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

Recent advances in liquid fuel production from plastic waste via pyrolysis: Emphasis on polyolefins and polystyrene

The management of plastic waste (PW) has become an indispensable worldwide issue because of the enhanced accumulation and environmental impacts of these waste materials. Thermo-catalytic pyrolysis has been proposed as an emerging technology for the valorization of PW into value-added liquid fuels. This review provides a comprehensive investigation of the latest advances in thermo-catalytic pyrolysis of PW for liquid fuel generation, by emphasizing polyethylene, polypropylene, and polystyrene. To this end, the current strategies of PW management are summarized. The various parameters affecting the thermal pyrolysis of PW (e.g., temperature, residence time, heating rate, pyrolysis medium, and plastic type) are discussed, highlighting their significant influence on feed reactivity, product yield, and carbon number distribution of the pyrolysis process. Optimizing these parameters in the pyrolysis process can ensure highly efficient energy recovery from PW. In comparison with non-catalytic PW pyrolysis, catalytic pyrolysis of PW is considered by discussing mechanisms, reaction pathways, and the performance of various catalysts. It is established that the introduction of either acid or base catalysts shifts PW pyrolysis from the conventional free radical mechanism towards the carbonium ion mechanism, altering its kinetics and pathways. This review also provides an overview of PW pyrolysis practicality for scaling up by describing techno-economic challenges and opportunities, environmental considerations, and presenting future outlooks in this field. Overall, via investigation of the recent research findings, this paper offers valuable insights into the potential of thermo-catalytic pyrolysis as an emerging strategy for PW management and the production of liquid fuels, while also highlighting avenues for further exploration and development.

Catalytic pyrolysis of harmful plastic waste to alleviate environmental impacts

Wax is a detrimental byproduct of plastic waste pyrolysis causing challenges upon its release into the environment owing to persistence and potential toxicity. In this study, the valorization of wax materials through conversion into BTEX (i.e., benzene, toluene, ethylbenzene, and xylene) was achieved via catalytic pyrolysis using zeolite-based catalysts. The potential of two types of waxes, spent wax (SW), derived from the pyrolysis of plastic waste, and commercial paraffin wax (PW), for BTEX generation, was investigated. Using HZSM-5, higher yields of oil (54.9 wt%) and BTEX (18.2 wt%) were produced from the pyrolysis of SW compared to PW (32.3 and 14.1 wt%, respectively). This is due to the improved accessibility of lighter hydrocarbons in SW to Brønsted and Lewis acid sites in HZSM-5 micropores, promoting cracking, isomerization, cyclization, Diels-Alder, and dehydrogenation reactions. Further, the use of HZSM-5 resulted in significantly larger yields of oil and BTEX from SW pyrolysis compared to Hbeta and HY. This phenomenon is ascribed to the well-balanced distribution of Brønsted and Lewis acid sites and the identical geometric structure of HZSM-5 micropores and BTEX molecules. The addition of Ga to HZSM-5 further led to 2.24% and 28.30% enhancements in oil and BTEX yields, respectively, by adjusting the acidity of the catalyst through the introduction of new Lewis acid sites. The regeneration of the Ga/HZSM-5 catalyst by removing deposited coke on the spent catalyst under air partially recovered catalytic activity. This study not only offers an efficient transformation of undesirable wax into valuable fuels but also provides an environmentally promising solution, mitigating pollution, contributing to carbon capture, and promoting a healthier and more sustainable environment. It also suggests future research directions, including catalyst optimization and deactivation management, feedstock variability exploration, and techno-economic analyses for sustainable wax conversion into BTEX via catalytic pyrolysis.

Comparison of the Effect of Kaolin and Bentonite Clay (Raw, Acid-Treated, and Metal-Impregnated) on the Pyrolysis of Waste Tire

This study investigates the effectiveness of kaolin and bentonite catalysts in improving liquid hydrocarbon yields during the pyrolysis of waste tires. Raw clay, nitric acid-treated clay, and mono- or bimetal-impregnated clay were used as catalysts in the pyrolysis of waste tire. Acid-treated kaolin produced a higher yield of liquid hydrocarbons (43.24-47%) compared to acid-treated bentonite (35.34-41.85%). This improvement in the liquid yield can be attributed to the higher specific surface area and pore diameter of the acid-treated clay in comparison to raw kaolin (39.48%) and raw bentonite (31.62%). Moreover, the use of metal-impregnated catalysts, such as Fe/kaolin and Ni/Fe/kaolin, resulted in higher liquid yields (47%) compared to the 3 M HNO3-treated kaolin catalyst (43.24%). Gas chromatography-mass spectrometry (GC-MS) analysis confirmed the presence of limonene, a crucial ingredient for commercial perfume production, in the liquid products. The calorific values of oil obtained through kaolin and bentonite catalysis were measured at 13,922 and 10,174 kcal/kg, respectively, further highlighting the potential of these catalysts in waste tire valorization.

