Recent Progress in Low-Cost Catalysts for Pyrolysis of Plastic Waste to Fuels

Polyethylene terephthalate conversion into liquid fuel by its co-pyrolysis with low- and high-density polyethylene employing scrape aluminium as catalyst

The co-pyrolysis of polyethylene terephthalate (PET) with low-density polyethylene (LDPE) and high-density polyethylene (HDPE) was carried out in a batch steel pyrolyzer in order to convert the PET into pyrolysis oil as its pyrolysis alone resulted in wax and gases. The study also aimed to increase the aromatic content of pyrolysis oil by the interaction of degradation fragments of linear chains of LDPE and HDPE with the benzene ring of PET during the pyrolysis. The reaction conditions were optimized for a higher yield of pyrolysis oil which were found to be 500 °C pyrolysis temperature with a heating rate of 0.5 °Cs-1, 1 h reaction time and 20 g of the initial mass of polymer mixture having 20% PET, 40% LDPE and 40% HDPE. Waste aluminium particles were applied as an economical catalyst in the process. The thermal co-pyrolysis yielded 8% pyrolysis oil, 32.3 wax, 39.7 wt% gases and 20% coke while the catalytic co-pyrolysis produced 30.2% pyrolysis oil, 4.2% wax, 53.6 wt% gases and 12% coke. The fractional distillation of catalytic oil resulted in 46% gasoline range oil, 31% kerosene range oil and 23% diesel range oil. These fractions resembled the standard fuels in terms of their fuel properties as well as FT-IR spectra. The GC-MS analysis revealed that the catalytic co-pyrolysis favoured the formation of relatively short-chain hydrocarbons with olefins and isoparaffins as major components while the thermal co-pyrolysis formed long-chain paraffins. The naphthenes and aromatics were also found in higher amounts in the catalytic oil compared with the thermal oil.

Catalytic flash pyrolysis for recovery of gasoline-range hydrocarbons from electric cable residue using a low-cost natural catalyst: An analytical Py-GC/MS study

This investigation's novelty and objective reside in exploring catalytic flash pyrolysis of cross-linked polyethylene (XLPE) plastic residue in the presence of kaolin, with the perspective of achieving sustainable production of gasoline-range hydrocarbons. Through proximate analysis, thermogravimetric analysis, and heating value determination, this study also assessed the energy-related characteristics of cross-linked polyethylene plastic residue, revealing its potential as an energy source (44.58 MJ kg-1) and suitable raw material for pyrolysis due to its low ash content and high volatile matter content. To understand the performance as a low-cost catalyst in the flash pyrolysis of cross-linked polyethylene plastic residue, natural kaolin was subjected to characterization through thermogravimetric analysis, X-ray diffractometry (XRD), Fourier transform infrared spectroscopy (FTIR), and X-ray fluorescence (XRF). Cross-linked polyethylene plastic residue was subjected to thermal and catalytic pyrolysis in an analytical microreactor coupled to gas chromatography-mass spectrometry (Py-GC/MS system), operating at 500 °C, to characterize the distribution and composition of volatile reaction products. The application of kaolin as a catalyst resulted in a decline of the relative concentration of hydrocarbons in the diesel range (C8-C24) from approximately 87 % to 28 %, and a reduction in lubricating oils (C14-C50) from about 70 % to 13 %, while concomitantly increasing the relative concentration of lighter hydrocarbons in the gasoline range (C8-C12) from around 28 % to 87 %. Therefore, catalytic flash pyrolysis offers the potential for converting this plastic waste into a new and abundant chemical source of gasoline-range hydrocarbons. This process can be deemed viable and sustainable for managing and valorizing cross-linked polyethylene plastic residue.

Microwave-Assisted Catalytic Deconstruction of Plastics Waste into Nanostructured Carbon and Hydrogen Fuel Using Composite Magnetic Ferrite Catalysts

