromatics selectivity.

In situ catalytic reforming of plastic pyrolysis vapors using MSW incineration ashes

The valorization of municipal solid waste incineration bottom and fly ashes (IBA and IFA) as catalysts for thermochemical plastic treatment was investigated. As-received, calcined, and Ni-loaded ashes prepared via hydrothermal synthesis were used as low-cost waste-derived catalysts for in-line upgrading of volatile products from plastic pyrolysis. It was found that both IBA and air pollution control IFA (APC) promote selective production of BTEX compounds (i.e., benzene, toluene, ethylbenzene, and xylenes) without significantly affecting the formation of other gaseous and liquid species. There was insignificant change in the product distribution when electrostatic precipitator IFA (ESP) was used, probably due to the lack of active catalytic species. Calcined APC (C-APC) demonstrated further improvement in the BTEX yield that suggested the potential to enhance the catalytic properties of ashes through pre-treatment. By comparing with the leaching limit values stated in the European Council Decision, 2003/33/EC for the acceptance of hazardous waste at landfills, all the ashes applied remained in the same category after the calcination and pyrolysis processes, except the leaching of Cl^- from the ESP, which was around the borderline. Therefore, the use of ashes in catalytic reforming application do not significantly deteriorate their metal leaching behavior. Considering its superior catalytic activity towards BTEX formation, C-APC was loaded with Ni at 15 and 30 wt%. The Ni-loading favored an increase in overall oil yield, while reducing the gas yield when compared to the benchmark Ni loaded ZSM catalyst. However, Ni addition also caused the formation of more heavier hydrocarbons (C20-C35) that would require post-treatment to recover favorable products like BTEX.

Catalytic methods for chemical recycling or upcycling of commercial polymers

Polymers (plastics) have transformed our lives by providing access to inexpensive and versatile materials with a variety of useful properties. While polymers have improved our lives in many ways, their longevity has created some unintended consequences. The extreme stability and durability of most commercial polymers, combined with the lack of equivalent degradable alternatives and ineffective collection and recycling policies, have led to an accumulation of polymers in landfills and oceans. This problem is reaching a critical threat to the environment, creating a demand for immediate action. Chemical recycling and upcycling involve the conversion of polymer materials into their original monomers, fuels or chemical precursors for value-added products. These approaches are the most promising for value-recovery of post-consumer polymer products; however, they are often cost-prohibitive in comparison to current recycling and disposal methods. Catalysts can be used to accelerate and improve product selectivity for chemical recycling and upcycling of polymers. This review aims to not only highlight and describe the tremendous efforts towards the development of improved catalysts for well-known chemical recycling processes, but also identify new promising methods for catalytic recycling or upcycling of the most abundant commercial polymers.

Valorisation of plastic waste via metal-catalysed depolymerisation

Metal-catalysed depolymerisation of plastics to reusable building blocks, including monomers, oligomers or added-value chemicals, is an attractive tool for the recycling and valorisation of these materials. The present manuscript shortly reviews the most significant contributions that appeared in the field within the period January 2010–January 2020 describing selective depolymerisation methods of plastics. Achievements are broken down according to the plastic material, namely polyolefins, polyesters, polycarbonates and polyamides. The focus is on recent advancements targeting sustainable and environmentally friendly processes. Biocatalytic or unselective processes, acid–base treatments as well as the production of fuels are not discussed, nor are the methods for the further upgrade of the depolymerisation products.

Tandem Heterogeneous Catalysis for Polyethylene Depolymerization via an Olefin-Intermediate Process

The accumulation of plastic waste in the environment has prompted the development of new chemical recycling technologies. A recently reported approach employed homogeneous organometallic catalysts for tandem dehydrogenation and olefin cross metathesis to depolymerize polyethylene (PE) feedstocks to a mixture of alkane products. Here, we build on that prior work by developing a fully heterogeneous catalyst system using a physical mixture of SnPt/γ-Al2O3 and Re2O7/γ-Al2O3. This heterogeneous catalyst system produces a distribution of linear alkane products from a model, linear C20 alkane, n-eicosane, and from a linear PE substrate (which is representative of high-density polyethylene), both in an n-pentane solvent. For the PE substrate, a molecular weight decrease of 73% was observed at 200 °C in 15 h. This type of tandem chemistry is an example of an olefin-intermediate process, in which poorly reactive aliphatic substrates are first activated through dehydrogenation and then functionalized or cleaved by a highly-active olefin catalyst. Olefin-intermediate processes like that examined here offer both a selective and versatile means to depolymerize polyolefins at lower severity than traditional pyrolysis or cracking conditions.

