Chemical recycling of plastic wastes with alkaline earth metal oxides: A review

Plastics have been widely used in daily life and industries due to their low cost and high durability, leading to huge production of plastics and tens of millions of plastic wastes every year. Chemical recycling can recycle contaminated and degraded plastics (that mechanical recycling cannot deal with) to obtain value-added products, which potentially solves the environmental problems caused by plastics and realizes a circular economy. Alkaline earth metal oxides, as a category of cost-effective and multi-functional materials, have been widely used in chemical recycling of common plastics, acting as three roles: catalyst, template, and absorbent. Among five commercial plastics, polyethylene terephthalate is suitable for pyrolysis and solvolysis. Polyethylene and polypropylene, which are ideal precursors for synthesis of carbon nanotubes, could be combined with biomass for co-pyrolysis. Polyvinyl chloride needs to be pretreated to reduce chloride content prior to pyrolysis. Depolymerization of polystyrene into monomers is attractive. This review summarized the chemical recycling approaches of commercial plastics and the strategies with alkaline earth metal oxides for the development of efficient recycling processes. It will aid understanding of the advances and challenges in the field and promote the future research.

Catalytic Pyrolysis of Waste Plastics over Industrial Organic Solid-Waste-Derived Activated Carbon: Impacts of Activation Agents

Renewable source-derived carbon is found to be a green alternative catalyst to zeolite for the pyrolysis of plastics. However, only polyethylene (PE) catalytic pyrolysis over biomass-derived carbon has been extensively studied. In this work, carbon was produced from industrial organic solid waste using different activation agents, and their catalytic performance on the thermal degradation of typical polymers, namely PE, polypropylene (PP), polystyrene (PS), and polyethylene terephthalate (PET) were investigated. The degradation mechanisms and the roles of different active sites of the carbons are discussed. Steam failed to activate the carbon, which has a low specific surface area (6.7 m2/g). Chemical activation using H3PO4 and ZnCl2 produces carbons with higher specific surface area and more porosity. The pyrolysis characteristics of LDPE, PP, PS, and PET catalyzed by the carbons were studied using TGA and a fixed-bed reactor. The thermogravimetric results indicate that all three carbons reduce the pyrolysis temperature. The analysis of the products shows that the P- and Zn-involved acid sites on the AC-HP and AC-ZN change the reaction pathway of plastics and promote: (1) C-C cracking and aromatization of polyolefins; (2) the protonation of phenyl carbon of PS to yield higher benzene, toluene, and ethylbenzene; and (3) the decarboxylation of the terephthalic acid intermediate of PET, resulting in higher CO2 and benzene. In addition, the high-value chemicals, long-chain alkylbenzenes, were found in the liquids of AC-ZN and AC-HP. The long-chain alkylbenzenes are probably formed by acid-catalyzed alkylation of aromatic hydrocarbons. This study provides basic data for the development of a cheap catalyst for plastic pyrolysis.

Carbon dioxide-mediated thermochemical conversion of banner waste using cobalt oxide catalyst as a strategy for plastic waste treatment

In this study, the effects of CO₂ thermochemical agent and a metal oxide catalyst (Co₃O₄) on thermochemical banner waste conversion were explored. The results revealed that compared to the non-catalytic conversion of banner waste under N₂ environment, the conversion under CO₂ yielded more non-condensable gases owing to an enhanced thermal cracking of volatiles. In addition, the CO and CH₄ yields at >700 °C in CO₂ increased considerably owing to the reverse water-gas shift reaction and CO₂ methanation. The CO₂ agent reduced the yields of condensables (e.g., benzoic acids, phthalic acids, esters, biphenyls, fluorenes) and decomposition residue (e.g., char and wax), which could be attributed to the enhancement of the thermal cracking of volatiles evolved during the banner waste conversion by CO₂ and the C-H and O-H bonds present in the feedstock. In addition, the Co₃O₄ catalyst promoted the decarboxylation reaction under N₂ environment, whereas it promoted the methanation and reverse water-gas shift reaction under CO₂. This indicates that compared to the non-catalytic CO₂-assisted banner waste conversion, the use of CO₂ for the conversion of banner waste in the presence of Co₃O₄ significantly increased the yields of CH₄ and CO. Furthermore, Co₃O₄ promoted the thermal cracking of polyester bond, thus decreasing the yields of long-chain chemical compounds. In addition, the simultaneous use of Co₃O₄ catalyst and CO₂ agent minimized the formation of char and wax. For all cases (N₂ versus CO₂, non-catalytic versus catalytic), an increase in temperature enhanced the total permanent gas yield and decreased the yields of condensables, char, and wax. The findings of this study revealed the importance of the synergistic use of Co₃O₄ catalyst and CO₂ agent for the plastic waste upcycling, such as banner waste.

