Dechlorination of polyvinyl chloride electric wires by hydrothermal treatment using K2CO3 in subcritical water

A low-temperature co-treatment of diethylhexyl phthalate-rich polyvinyl chloride and waste copper catalyst by subcritical water (hydrothermal treatment): Dechlorination, recovery of diethylhexyl phthalate and copper

As one of the most widespread plastics in the world, the recycling of diethylhexyl phthalate-rich polyvinyl chloride (DEHP-rich PVC) faces great challenges because of the high levels of Cl and plasticizers. On the other hand, waste copper catalyst (WCC) discharged from various industrial processes is not effectively recycled. In this study, a significant synergistic effect between the DEHP-rich PVC and WCC was found in a subcritical water (SubCW) medium, and a co-treatment of the DEHP-rich PVC and WCC was developed by the SubCW process. The introduction of WCC significantly improved the dechlorination efficiency of the DEHP-rich PVC to 96.03 % at a low temperature of 250 °C. Under the optimal conditions, the leaching of copper from WCC reached a maximum of 81.08 %. Oil products included DEHP (55.7 %, GC peak area%), 3-methyl-3-heptene (37.3 %, GC peak area%), and 2-ethyl-1-hexanol (7.0 %, GC peak area%). The dechlorination pathways of the DEHP-rich PVC included hydroxyl substitution and direct dechlorination. HCl released from the DEHP-rich PVC led to a decrease in the pH of the system and significant copper leaching from the WCC. DEHP was decomposed by hydrolysis, dehydration, and rearrangement reaction by the SubCW co-treatment process. The enhancement mechanism of the WCC for the dechlorination of the DEHP-rich PVC was based on that the conversion of copper species in the SubCW promoted the formation of hydroxyl radicals and the hydroxyl substitution for chlorine in PVC molecular chain. The proposed SubCW low-temperature co-treatment could be a prospective strategy for the low-energy and synchronous recovery of the two different wastes of the DEHP-rich PVC and WCC.

Acidic process fluid from hydrothermal carbonization improves dechlorination of waste PVC and produces clean solid and liquid fuels

Dechlorination of waste PVC (WPVC) by hydrothermal treatment (HTT) is a potential technology for upcycling WPVC in order to create non-toxic products. Literature suggests that acids can improve the HTT process, however, acid is expensive and also results in wastewater. Instead, the acidic process fluid (PF) of hydrothermal carbonization (HTC) of orange peel was utilized in this study to enhance the dechlorination of WPVC during HTT. Acidic HTT (AHTT) experiments were carried out utilizing a batch reactor at 300-350 °C, and 0.25-4 h. The finding demonstrated that the dechlorination efficiency (DE) is high, which indicates AHTT can considerably eliminate chlorine from WPVC and relocate to the aqueous phase. The maximum DE of 97.57 wt% was obtained at 350 °C and 1 h. The AHTT temperature had a considerable impact on the WPVC conversion since the solid yield decreases from 56.88 % at 300 °C to 49.85 % at 350 °C. Moreover, AHTT char and crude oil contain low chloride and considerably more C and H, leading to a considerably higher heating value (HHV). The HHV increased from 23.48 to 33.07 MJ/kg when the AHTT time was raised from 0.25 to 4 h at 350 °C, indicating that the AHTT time has a beneficial effect on the HHV. The majority fraction of crude oil evaporated in the boiling range of lighter fuels include gasoline, kerosene, and diesel (57.58-83.09 wt%). Furthermore, when the AHTT temperature was raised from 300 to 350 °C at 1 h, the HHV of crude oils increased from 26.11 to 33.84 MJ/kg. Crude oils derived from AHTT primarily consisted of phenolic (50.47-75.39 wt%), ketone (20.1-36.34 wt%), and hydrocarbon (1.08-7.93 wt%) constituents. In summary, the results indicated that AHTT is a method for upcycling WPVC to clean fuel.