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.

Conversion of Waste Plastic to Oils for Tribological Applications

Plastics are widely used owing to their light weight, easy production, and low cost. Even though plastics find application in different fields of industries and households, they do not degrade easily. If plastics are not disposed of appropriately, it has been shown that they cause widespread environmental pollution, which poses risks to human health. Recycling waste plastics has been an alternative to mitigating plastic pollution, which usually requires high labour costs and produces contaminated water during processing. If plastic recycling will contribute to the development of tribological products like lubricating oils, it is a safer alternative to disposing of plastics in the environment. In order to understand the tribological use of plastics by recycling, the present study reviews different techniques that can be employed to transform waste plastics into petroleum-based oils. The viscosity, density, and friction of pyrolyzed waste plastic oils are investigated and compared with commercial lubricants to assess their potential lubrication applications. The segregation processes, catalytic isomerization dewaxing, and Fischer–Tropsch method to recycle waste plastics are also reviewed to provide an insight into the methods to transform pyrolyzed waste plastic into lubricants.

Kinetic studies on the pyrolysis of plastic waste using a combination of model-fitting and model-free methods

In this work, the pyrolysis behavior of plastic waste-TV plastic shell-was investigated, based on thermogravimetric analysis and using a combination of model-fitting and model-free methods. The possible reaction mechanism and kinetic compensation effects were also examined. Thermogravimetric analysis indicated that the decomposition of plastic waste in a helium atmosphere can be divided into three stages: the minor loss stage (20-300°C), the major loss stage (300-500°C) and the stable loss stage (500-1000°C). The corresponding weight loss at three different heating rates of 15, 25 and 35 K/min were determined to be 2.80-3.02%, 94.45-95.11% and 0.04-0.16%, respectively. The activation energy (E_a) and correlation coefficient (R²) profiles revealed that the kinetic parameters calculated using the Friedman and Kissinger-Akahira-Sunose method displayed a similar trend. The values from the Flynn-Wall-Ozawa and Starink methods were comparable, although the former gave higher R² values. The E_α values gradually decreased from 269.75 kJ/mol to 184.18 kJ/mol as the degree of conversion (α) increased from 0.1 to 0.8. Beyond this range, the E_α slightly increased to 211.31 kJ/mol. The model-fitting method of Coats-Redfern was used to predict the possible reaction mechanism, for which the first-order model resulted in higher R² values than and comparable E_α values to those obtained from the Flynn-Wall-Ozawa method. The pre-exponential factors (lnA) were calculated based on the F1 reaction model and the Flynn-Wall-Ozawa method, and fell in the range 59.34-48.05. The study of the kinetic compensation effect confirmed that a compensation effect existed between E_a and lnA during the plastic waste pyrolysis.

Carbonization: A feasible route for reutilization of plastic wastes

Plastics not only bring convenience and color to human life, but also bring endless troubles and disaster to our environment. Reutilization of plastic wastes is in favor of energy conservation and emission reduction, thereby is a significant pathway of plastic wastes disposal. Carbonization is an effective way of converting polymer precursors to valuable carbon materials for use in fields of energy conversion and storage, environmental protection and restoration. Here, we present a systematic multi-perspective overview of carbonization as a feasible route of reutilization of plastic wastes. A brief summary of conventional routes for plastic wastes is followed by a brief introduction of carbonization for converting plastics to carbon materials. Special emphasis is paid on the carbonization pathways and mechanisms of common plastics. Finally, the feasibility, application prospect and challenge of carbonization as one method of reutilization of plastic wastes are proposed. By presenting a consolidated information source on different carbonization mechanisms, this review provides a valuable guideline for reutilization of plastic wastes by carbonization.

High Temperature Pyrolysis of Municipal Plastic Waste Using Me/Ni/ZSM-5 Catalysts: The Effect of Metal/Nickel Ratio

This work is dedicated to the high temperature pyrolysis of municipal plastic waste using Me/Ni/ZSM-5 catalysts. Catalysts were synthetized by wet impregnation. In addition to nickel, synthetic zeolite catalysts contain calcium, ceria, lanthanum, magnesia or manganese. Catalysts were prepared and tested using 0.1, 0.5 and 2.0 Me/Ni ratios. Catalyst morphology was investigated by SEM and surface analysis. Higher concentrations of second metals can block catalyst pore channels due to the more coke formation, which leads to smaller surface area. Furthermore, the chemicals used for the impregnation were among the catalyst grains, especially in case of 2.0 Me/Ni ratios. For pyrolysis, a horizontal tubular furnace reactor was used at 700 °C. The highest hydrogen and syngas yields were observed using ceria- and lanthanum-covered catalysts. The maximum production of syngas and hydrogen (69.8 and 49.2 mmol/g raw material) was found in the presence of Ce/Ni/ZSM-5 catalyst with a 0.5 Me/Ni ratio.