Upcycling of PET waste into methane-rich gas and hierarchical porous carbon for high-performance supercapacitor by autogenic pressure pyrolysis and activation

The explosive growth of polyethylene terephthalate (PET) wastes has brought serious pollution to the environment. Here, PET waste was upcycled into methane-rich pyrolysis gas and carbon material for energy storage through autogenic pressure pyrolysis and post-activation. The pyrolysis gas contained 34.58 ± 0.23 vol% CH₄. After CO₂ removal, the high caloric value of the pyrolysis gas could reach 29.2 MJ m^-3, which could be used as a substitute natural gas. Pyrolytic carbon was further activated by KOH and ZnCl₂. KOH-activated carbon (AC-K) obtained a hierarchical porous structure, a high specific surface area of 2683 m² g^-1 and abundant surface functional groups. Working as supercapacitor electrodes, AC-K exhibited an outstanding specific capacitance of 325 F g^-1 at a current density of 0.5 A g^-1. After 5000 charge-discharge cycles, AC-K still retained 91.86% of the initial specific capacitance. This study provides a sustainable way to control plastic-derived pollution and alleviate the energy crisis.

Biocrude Oil from Algal Bloom Microalgae: A Novel Integration of Biological and Thermochemical Techniques

Algal bloom microalgae are abundant in polluted water systems, but their biocrude oil production potential via hydrothermal liquefaction (HTL) is limited. This study proposed a novel process that combined biological (dark fermentation) and thermochemical (HTL) techniques aimed at changing the feedstock characteristics to be more suitable for thermochemical conversion, herein named integrated dark fermentation-hydrothermal liquefaction (DF-HTL). DF-HTL conversion of algae significantly enhanced the biocrude oil yield (wt %), carbon content (mol), energy content (MJ), and energy conversion ratios by 9.8, 29.7, 40.0, and 61.0%, respectively, in comparison to the control. Furthermore, DF-HTL processing significantly decreased the aqueous byproduct yield (wt %), carbon content (mol), nitrogen content (mol), and ammonia content (mol) by 19.0, 38.4, 25.0, and 13.2%, respectively, in comparison to the control. Therefore, DF-HTL reduced the environmental impact associated with disposing of the wastewater byproduct. However, DF-HTL also augmented the nitrogen content (mol) of the biocrude oil by 42.2% in comparison to the control. The benefits of DF-HTL were attributed to the increased acid content, the incorporation of H₂ as a processing gas, and the enhancement of the Maillard reaction, which shifted the distribution of reaction products from the aqueous phase to the biocrude oil phase. This article provides insights into the efficacy of a novel integrated biological-thermochemical processing method with distinct environmental and energetic advantages over conventional HTL that heightens the biocrude oil yield for feedstocks with a high carbohydrate and a high protein content.