Finding new catalysts and pyrolysis technologies for efficiently recycling wasted plastics into fuels and structured solid materials of high selectivity is the need of time. Catalytic pyrolysis is a thermochemical process that cracks the feedstock in an inert gas environment into gaseous and liquid fuels and a residue. This study is conducted on microwave-assisted catalytic recycling of wasted plastics into nanostructured carbon and hydrogen fuel using composite magnetic ferrite catalysts. The composite ferrite catalysts, namely, NiZnFe2O4, NiMgFe2O4, and MgZnFe2O4 were produced through the coprecipitation method and characterized for onward use in the microwave-assisted valorization of wasted plastics. The ferrite nanoparticles worked as a catalyst and heat susceptor for uniformly distributed energy transfer from microwaves to the feedstock at a moderate temperature of 450°C. The type of catalyst and the working parameters significantly impacted the process efficiency, gas yield, and structural properties of the carbonaceous residue. The tested process took 2-8 minutes to pulverize feedstock into gas and carbon nanotubes (CNTs), depending on the catalyst type. The NiZnFe2O4-catalyzed process produced CNTs with good structural properties and fewer impurities compared to other catalysts. The NiMgFe2O4 catalyst performed better in terms of hydrogen evolution by showing 87.5% hydrogen (H2) composition in the evolved gases. Almost 90% of extractable hydrogen from the feedstock evolved during the first 2 minutes of the reaction.

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

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

In-depth analysis of the effect of catalysts on plasma technologies for treatment of various wastes

Energy security and waste management are gaining global attention. The modern world is producing a large amount of liquid and solid waste as a result of the increasing population and industrialization. A circular economy encourages the conversion of waste to energy and other value-added products. Waste processing requires a sustainable route for a healthy society and clean environment. One of the emerging solutions for waste treatment is plasma technology. It converts waste into syngas, oil, and char/slag depending on the thermal/non-thermal processes. Most of all the types of carbonaceous wastes can be treated by plasma processes. The addition of a catalyst to the plasma process is a developing field as plasma processes are energy intensive. This paper covers the detailed concept of plasma and catalysis. It comprises various types of plasma (non-thermal and thermal) and catalysts (zeolites, oxides, and salts) which have been used for waste treatment. Catalyst addition improves gas yield and hydrogen selectivity at moderate temperatures. Depending on the properties of the catalyst and type of plasma, comprehensive points are listed for the selection of the right catalyst for a plasma process. This review offers an in-depth analysis of the research in the field of waste-to-energy using plasma-catalytic processes.

Life-Cycle Assessment of the thermal and catalytic pyrolysis over sepiolite of face masks

Since the start of the global COVID-19 pandemic, extensive quantities of face masks have been used and discarded. Most of these masks end up in landfills, causing a high environmental impact and no benefits. However, there are alternative ways to deal with this waste in a more sustainable way. For example, valorisation of face masks through pyrolysis has received special attention because it offers efficient application to produce a liquid oil that can be used as a diesel substitute and a solid char that can be used as an activated carbon substitute after activation. In this context, this study applies the Life-Cycle Assessment methodology to quantify and analyse the environmental impacts of different treatment scenarios based on the pyrolysis of surgical masks and FFP2 masks. It also compares their environmental performance with the conventional practice of landfilling. The scenarios studied include both thermal and catalytic pyrolysis by using sepiolite, a low-cost material abundant in Spain. Data on the pyrolysis process were obtained from laboratory experiments. It was found that the use of the produced oil as a diesel substitute very significantly reduces the environmental impact in all pyrolysis scenarios. Consequently, the pyrolysis of face masks can reduce the environmental impact caused by the treatment of this waste material. Furthermore, the thermal pyrolysis performs environmentally better than the catalytic pyrolysis. In all scenarios, freshwater ecotoxicity and marine ecotoxicity are the environmental impact categories that cause the highest environmental impact overall.

Synthesis and Application of ZSM-5 Catalyst Supported with Zinc and/or Nickel in the Conversion of Pyrolytic Gases from Recycled Polypropylene and Polystyrene Mixtures under Hydrogen Atmosphere

Currently, catalytic pyrolysis has become a versatile and highly useful technology in the treatment of different plastic wastes. Thus, the development of selective catalysts to carry out cracking reactions and obtain a greater fraction of the desired products is essential. This study focuses on the synthesis of monometallic (Ni) and bimetallic (Ni-Zn) catalysts supported on ZSM-5 zeolite using an impregnation and co-impregnation method, respectively. The obtained catalysts were characterized by FTIR spectroscopy, N2 adsorption/desorption measurements, scanning electron microscopy (SEM) and energy dispersive X-Ray spectroscopy (EDS), temperature programmed NH3 desorption (TPD-NH3) and thermogravimetric analysis (TGA). In this way, a mixture of polystyrene and polypropylene recycled with a catalyst/plastic waste ratio of 1:500 was used for pyrolysis tests. The best results were obtained using the Ni-Zn/ZSM-5 catalyst, which included better impregnation, increased surface acidity, decreased dispersion and a shorter reaction time in the catalytic pyrolysis process. Under the optimized conditions, catalytic pyrolysis showed an excellent performance to generate hydrocarbons of greater industrial interest.