Steam reforming of polystyrene at a low temperature for high H2/CO gas with bimetallic Ni-Fe/ZrO2 catalyst

Recovery of chemicals and fuels from unrecyclable waste plastics at high temperatures (>800 °C) has received much research attention. Thermodynamic equilibrium calculation suggests that it is possible to perform the low-temperature steam reforming of polystyrene. In this study, we synthesized a Ni-Fe bimetallic catalyst for the low-temperature (500 °C) steam reforming of polystyrene. XRD characterization showed that Ni-Fe alloy was formed in the catalyst. Compared to conventional Ni catalysts, the Ni-Fe bimetallic catalysts can significantly increase the H₂/CO ratio in the produced gas with high gas production yield. The online gas analysis revealed that H₂, CO, and CO₂ were formed in the same temperature range. H₂ and CO were formed simultaneously through steam reforming reactions, and CO₂ was formed through water-gas shift reaction. New morphologies of carbon deposition on the catalyst surface were found, suggesting that wax could be condensed on the catalyst surface at a low temperature.

Catalytic fast co-pyrolysis of waste greenhouse plastic films and rice husk using hierarchical micro-mesoporous composite molecular sieve

Catalytic fast co-pyrolysis of waste greenhouse plastic films and rice husk over a hierarchical HZSM-5/MCM-41 catalyst was performed in an analytical Py-GC/MS. We evaluated the effect of pyrolysis temperature and the ratio of rice husk to waste greenhouse plastic films on the total peak area of condensable organic products and CO₂. In order to evaluate synergy possibilities among the two feedstocks, we performed non-catalytic pyrolysis and catalytic fast pyrolysis of rice husk and waste greenhouse plastic films separately. In addition, we report results for the catalytic fast co-pyrolysis of the mixture rice husk and waste greenhouse plastic films. The maximum relative content of hydrocarbons from catalytic fast co-pyrolysis of rice husk and waste greenhouse plastic films is obtained at 600 °C. When the mass ratio of rice husk to waste greenhouse plastic films is 1:1.5, the relative content of hydrocarbons reaches a maximum (71.1%). The hierarchical micro-mesoporous composite molecular sieve used in this work has outstanding catalytic activity and increases the relative content of hydrocarbons.

Modification of acidic and textural properties of a sulphated zirconia catalyst for efficient conversion of high-density polyethylene into liquid fuel

Consumption of plastic has a rapid increase of about 8% per annum and reached to 400 million per tonnes approximately, where about 50% of plastic was disposed after using only once. Different techniques for treating this increased waste faced a number of issues related to cost and environmental and sustainable development. Catalytic conversion has been found as one of the most viable solutions to solve this problem. Sulphated zirconia (SZ) catalyst modified with calcium carbide (CC) was found to improve high-density polyethylene (HDPE) conversion into liquid fuel. The liquid content was improved from 39.0wt% to 66.0wt% at 410 °C. HDPE was converted 100% by weight using, SZ/CC with 66wt% liquid yield as compared to the conversion of approximately 98wt% with about 40wt% only liquid yield for the pure SZ. The composition of hydrocarbon liquid product was significantly changed from paraffin (16%) and aromatic (58%) to olefin (74%) and naphthenic (23%) compounds. This significant increase in liquid was related to changes in the acidic and textural characteristics of the new hybrid catalyst, SZ/CC where the total ammonia desorption of 337.0 μm NH₃/g for the SZ was modified to 23.4 μm NH₃/g for the SZ/CC. Both SZ and SZ/CC catalysts showed characteristics of mesoporous material, where the internal pore volume of SZ had reduced from 0.21 mL/g for SZ to 0.04 mL/g for SZ/CC. Furthermore, XRD analysis indicated the presence of a new compound, CaZrO₃ in the SZ/CC, which confirmed a chemical interaction between the SZ and CC through sintering of ZrO₂ and CaO. Therefore, the SZ/CC catalyst improves the liquid yield significantly and the selectivity towards olefinic and naphthenic compounds.