Latest Trends in Pyrolysis Gas Chromatography for Analytical and Applied Pyrolysis of Plastics

Pyrolysis is considered to be a promising method for polymer characterization (in the field of analytical pyrolysis) and for chemical feedstock recovery from plastic wastes (in the field of applied pyrolysis) because it can decompose any polymeric material into smaller molecules by applying heat alone in an inert atmosphere. Pyrolysis-gas chromatography (Py-GC) involves pyrolyzing polymeric materials in a micropyrolyzer and a subsequent direct GC analysis of pyrolyzates. Py-GC has immense potential for applications in the fields of both analytical and applied pyrolysis, as it allows for rapid and accurate analysis of pyrolyzates. This is beneficial for elucidating microstructure and composition of polymers and for a rapid screening of pyrolysis conditions for designing feedstock recycling processes. In this review, we examined the latest research trends in Py-GC applications for polymer characterization, analysis of plastics in the environment, and chemical feedstock recovery from plastics.

Direct Gas-Phase Derivatization by Employing Tandem μ-Reactor-Gas Chromatography/Mass Spectrometry: Case Study of Trifluoroacetylation of 4,4'-Methylenedianiline

Pyrolysis-gas chromatography/mass spectrometry (Py-GC/MS) is a promising technique allowing the rapid characterization of the polymer structure and additives of microgram-scale plastics. However, the Py-GC/MS analysis of polymers with urethane bonds is challenging because they produce highly reactive pyrolyzates such as amines and isocyanates polymerizing in the GC column, which limits the efforts to elucidate the pyrolysis mechanism and plastic characterization by online GC analysis. Herein, a novel pyrolysis-gas-phase derivatization-GC/MS (Py-GPD-GC/MS) technique was developed, allowing the pyrolysis of polymers and the subsequent direct gas-phase derivatization of pyrolyzates, employing a modified tandem μ-reactor-GC/MS system. This work conducted the gas-phase trifluoroacetylation of 4,4'-methylenedianiline (MDA), which is one of the major polyurethane (PU) pyrolyzates, using N-methyl-bis-trifluoroacetamide (MBTFA) as a derivatization agent. The trifluoroacetylation gas-phase reaction was monitored by in situ GC/MS analysis and the effects of derivatization conditions were investigated. The highest MDA conversion observed was 65.6 area %. Furthermore, the sequential PU pyrolysis and direct trifluoroacetylation of PU pyrolyzates in the first μ-reactor and second μ-reactor, respectively, were successfully operated, achieving the inhibited polymerization and detection of trifluoroacetylated derivatives. Thus, the Py-GPD-GC/MS method has a significant potential to be applied for other combinations of pyrolyzates and derivatization reactions, enabling deeper characterization of plastics producing highly reactive pyrolyzates that cannot be accurately analyzed by conventional Py-GC/MS analysis.

Reduction of polycyclic compounds and biphenyls generated by pyrolysis of industrial plastic waste by using supported metal catalysts: A case study of polyethylene terephthalate treatment

The accumulation of industrial plastic waste in the environment is a global growing concern. Thermochemical process is a preferred method to dispose plastic waste mainly because it can reduce volume of the waste; however, the thermochemical disposal of plastic waste can emit harmful chemical species such as benzene derivatives and polycyclic hydrocarbons. As an effort to overcome this challenge, supported metal catalysts (carbon-supported Pd and Pt catalysts) were used to inhibit the formation of polycyclic compounds and biphenyl derivatives by pyrolysis of polyethylene terephthalate (PET). Less polycyclic compounds and biphenyl derivatives were generated during the Pd or Pt-catalyzed PET pyrolysis than non-catalytic PET pyrolysis. The concentrations of polycyclic compounds and biphenyl derivatives were 107 % and 56 % lower for the Pt-catalyzed pyrolysis at 700 °C than non-catalytic pyrolysis, respectively. The Pt catalyst was more effective to suppress the generation of polycyclic compounds and biphenyl derivatives during the PET pyrolysis than the Pd catalyst at temperatures from 400 to 800 °C. This was likely because the Pt sites catalyzes decyclization reaction and/or free radical mechanism that is dominant in thermal cracking of carbonaceous substances such as PET. The results of this study would help develop environmentally friendly industrial plastic waste treatment methods via thermochemical processes.