Catalytic pyrolysis of waste polypropylene using low-cost natural catalysts

The objective of this research is to produce oil from the catalytic pyrolysis of waste polypropylene (WPP) using a low-cost natural catalyst. Three natural catalysts were examined, i.e. Kaolin, Hematite, and white sand. Different catalyst-to-plastic ratios were examined, i.e. 1:1, 1:2, 1:4, 1:6, and 1:8. The utilized catalysts were elementally analyzed using the XRF analysis and the surface area was analyzed by the BET multi-point method. The WPP thermal degradation behavior was investigated by the thermogravimetric analysis (TGA), then the generated liquid oil was analyzed using the gas chromatography-mass spectrometry (GC-MS) and the differential scanning calorimetry (DSC). Thermal cracking without a catalyst produced a yield of 70 wt% of liquid oil, and the maximum oil yield in case of using Hematite and white sand as a catalysts were 70 wt% and 68 wt%, respectively. However, the ratio of 1:2 of the Kaolin to the WPP produced the highest oil yield of 80.75 wt%, and the ratio of 1:8 of the white sand to the WPP produced the highest gas yield, i.e. 44 wt%. Using Kaolin in the catalytic pyrolysis of WPP produced oil with the lowest percentage of heavy oils, i.e. 25.98%, and the highest percentage of light oils, which is 25.37%, when compared to other catalysts such as Hematite and white sand. Kaolin has the lowest cost of oil production compared to Hematite and white sand, which is 0.28 $/kg of oil. Kaolin is an economical catalyst that improves the quality, as well as the quantity of the produced oil in comparison to Hematite, white sand and the non-catalytic case.

The clean energy aspect of plastic waste - hydrogen gas production, CO2 reforming, and plastic waste management coincide with catalytic pyrolysis - an extensive review

Clean hydrogen has future fuel capable of receiving an abundance of carbon-neutral energy from hydrogen. In the recent world, new hydrogen affirmation projects have been launched for a green environment. On another side, plastic waste and CO2 threaten the green environment. Vacuum in plastic waste management, plastic waste leads to exhibiting harmful chemicals to the environment. The growth rate of the CO2 concentration in air is 2.45 ppm per year, steadily increasing in 2022. It is realized that uneven climate change, temperature raising the global level, ocean mean level raising, and frequent acidification are dangerous to living and ecosystems. This review discussed tackling multiple harmful environmental fatly by pyrolysis techniques; catalytic pyrolysis is almost reaching the commercialization stage. Recent pyrolysis upgradation methods with hydrogen gas production and the continuous development and execution of sustainable solutions for plastic waste management and CO2 reforming are discussed. Production of carbon nanotubes by plastic waste, the importance of catalyst modification, and the effect of catalyst deactivation are discussed. From this study, integrating the different applications with catalytic modification creates room for multipurpose pyrolysis, CO2 reforming, and hydrogen gas production by pyrolysis techniques capable of giving a sustainable solution for climate change issues and a clean environment. Additionally, carbon utilization by way of carbon nanotube production is also done. Overall, the review supports achieving clean energy from plastic waste.

A Review on Catalytic Fast Co-Pyrolysis Using Analytical Py-GC/MS

Py-GC/MS combines pyrolysis with analytical tools of gas chromatography (GC) and mass spectrometry (MS) and is a quick and highly effective method to analyse the volatiles generated from small amounts of feeds. The review focuses on using zeolites and other catalysts in the fast co-pyrolysis of various feedstocks, including biomass wastes (plants and animals) and municipal waste materials, to improve the yield of specific volatile products. The utilisation of zeolite catalysts, including HZSM-5 and nMFI, results in a synergistic reduction of oxygen and an increase in the hydrocarbon content of pyrolysis products. The literature works also indicate HZSM-5 produced the most bio-oil and had the least coke deposition among the zeolites tested. Other catalysts, such as metals and metal oxides, and feedstocks that act as catalysts (self-catalysis), such as red mud and oil shale, are also discussed in the review. Combining catalysts, such as metal oxides and HZSM-5, further improves the yields of aromatics during co-pyrolysis. The review highlights the need for further research on the kinetics of the processes, optimisation of feed-to-catalyst ratios, and stability of catalysts and products.