Hydrothermal dechlorination strategy for high-quality oil recovery from polyvinyl chloride

The global production of PVC is around 3.5 million tons each year. Unfortunately, the disposal of PVC waste releases toxic substances such as hydrochloric acid, polychlorinated dioxins, and furans, which can harm the environment. Therefore, there is an urgent need for a safe and environmentally friendly thermochemical treatment method that reduces the damage caused by HCl gas produced during PVC pyrolysis and improves the quality of pyrolysis oil. Hydrothermal treatment technology is one of the potential dechlorination strategies for PVC. However, its efficiency is reduced in the supercritical region, while the additives used result in secondary pollution and increased operating costs. This study is pioneering in its approach, aiming to produce high-quality oil with reduced chlorine through low-temperature hydrothermal treatment of PVC, all without additives. The results are promising, indicating that by administering steam at 250 °C with a 2.0-3.0 g-steam/g-feed ratio, we can significantly reduce chlorine content to 0.13 % while achieving an oil yield of up to 14.9 % from PVC. The hydrothermal process can reduce CO2 emissions by 15-43 % compared to pyrolysis methods, providing a simultaneous opportunity for carbon neutrality and resource recovery.

Hydrothermal carbonisation of polyvinyl chloride in ethanol-water/water system for solid fuels: Dechlorination, characteristics analysis of hydrochar, and reaction path

Polyvinyl chloride (PVC) waste plastic is a typical solid waste. In this paper, the dechlorination and carbonization behavior of PVC in ethanol-water/water system under different process parameters (temperature, residence time, solid-liquid ratio) was studied, and hydrothermal carbon was characterized by SEM, elemental analysis, TG-DTG, XPS, Py-GC/MS. The results show that temperature is the key to the hydrothermal dechlorination of PVC, and the dechlorination efficiency of PVC is the highest by parameter optimization (220°C-90 min-10% S/D-80% E/D), which can reach 96.33 %. With the removal of Cl, the surface of the PVC matrix changed from full and smooth flocculent to honeycomb with uniform pore size distribution. Thermogravimetric analysis shows that the combustion of hydrochar can be divided into three stages: HCl precipitation and volatile combustion, semi-coke and coke combustion, and fixed carbon combustion. The combustion parameters and kinetic parameters of hydrochar were measured, and it was found that the hydrothermal carbonization of PVC at higher temperatures and ethanol-water ratio could improve the combustion performance of hydrochar. The highest calorific value can reach 36.68 MJ/mol. Py-GC/MS analyzed the distribution of the pyrolysis products, and alkylbenzene and aliphatic were the main products of pyrolysis. The structural analysis of hydrochar showed that C-C and CC accounted for the largest proportion, accompanied by a small amount of C-O and CO and trace C-Cl. The possible reaction mechanism of the hydrothermal carbonization of PVC was analyzed based on the distribution of functional groups and compound composition. This work provides an effective and sustainable method for the recycling of refractory chlorinated plastics.

Chemiluminescence sensing for Hg2+ in environment water using carbon materials from PVC dechlorination as signal initiator

Chemiluminescence (CL) sensing with good performance remains a challenge. The utilization of secondary residues from polyvinyl chloride (PVC) treatment is the key to improve PVC recycling rate. Herein, dechlorinated carbon materials from PVC/iron scrap co-treatment in subcritical water were used as CL sensing element. It was found that tiny changes in the spatial structure of aptamer could cause huge changes in CL signal of the residue-luminol system. A CL biosensor was constructed for mercury in environment water for the first time. The detection limit was estimated to be 0.37 pM. High sensitivity was mainly due to strong CL triggering and signal amplification from residues and effective regulating residue activity by aptamer space dimension. For real water samples, the results by residue CL analysis were consistent with that by cold vapor atom adsorption spectroscopy (CVAAS). Most strikingly, the used material was secondary residues from the treatment of PVC waste, which reduced the time and energy consumption of CL sensing. This research proposed the approach for routine monitoring mercury in environment but also provided the reference for developing other environmentally beneficial analysis platforms.