Pyrolysis of Polyethylene Terephthalate over Carbon-Supported Pd Catalyst

Pyrolysis of polyethylene terephthalate (PET) produces polycyclic hydrocarbons and biphenyl derivatives that are harmful to human health and the environment. Therefore, a palladium metal catalyst (5 wt.% Pd loaded on activated carbon) was used to prevent the formation of harmful materials. When a Pd catalyst/PET ratio of 0.01 was applied in pyrolysis of PET, it did not show a meaningful difference in the generation of polycyclic hydrocarbons and biphenyl derivatives. However, when a Pd catalyst/PET ratio of 0.05 was used during pyrolysis, it prevented their formation and generation at experimental temperature ranges (400–700 °C). For example, the concentration of 2-naphthalenecarboxylic acid produced, which is a typical polycyclic hydrocarbon material, was reduced by 44%. In addition, the concentration of biphenyl-4-carboxylic acid, which is contained in biphenyl derivatives, was reduced by 79% compared to non-catalytic pyrolysis at 800 °C. This was because the ring-opening reaction and free radical mechanism caused by the Pd catalyst and thermal cracking were dominant during the pyrolysis of PET. Apart from these materials, amine compounds were generated as products of the pyrolysis of PET. Amine concentration showed a similar trend with polycyclic hydrocarbons and benzene derivatives. Based on these results, the total concentration of polycyclic hydrocarbons and biphenyl derivatives was compared; the results confirmed that the concentrations of all substances were reduced. This research suggests that a metal-supported catalyst will help create a more environmentally friendly and reliable method of industrial plastic waste disposal.

Real time monitoring of slow pyrolysis of polyethylene terephthalate (PET) by different mass spectrometric techniques

In the context of waste upgrading of polyethylene terephthalate (PET) by pyrolysis, this study presents three on-line mass spectrometric techniques with soft ionization for monitoring the emitted decomposition products and their thermal dependent evolution profiles. Pyrolysis experiments were performed using a thermogravimetric analyzer (TGA) under nitrogen atmosphere with a heating rate of 5 °C/min from 30 °C to 600 °C. Single-photon ionization (SPI at 118 nm/10.5 eV) and resonance enhanced multiple photon ionization (REMPI at 266 nm) were used with time-of-flight mass spectrometry (TOF-MS) for evolved gas analysis (TGA-SPI/REMPI-TOFMS). Additionally, the chemical signature of the pyrolysis products was investigated by atmospheric pressure chemical ionization (APCI) ultra high resolution Fourier Transform ion cyclotron resonance mass spectrometry (FT-ICR MS) which enables assignment of molecular sum formulas (TGA-APCI FT-ICR MS). Despite the soft ionization by SPI, the fragmentation of some compounds with the loss of the [O-CH = CH2] fragment is observed. The major compounds were acetaldehyde (m/z 44), benzoic acid (m/z 122) and a fragment of m/z 149. Using REMPI, aromatic species were selectively detected. Several series of pyrolysis products were observed in different temperature intervals, showing the presence of polycyclic aromatic hydrocarbons (PAHs), especially at high temperatures. FT-ICR MS data showed, that the CHO₄ class was the most abundant compound class with a relative abundance of 45.5%. The major compounds detected with this technique corresponded to m/z 193.0495 (C₁₀H₉O₄⁺) and 149.0233 (C₈H₅O₃⁺). Based on detailed chemical information, bulk reaction pathways are proposed, showing the formation of both cyclic monomer/dimer and linear structures.