Catalytic fabrication of graphene, carbon spheres, and carbon nanotubes from plastic waste

In this study, we reported sustainable and economical upcycling methods for utilizing plastics such as polyethylene terephthalate (PET) and polypropylene (PP) compiled from the garbage of a residential area as cheap precursors for the production of high-value carbon materials such as graphene (G), carbon spheres (CS), and carbon nanotubes (CNTs) using different thermal treatment techniques. Graphene, carbon spheres, and carbon nanotubes were successfully synthesized from PET, PP, and PET, respectively via catalytic pyrolysis. XRD and FTIR analyses were conducted on the three materials, confirming the formation of carbon and their graphitic structure. TEM images displayed uniform and consistent morphological structures of the fabricated materials. EDX data confirmed that the prepared carbon-based materials only contained carbon and oxygen without any significant contaminations. XPS results revealed significant peaks in the C 1s spectra associated with sp2 and sp3 hybridized carbon for the three materials. BET spectra showed that the prepared CNTs (54.872 m2 g-1) have the highest surface area followed by carbon spheres (54.807 m2 g-1). The thermal stability of graphene surpassed both carbon spheres and carbon nanotubes which is mainly attributed to the stronger inter-molecular bonds of graphene. Based on the characterization of the prepared materials, these materials are promising to be utilized in environmental remediation applications due to their high carbon content, low cost, and high surface area.

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.

Conversion of polypropylene-derived crude pyrolytic oils using hydrothermal autoclave reactor and ni/aceh natural zeolite as catalysts

The accumulation of plastic waste has urged researchers to develop methods of waste conversion into valuable products, which is fuel. This study aimed to synthesize Ni embedded onto Aceh natural zeolite (Ni/Aceh-zeolite) as a cheap catalyst which could be used in the reforming process to improve the quality of oil produced from polypropylene (PP) pyrolysis. Ni/Aceh-zeolite was synthesized from Ni(NO₃)₂·6H₂O and acid-activated natural zeolite through impregnation and calcination. The catalyst was found to have particle sizes ranging from 100 to 200 nm of 20 wt% Ni content. The reforming process using Ni/Aceh natural zeolite with Ni loading of 15 wt% yielded the highest amounts of liquid product (yield = 65%) and gasoline fractions (C₅-C₁₂, 96.71%). However, the highest high heating value of 45.467 MJ/kg was found in the liquid product obtained with 20% Ni/Aceh-zeolite. In conclusion, Ni/Aceh-zeolite could be used in the reforming process of PP pyrolysis-derived oil, which could reach a quality similar to that of commercial gasoline.

Pyrolysis Combined with the Dry Reforming of Waste Plastics as a Potential Method for Resource Recovery—A Review of Process Parameters and Catalysts

Emissions of greenhouse gases and growing amounts of waste plastic are serious environmental threats that need urgent attention. The current methods dedicated to waste plastic recycling are still insufficient and it is necessary to search for new technologies for waste plastic management. The pyrolysis-catalytic dry reforming (PCDR) of waste plastic is a promising pro-environmental way employed for the reduction of both CO2 and waste plastic remains. PCDR allows for resource recovery, converting carbon dioxide and waste plastics into synthetic gas. The development and optimization of this technology for the high yield of high-quality synthesis gas generation requires the full understanding of the complex influence of the process parameters on efficiency and selectivity. In this regard, this review summarizes the recent findings in the field. The effect of process parameters as well as the type of catalyst and feedstock are reviewed and discussed.

Pyrolysis of RDF and Catalytic Decomposition of the Produced Tar in a Char Bed Secondary Reactor as an Efficient Source of Syngas

One of the technical limitations of refuse-derived fuel (RDF) pyrolysis is the high content of tar in its gas products. In order to resolve this problem, a two-stage RDF pyrolysis with a catalyst based on char from RDF pyrolysis is proposed. This paper presents the results of municipal waste pyrolysis beginning in an oven heated to 480 °C and ending with catalytic tar cracking carried out in the temperature range from 800 to 1000 °C. Thermal and catalytic pyrolysis with a char catalyst containing a minimum of 6% Fe resulted in increases in the CO and H2 contents in gas products and decreases in CO2 and CH4. At 1000 °C, the mass ratio of gaseous products to liquids was greater than 6. The residence time of the gases in the catalytic zone was about 3–5 s. The reactor was a good source of hydrogen and carbon monoxide.

Progress on Catalyst Development for the Steam Reforming of Biomass and Waste Plastics Pyrolysis Volatiles: A Review

In recent decades, the production of H₂ from biomass, waste plastics, and their mixtures has attracted increasing attention in the literature in order to overcome the environmental problems associated with global warming and CO₂ emissions caused by conventional H₂ production processes. In this regard, the strategy based on pyrolysis and in-line catalytic reforming allows for obtaining high H₂ production from a wide variety of feedstocks. In addition, it provides several advantages compared to other thermochemical routes such as steam gasification, making it suitable for its further industrial implementation. This review analyzes the fundamental aspects involving the process of pyrolysis-reforming of biomass and waste plastics. However, the optimum design of transition metal based reforming catalysts is the bottleneck in the development of the process and final H₂ production. Accordingly, this review focuses especially on the influence the catalytic materials (support, promoters, and active phase), synthesis methods, and pyrolysis-reforming conditions have on the process performance. The results reported in the literature for the steam reforming of the volatiles derived from biomass, plastic wastes, and biomass/plastics mixtures on different metal based catalysts have been compared and analyzed in terms of H₂ production.