Insights into the evolution of chemical structure and pyrolysis reactivity of PVC-derived hydrochar during hydrothermal carbonization

Hydrothermal carbonization (HTC) is emerging as an effective technology to convert PVC into highly valuable materials via the removal of chlorine. This means that an in-depth understanding of HTC requires the hydrochar structure, thermal degradation behavior, and relationship between structure and thermal reactivity to be understood. In this work, two typical PVC waste materials were selected for HTC experiments at different temperatures. The structure of the hydrochar was characterized in detail by compositional analysis, FTIR spectroscopy, and 13C NMR analysis. Furthermore, the thermal degradation behavior of the hydrochar was analyzed. The changes after thermal degradation were used to establish a correlation with pyrolysis reactivity. The results showed that the C content and chemical structure of the hydrochar approached that of bituminous coal with increasing HTC temperature. Compared with the untreated PVC feedstock, the hydrochar exhibited higher levels of oxygen-containing functional groups on its surface, and its carbon skeleton structure changed from polymeric straight chains to short-chain paraffins, cycloalkanes, and aromatics. A negative correlation was observed between the CPI value of the hydrochar derived from SPVC and the HTC temperature. The structural evolution path of the hydrochar was altered by additives, which improved its thermal reactivity. These findings are expected to play a significant role in bridging the gap from the creation of a theoretical potential energy source to the development of a sustainable alternative renewable fuel.

Migration Mechanism of Chlorine during Hydrothermal Treatment of Rigid PVC Plastics

Rigid PVC plastics (R-PVC) contain large amounts of chlorine, and improper disposal can adversely affect the environment. Nevertheless, there is still a lack of sufficient studies on hydrothermal treatment (HTT) for the efficient dechlorination of R-PVC. To investigate the migration mechanism of chlorine during the HTT of R-PVC, R-PVC is treated with HTT at temperatures ranging from 220 °C to 300 °C for 30 min to 90 min. Hydrochar is characterized via Fourier transform infrared spectrometry and X-ray photoelectron spectroscopy. The results revealed that the hydrothermal temperature is the key factor that affects the dechlorination of R-PVC. Dramatic dechlorination occurs at temperatures ranging from 240 °C to 260 °C, and the dechlorination efficiency increases with the increase in the hydrothermal temperature. The main mechanism for the dechlorination of R-PVC involves the nucleophilic substitution of chlorine by -OH. CaCO3 can absorb HCl released by R-PVC and hinder the autocatalytic degradation of R-PVC; hence, the dechlorination behavior of R-PVC is different from that of pure PVC resins. Based on these results, a possible degradation process for R-PVC is proposed. This study suggests that HTT technology can be utilized to convert organochlorines in R-PVC to calcium chloride, achieving the simultaneous dechlorination of R-PVC and utilization of products.

Debromination of Waste Circuit Boards by Reaction in Solid and Liquid Phases: Phenomenological Behavior and Kinetics

The debromination of waste circuit boards (WCBs) used in computer motherboards and components has been studied with two different pieces of equipment. Firstly, the reaction of small particles (around one millimeter in diameter) and larger pieces obtained from WCBs was carried out with several solutions of K2CO3 in small non-stirred batch reactors at 200–225 °C. The kinetics of this heterogeneous reaction has been studied considering both the mass transfer and chemical reaction steps, concluding that the chemical step is much slower than diffusion. Additionally, similar WCBs were debrominated using a planetary ball mill and solid reactants, namely calcined CaO, marble sludge, and calcined marble sludge. A kinetic model has been applied to this reaction, finding that an exponential model is able to explain the results quite satisfactorily. The activity of the marble sludge is about 13% of that of pure CaO and is increased to 29% when slightly calcinating its calcite at only 800 °C for 2 h.

Hydrothermal treatment of polyvinyl chloride: Reactors, dechlorination chemistry, application, and challenges

Polyvinyl chloride (PVC) plastic wastes can bring a series of problems during pyrolysis or incineration such as the emission of dioxins, corrosion, slagging in the reactors, etc. Hydrothermal treatment of PVC plastics has been intensively studied as it can efficiently remove chlorine from PVC plastics under relatively mild reaction conditions (220-300 °C) to provide value-added products. Meanwhile, the research progress, knowledge gaps, and challenges in this field have not been well addressed yet. This paper gives a comprehensive review of hydrothermal dechlorination of PVC plastics regarding reactors, process variables and fundamentals, possible applications, and challenges. The main pathways of hydrothermal dechlorination of PVC plastics are elimination and -OH nucleophilic substitution. Catalytic hydrothermal and co-hydrothermal optimize the chemical reactions and transportation, boosting the dechlorination of PVC plastics. Hydrochar derived from PVC plastics, on the one hand, is coalified close to sub-bituminous and bituminous coal and can be used as low-chlorine solid fuel. On the other hand, it is also a porous material with aromatic structure and oxygen-containing functional groups, with good potential as adsorbent or energy storage materials. Further studies are expected to focus on waste liquid treatment, revealing the energy and economic balance, reducing the dechlorination temperature and pressure, expanding the application of products, etc. for promoting the implementation of the hydrothermal treatment of PVC plastic wastes.