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.

Upcycling face mask wastes generated during COVID-19 into value-added engineering materials: A review

Billions of disposable face masks (i.e., single-use masks) are used and discarded worldwide monthly due to the COVID-19 outbreak. The immethodical disposal of these polymer-based wastes containing non-biodegradable constituents (e.g., polypropylene) has provoked marked and severe damage to the ecosystem. Meanwhile, their ever-growing usage significantly strains the present-day waste management measures such as landfilling and incineration, resulting in large quantities of used face-covering masks landing in the environment as importunate contaminants. Hence, alternative waste management strategies are crucially demanded to decrease the negative impacts of face mask contamination. In this venue, developing high-yield, effective, and green routes toward recycling or upcycling face mask wastes (FMWs) into value-added materials is of great importance. While existing recycling processes assist the traditional waste management, they typically end up in materials with downgraded physicochemical, structural, mechanical, and thermal characteristics with reduced values. Therefore, pursuing potential economic upcycling processes would be more beneficial than waste disposal and/or recycling processes. This paper reviews recent advances in the FMWs upcycling methods. In particular, we focus on producing value-added materials via various waste conversion methods, including carbonization (i.e., extreme pyrolysis), pyrolysis (i.e., rapid carbonization), catalytic conversion, chemical treatment, and mechanical reprocessing. Generally, the upcycling methods are promising, firming the vital role of managing FMWs' fate and shedding light on the road of state-of-the-art materials design and synthesis.

Recent Advances in Catalytic Pyrolysis of Municipal Plastic Waste for the Production of Hydrocarbon Fuels

Currently, the resources of fossil fuels, such as crude oil, natural gas, and coal, are depleting day by day due to increasing energy demands. Nowadays, plastic items have witnessed a substantial surge in manufacturing due to their wide range of applications and low cost. Therefore, the amount of plastic waste is increasing rapidly. Hence, the proper management of plastic wastes for sustainable technologies is the need of the hour. Chemical recycling technologies based on pyrolysis are emerging as the best waste management approaches due to their robustness and better economics. However, research on converting plastic waste into fuels and other value-added goods has yet to be undertaken, and more R&D is required to make waste-plastic-based fuels economically viable. In this review article, the current status of the plastic waste pyrolysis process is discussed in detail. Process-controlling parameters such as temperature, pressure, residence time, reactor type, and catalyst dose are also investigated in this review paper. In addition, the application of reaction products is also described in brief. For example, plasto-oil obtained by catalytic pyrolysis may be utilized in various sectors, e.g., transportation, industrial boilers, and power generation. On the other hand, byproducts, such as solid residue (plasto-char), could be used as a road construction material or to make activated carbon or graphenes, while the non-condensable gases have a good potential to be utilized as heating/energy source.

Understanding the Iron-Cobalt Synergies in ZSM-5: Enhanced Peroxymonosulfate Activation and Organic Pollutant Degradation

Iron- and cobalt-based heterogeneous catalysts are widely applied for activating peroxymonosulfate (PMS) to degrade organic pollutants. However, few studies have unveiled the clear synergistic mechanism of iron and cobalt in ZSM-5. In this paper, the synergistic mechanism of enhanced PMS activation was revealed by constructing iron and cobalt bimetal modified ZSM-5 zeolite catalysts (FeCo-ZSM-5). The tetracycline hydrochloride (TCH) degradation experiments showed that the catalytic activity of FeCo-ZSM-5-2:3 was much higher than those of Fe-ZSM-5 and Co-ZSM-5. In addition, the influences of catalyst dosage, PMS concentration, reaction temperature, initial pH, and coexisting ions on TCH removal were systematically investigated in this paper. Density functional theory calculations indicated that Co was the main active site for PMS adsorption, and Fe increased the area of Co's positive potential mapped to the electron cloud. The Fe-Co bimetallic doping increased the area of positive potential mapped to the electron cloud and benefited the adsorption of PMS on the catalyst surface, which revealed the synergistic mechanism of bimetals. Electron paramagnetic resonance spectra and quenching experiments showed that sulfate radicals, singlet oxygen, and hydroxyl radicals were involved in the degradation of TCH. Furthermore, liquid chromatography-mass spectrometry was conducted to propose possible degradation pathways. This work provides certain guiding significance in understanding the synergistic effect of heterogeneous catalysts for tetracycline wastewater treatment.