Thermal degradation of waste plastics under non-sweeping atmosphere: Part 1: Effect of temperature, product optimization, and degradation mechanism

Continuous generation of plastic waste has prompted substantial research efforts in its utilization as a feedstock for energy generation. Pyrolysis has emerged as one of the best waste management technique for energy extraction from the plastic waste. The objective of this work is to investigate the effect of operating temperature on the liquid product yields in the pyrolysis process by non-isothermal heating. Non-catalytic thermal pyrolysis of waste polyethylene (PE) [high density polyethylene (HDPE)], waste polypropene (PP), waste polystyrene (PS), waste polyethylene terephthalate (PET) and mixed plastic waste (MPW) was carried out in a non-sweeping atmosphere in a semi-batch reactor at four different temperatures 450, 500, 550, and 600 °C. The minimum degradation temperature of the mixed and individual plastics was obtained using a thermogravimetric apparatus (TGA) at a heating rate of 20^°C/min. The TGA results show that all plastics degrade in a single step and the degradation temperatures of PS > PET > PP > HDPE, while mixed plastic degradation indicates two distinct degradation steps. Further, a waste polymer shows a lower degradation temperature than the virgin polymer. The degradation of HDPE is found to produce the maximum oil yield with minimum solid residue. The degradation of PET results in the highest amount of solid and benzoic acid as crystals and gas with no oil. Degradation of mixed plastic causes oil yield in the intermediate range of pyrolysis of individual plastic wastes. Overall, 500 °C is observed to be an optimum temperature for the recovery of low-density pyrolytic oil with the highest liquid yield. The degradation of PE and PP is found to be caused by random chain scission followed by inter and intramolecular hydrogen transfer. The degradation of PS occurs by side elimination or end chain scission followed by β-scission mechanism. The degradation of mix plastics results from random chain scission followed by β-scission mechanism. The effect of temperature on oil and gas recovery as well as recovery time was also assessed.

Hazardous waste dewatering and dry mass reduction through hydrophobic modification by a facile one-pot, alkali-assisted hydrothermal reaction

Hazardous waste dewatering is important for volume reduction and further treatment. Hazardous organic wastes with low ratio of free to bound water, and low flash point are difficult to dewater and pose an explosion risk for conventional thermal drying. Here, we develop a facile one-pot, alkali-assisted hydrothermal treatment (AHT) method for cost-efficient hazardous waste dewatering, dry mass minimization and volume reduction. Wet paint sludge (WPS), a hazardous organic waste, was reduced (79% by total weight and 52% by dry mass) by dewatering through AHT hydrophobic modification, and the product was nonflammable. Conversion of bound water to free water enhanced WPS dissolution for further decomposition. Alkali was critical for boosting ether demethylation in the solid phase, and cleavage of ethers forming alcohols that facilitated transfer of solid mass into the liquid phase. Polar functional groups were eliminated through AHT, which increased the relative abundance of hydrophobic functional groups on the surface of solid residues and promoted dewatering. We also demonstrate that AHT can be widely adapted and scaled up to treat various hazardous organic waste streams, which is of significant industrial and environmental interest.

Degradation of PVC waste into a flexible polymer by chemical modification using DINP moieties

We propose a chemical modification method to produce flexible PVC with DINP moieties.

Plastic waste as a significant threat to environment - a systematic literature review

Context Materials which exceed the balance of their production and destruction lead to the deterioration in the environment. Plastic is one such material which poses a big threat to the environment. A huge amount of plastic is produced and dumped into the environment which does not readily degrade naturally. In this paper, we address the organization of a large body of literature published on the management of waste plastics being the most challenging issue of the modern world. Objectives To address the issue of the management of waste plastics, there is a dire need to organize the literature published in this field. This paper presents a systematic literature review on plastic waste, its fate and biodegradation in the environment. The objective is to make conclusions on possible practical techniques to lessen the effects of plastic waste on the environment. Method A systematic literature review protocol was followed for conducting the present study [Kitchenham B, Brereton OP, Budgen D, Turner M, Bailey J, Linkman S. Systematic literature reviews in software engineering - A systematic literature review. Inf Softw Technol 2009;51(1):7-15.]. A predefined set of book sections, conference proceedings and high-quality journal publications during the years 1999 to September 2017 were used for data collection. Results One hundred and fifty-three primary studies are selected, based on predefined exclusion, inclusion and quality criteria. These studies will help to identify the fate of different waste plastics, their impact and management and the disposal techniques frequently used. The study also identifies a number of significant techniques and measures for the conversion of waste plastic materials into useful products. Conclusion Five fundamental strategies are used for the handling of plastic waste. These strategies include: recycling, depositing in landfill, incineration, microbial degradation and conversion into useful materials. All of these methods have their own limitations, due to which there is need to explore the studies for optimum solutions of the management of plastics waste.