A carbothermic hybrid synthesized using waste halogenated plastic in sub/supercritical CO2 and its application for lithium recovery

Facile fabrication of porous carbon materials from waste halogenated plastic is highly attractive but frequently hampered due to potential release of halogenated organic pollutants. In this study, a novel type of carbon hybrid was tentatively synthesized from a real-world halogenated plastic as an inexpensive carbon source by sub/supercritical carbon dioxide carbonization technique. It was found that halogen-free carbon carrier was advantageously synthesized through carbonization of halogenated plastic without using catalysts due to zip depolymerization, random chain cracking and free radical reactions induced by sub/supercritical carbon dioxide technique. Exhibiting with more abundant functional groups including C-O, CO groups than pyrolytic carbon carrier, the derived carbon carrier demonstrated excellent performance in selective recovery of lithium from cathode powder with highest recovery efficiency of 93.6%. Mechanism study indicated that cathode powder was transformed into low-valence states of transition metals/metal oxides and released lithium as lithium carbonate due to collapse of oxygen framework via carbothermic reduction. This work provides an applicable and green process for synthesis of alternative carbon carrier from waste halogenated plastic and its application as carbothermic reductant in lithium recovery.

Solid fuel production from co-hydrothermal carbonization of polyvinyl chloride and corncob: Higher dechlorination efficiency and process water recycling

The hydrothermal carbonization (HTC) of polyvinyl chloride (PVC) and wet herbal agricultural wastes for solid fuel production remains bleak economics and sustainability because of high chloride residual, wastewater burden and low production capacity. In this study, the HTC dechlorination was investigated using the first-order reaction kinetic analysis. We found that the co-hydrothermal carbonization (co-HTC) of PVC and the typical biomass (corncob) achieved a staggering drop of dechlorination activation energy from 189.95 kJ/mol to 110.04 kJ/mol. The co-HTC process achieved rapid dechlorination and carbonization due to synergistic effect, to suppress the chlorine content in bituminous-coal-like hydrochar less than 0.05 %. The process wastewater (process water) from co-HTC was recycled four times to evaluate the reusability and chemical evolution. The organics in co-HTC environment enhanced the carbonization which was confirmed by the improved heating value (30.06 to 32.42 MJ·kg^-1), hydrochar yield (33.33 % to 36.47 %) and energy recovery efficiency (57.73 % to 68.13 %). The Fourier transform infrared spectroscopy (FTIR) and scanning electron microscopy (SEM) evidenced the process water recirculation maintained high chloride removal. Moreover, the possible formation pathways of two kinds of hydrochars were discussed through the chemical composition of the aqueous phase and the characteristic structures of hydrochar. The co-HTC and process water recycling strategies provide a more promising prospect to convert PVC and biomass wastes into solid fuels.

Mechanochemical debromination of waste printed circuit boards with marble sludge in a planetary ball milling process