Thermocatalytic Conversion of Plastics into Liquid Fuels over Clays

Recycling polymer waste is a great challenge in the context of the growing use of plastics. Given the non-renewability of fossil fuels, the task of processing plastic waste into liquid fuels seems to be a promising one. Thermocatalytic conversion is one of the methods that allows obtaining liquid products of the required hydrocarbon range. Clays and clay minerals can be distinguished among possible environmentally friendly, cheap, and common catalysts. The moderate acidity and the presence of both Lewis and Brønsted acid sites on the surface of clays favor heavier hydrocarbons in liquid products of reactions occurring in their pores. Liquids produced with the use of clays are often reported as being in the gasoline and diesel range. In this review, the comprehensive information on the thermocatalytic conversion of plastics over clays obtained during the last two decades was summarized. The main experimental parameters for catalytic conversion of plastics according to the articles’ analysis, were the reaction temperature, the acidity of modified catalysts, and the catalyst-to-plastic ratio. The best clay catalysts observed were the following: bentonite/spent fluid cracking catalyst for high-density polyethylene (HDPE); acid-restructured montmorillonite for medium-density polyethylene (MDPE); neat kaolin powder for low-density polyethylene (LDPE); Ni/acid-washed bentonite clay for polypropylene (PP); neat kaolin for polystyrene (PS); Fe-restructured natural clay for a mixture of polyethylene, PP, PS, polyvinyl chloride (PVC), and polyethylene terephthalate (PET). The main problem in using natural clays and clay minerals as catalysts is their heterogeneous composition, which can vary even within the same deposit. The serpentine group is of interest in studying its catalytic properties as fairly common clay minerals.

Conversion of plastic waste into fuels: A critical review

Plastic wastes have posed serious threats to the environment, including decrease of soil nutrient effectiveness and agricultural production as well as emerge of ecological instability. Fuel conversion from plastic waste is regarded as a promising strategy for its disposal and energy utilization. Plastic wastes can be converted into target fuels by adjusting cracking of chemical bonds. Currently, numerous technologies regarding fuel conversion from plastic wastes have been reported, including conventional pyrolysis, novel heat treatment and advanced oxidation. However, systematic summary and comparative analysis of different technologies are still scarcely reported. In this review, fuel conversion from plastic wastes was summarized comprehensively, highlighting novel heat treatment and advanced oxidation technologies reported in recent years. Furthermore, the superiority and drawbacks of each technology were analyzed, and future prospects of technology application were proposed. With lower reaction temperature and higher-value fuel, novel heat treatment of plastics is more popular than traditional one. Advanced oxidation can be controlled to convert plastics into fuels under room temperature and pressure, guiding the new normal in energy utilization of plastic wastes. This review aims to provide inspiration for energy utilization of solid waste, addressing the issues of white pollution and energy shortage.

Recent Trends in the Pyrolysis of Non-Degradable Waste Plastics

Waste plastics are non-degradable constituents that can stay in the environment for centuries. Their large land space consumption is unsafe to humans and animals. Concomitantly, the continuous engineering of plastics, which causes depletion of petroleum, poses another problem since they are petroleum-based materials. Therefore, energy recovering trough pyrolysis is an innovative and sustainable solution since it can be practiced without liberating toxic gases into the atmosphere. The most commonly used plastics, such as HDPE, LDPE (high- and low-density polyethylene), PP (polypropylene), PS (polystyrene), and, to some extent, PC (polycarbonate), PVC (polyvinyl chloride), and PET (polyethylene terephthalate), are used for fuel oil recovery through this process. The oils which are generated from the wastes showed caloric values almost comparable with conventional fuels. The main aim of the present review is to highlight and summarize the trends of thermal and catalytic pyrolysis of waste plastic into valuable fuel products through manipulating the operational parameters that influence the quality or quantity of the recovered results. The properties and product distribution of the pyrolytic fuels and the depolymerization reaction mechanisms of each plastic and their byproduct composition are also discussed.