Catalytic fast pyrolysis of polyethylene terephthalate plastic for the selective production of terephthalonitrile under ammonia atmosphere

Terephthalonitrile (TPN) was directly produced from polyethylene terephthalate (PET) plastic via catalytic fast pyrolysis with ammonia. The optimal condition for producing TPN was over 1 g γ-Al₂O₃-2 wt% catalyst at 500 °C under carrier gas (50% NH₃ and 50% N₂) with yield of nitriles and TPN of 58.1 and 52.3 C%, respectively. The selectivity of TPN in the nitriles was around 90%. Meanwhile, a bit of aromatics, benzonitrile, acetonitrile were also produced as by-products with the total yields of less than 3 C%. The catalyst deactivated slightly after 5 cycles. Possible reaction routes were proposed and it was found that terephthalic acid, benzoic acid, related esters and amides were the major intermediates from PET to nitriles. Acetonitrile could be produced from acetaldehyde and its corresponding imines. In addition, 32.1 C% TPN with high purity (>95%) was obtained via freezing recrystallization. Catalytic pyrolysis with ammonia process was a promising technology for converting waste PET plastics to TPN. This study provided a new method for producing N-containing chemicals from polyester plastics.

Selective Production of Terephthalonitrile and Benzonitrile via Pyrolysis of Polyethylene Terephthalate (PET) with Ammonia over Ca(OH)2/Al2O3 Catalysts

A series of Ca(OH)2/Al2O3 catalysts were synthesized for selectively producing N-containing chemicals from polyethylene terephthalate (PET) via catalytic fast pyrolysis with ammonia (CFP-A) process. During the CFP-A process, the carboxyl group in PET plastic was efficiently utilized for the selective production of terephthalonitrile and benzonitrile by controlling the catalysts and pyrolysis parameters (e.g. temperature, residence time, ammonia content). The best conditions were selected as 2% Ca(OH)2/γ-Al2O3 (0.8 g), 500 °C under pure ammonia with 58.3 C% terephthalonitrile yield and 92.3% selectivity in nitriles. In addition, 4% Ca(OH)2/ Al2O3 was suitable for producing benzonitrile. With catalyst dosage of 1.2 g, residence time of 1.87 s, pyrolysis temperature of 650 °C and pure ammonia (160 mL/min carrier gas flow rate), the yield and selectivity of benzonitrile were 30.4 C% and 82.6%, respectively. The catalysts deactivated slightly after 4 cycles.

Hydrogen and steam injected tandem μ-reactor GC/FID system: phenol recovery from bisphenol A and alkylphenols using Ni/Y zeolite

Hydrogen and steam injected tandem μ-reactor-GC/FID system achieved online quantification of products from hydrogenation and dealkylation of bisphenol A and alkylphenols using Ni/Y zeolite.

Selective phenol recovery via simultaneous hydrogenation/dealkylation of isopropyl- and isopropenyl-phenols employing an H2 generator combined with tandem micro-reactor GC/MS

The pyrolysis of bisphenol A (BPA), an essential process ingredient used in industry and many everyday life products, helps produce low-industrial-demand chemicals such as isopropenyl- and isopropyl-phenols (IPP and iPrP). In this study, tandem micro-reactor gas chromatography/mass spectrometry combined with an H₂ generator (H₂-TR-GC/MS) was employed for the first time to investigate the selective recovery of phenol via simultaneous hydrogenation/dealkylation of IPP and iPrP. After investigating the iPrP dealkylation performances of several zeolites, we obtained full iPrP conversion with over 99% phenol selectivity using the Y-zeolite at 350 °C. In contrast, when applied to IPP, the zeolite acid centres caused IPP polymerisation and subsequent IPP-polymer cracking, resulting in many byproducts and reduced phenol selectivity. This challenge was overcome by the addition of 0.3 wt% Ni on the Y-zeolite (0.3Ni/Y), which enabled the hydrogenation of IPP into iPrP and subsequent dealkylation into phenol (full IPP conversion with 92% phenol selectivity). Moreover, the catalyst deactivation and product distribution over repetitive catalytic use were successfully monitored using the H₂-TR-GC/MS system. We believe that the findings presented herein could allow the recovery of phenol-rich products from polymeric waste with BPA macro skeleton.