An effective management of waste printed circuit board (WCB) recycling presents significant advantages of an economic, social, and environmental nature. This is particularly the case when a suitable valorisation is made of the non-metallic parts of the WCBs, well known for their "hidden" toxicological risks. Such benefits motivate research on techniques that could contribute to mitigating their adverse socio-environmental impacts. In this work, waste printed circuit boards (WCBs) containing tetrabromobisphenol A (TBBPA) as a brominated flame retardant (BFR) underwent debromination using a mechanochemical treatment (MCT) and marble sludge, another recoverable waste, as well as pure CaO as additives. All runs in this work were performed at an intermediate rotation speed of 450 rpm, using additive/WCB mass ratios (R_m) of 4:1 and 8:1, ball to powder ratios (BPR) of 20:1 and 50:1, treatment times from 2.5 h to 10 h, two WCB sizes (powder and 0.84 mm) and marble sludge, from original to precalcined conditioning. Stainless steel jars and balls were used to verify the effect of each parameter on the system and to seek an optimum process. Complete debromination of 0.84 mm WCBs was achieved at 450 rpm, using a R_m of 8:1, a BPR of 50:1, a residence time of 10 h (more than 95% in only 5 h), and a precalcined marble sludge as additive. The results revealed that when using a R_m of 4:1 instead of 8:1, more waste could be effectively treated, per batch with a lesser need for additives, at the expense of a slightly lower level of debromination efficiency. In the same way, an appropriate apparent ball diameter (with respect to the volume of the used jar) should be carefully studied in relation to WCB size in order to achieve a beneficial total amount of energy transfer during milling.

Debromination and Reusable Glass Fiber Recovery from Large Waste Circuit Board Pieces in Subcritical Water Treatment

The great economic, social, and environmental interest that favors an effective management of the recycling of waste printed circuit boards (WCBs) encourages research on the improvement of processes capable of mitigating their harmful effects. In this work, the debromination of large WCBs was first performed through a hydrothermal process employing potassium carbonate as an additive. A total of 32 runs were carried out at 225 °C, various CO₃ ^2-/Br^- anionic ratios of 1:1, 2:1, 4:1, and 6:1, treatment times from 30 to 360 min, proportion of submerged WCBs in the liquid of 100, 50, and 25% that corresponded with the use of three WCB sizes of 20 mm × 16.5 mm, 20 mm × 33 mm, and 80 mm × 33 mm, respectively, and solid/liquid ratios of 1:2 and 1:1 g/mL without other metallic catalysts. A debromination efficiency of 50 wt % was reached at only 225 °C (limited by mechanical reasons) and 360 min, using a CO₃ ^2-/Br^- anionic ratio of 4:1 and a solid/liquid ratio of 1:2 for a large WCB with only 25% of its volume submerged in the liquid. This means conservation of water and energy compared to previous studies. A muffle furnace was used later to thermally treat a total of 101 debrominated samples, at constant temperature or following a temperature scaling program. An estimated decrease in resistance to rupture of glass fibers of only around 50% was accomplished by following a temperature scaling program up to 475 °C, obtaining clean glass fibers of large size. The simple techniques proposed to obtain reusable glass fibers from WCBs as large as the size of the reactor allows (as it might be in their original size) could significantly improve interest in the industry.

A Win-Win Combination to Inhibit Persistent Organic Pollutant Formation via the Co-Incineration of Polyvinyl Chloride E-Waste and Sewage Sludge

Persistent organic pollutant inhibition in the combustion process of polyvinyl chloride (PVC) by prior addition of an inhibitor is currently being studied, reducing the emission of pollutants, and thus reducing the large amount of waste PVC destined for landfill. In this work, the use of sewage sludge (SS) as an alternative to chemical inhibitors to improve the quality emissions of the incineration of polyvinyl chloride waste (PVC e-waste) was studied and optimized. Different combustion runs were carried out at 850 °C in a laboratory tubular reactor, varying both the molar ratio R_i (0.25, 0.50, 0.75) between inhibitors (N + S) and chlorine (Cl) and the oxygen ratio λ (0.15, 0.50) between actual oxygen and stoichiometric oxygen. The emissions of several semivolatile compounds families such as polycyclic aromatic hydrocarbons (PAHs), polychlorobenzenes (ClBzs), and polychlorophenols (ClPhs), with special interest in the emissions of the most toxic compounds, i.e., polychlorinated dibenzo-p-dioxins and polychlorinated dibenzofurans (PCDD/Fs) and dioxin-like polychlorinated biphenyls (dl-PCBs), were analyzed. A notable decrease in PCDD/F and dl-PCB formation was achieved in most of the experiments, especially for those runs performed under an oxygen-rich atmosphere (λ = 0.50), where the addition of sludge was beneficial with inhibition ratios Ri ≥ 0.25. An inhibition ratio of 0.75 showed the best results with almost a 100% reduction in PCDD/F formation and a 95% reduction in dl-PCB formation.