Two-stage thermal pyrolysis of plastic solid waste: Set-up and operative conditions investigation for gaseous fuel production

In response to the escalating global challenge of mounting plastic waste and the imperative to adopt more sustainable practices for resource utilization, our study focuses on the utilization of plastic solid waste (PSW) through a two-stage thermal pyrolysis process. This aims to demonstrate its potential as a high-performance alternative to existing two-stage catalytic pyrolysis methods. The experimentation involved processing real scrap PSW material in a lab-scale batch set-up, emphasizing optimizing residence time in the cracking reactor to maximize gas yield and its lower heating value (LHV). The study underscores the advantages of the employed two-stage thermal pyrolysis apparatus through a comparative analysis with established set-up dedicated to maximizing gas yield. Once the operative conditions were explored, resulting pyrolysis products underwent detailed characterization to assess their suitability as a sustainable fuel source. The study also presents a practical application of the produced gaseous fuel, envisioning its combustion in an internal combustion engine (ICE), known for its flexibility regarding fuel properties. This application is demonstrated through a simulation conducted in Unisim Design©. The successful processing of real PSW material in the two-stage lab-scale experimental set-up showcased optimal gas yield achievements (>65 % w/w) with an LHV (∼41 MJ/kg), comparable to that of natural gas. This emphasizes the potential of these sustainable alternatives to replace fossil fuels, especially in the context of ICE applications. The integration of the pyrolysis plant with an ICE demonstrated promising prospects for generating electricity in the transportation sector and facilitating thermal power for heat integration in pyrolysis reactors.

Experimental investigation on slow thermal pyrolysis of real-world plastic wastes in a fixed bed reactor to obtain aromatic rich fuel grade liquid oil

Plastic wastes have become one of the biggest global environmental issues and thus recycling such massive quantities is targeted. Thermal pyrolysis has been the most suitable approach to convert the waste plastic into a source of energy. This study aims to compare the thermal pyrolysis of waste plastic with that of the modal plastic compounds in a fixed bed reactor. The liquid oil, obtained from the thermal pyrolysis of HDPE, LDPE, PP and PS wastes were characterized using FT-IR, GC-MS and 1H NMR. Also, their fuel properties such as viscosity and calorific values were characterized using parallel plate rheometer and bomb calorimeter respectively. C10-C44 paraffins and C10-C22 olefins were obtained along with aromatics and alcohols in different type of plastic waste pyrolysis oil. The viscosity of the plastic oil is within kerosene and diesel range. The calorific values of the oils are at par with the Petro fuels.

Plastic waste as pyrolysis feedstock for plastic oil production: A review

Turning plastic waste into plastic oil by pyrolysis is one of the promising techniques to eradicate plastic waste pollution and accelerate the circular economy of plastic materials. Plastic waste is an attractive pyrolysis feedstock for plastic oil production owing to its favorable chemical properties of proximate analysis, ultimate analysis, and heating value other than its abundant availability. Despite the exponential growth of scientific output from 2015 to 2022, a vast majority of the current review articles cover the pyrolysis of plastic waste into a series of fuels and value-added products, and up-to-date reviews exclusively on plastic oil production from pyrolysis are relatively scarce. In light of this void in the current review articles, this review attempts to provide an up-to-date overview of plastic waste as pyrolysis feedstock for plastic oil production. A particular emphasis is placed on the common types of plastic as primary sources of plastic pollution, the characteristics (proximate analysis, ultimate analysis, hydrogen/carbon ratio, heating value, and degradation temperature) of various plastic wastes and their potential as pyrolysis feedstock, and the pyrolysis systems (reactor type and heating method) and conditions (temperature, heating rate, residence time, pressure, particle size, reaction atmosphere, catalyst and its operation modes, and single and mixed plastic wastes) used in plastic waste pyrolysis for plastic oil production. The characteristics of plastic oil from pyrolysis in terms of physical properties and chemical composition are also outlined and discussed. The major challenges and future prospects for the large-scale production of plastic oil from pyrolysis are also addressed.

Statistical prediction and sensitivity analysis of kinetic rate constants for efficient thermal valorization of plastic waste into combustible oil and gases

Sensitivity analyses of rate constants for chemical kinetics of the pyrolysis reaction are essential for the efficient valorization of plastic waste into combustible liquids and gases. Finding the role of individual rate constants can provide important information on the process conditions, quality, and quantity of the pyrolysis products. The reaction temperature and time can also be reduced through these analyses. For sensitivity analysis, one possible approach is to estimate the kinetic parameters using MLRM (multiple linear regression model) in SPSS. To date, no research reports on this research gap are documented in the published literature. In this study, MLRM is applied to kinetic rate constants, which slightly differ from experimental data. The experimental and statistically predicted rate constants varied up to 200% from their original values to perform sensitivity analysis using MATLAB software. The product yield was examined after 60 min of thermal pyrolysis at a fixed temperature of 420 °C. The predicted rate constant "k(8)" with a slight difference of 0.02 and 0.04 from the experiment revealed 85% oil yield and 40% light wax after 60 min of operation. The heavy wax was missing from the products under these conditions. This rate constant can be utilized to maximize the commercial-scale extraction of liquids and light waxes from thermal pyrolysis of plastics.

Life cycle water footprint comparison of biomass-to-hydrogen and coal-to-hydrogen processes

Water is essential for the industrial production of hydrogen. This study investigates the production of hydrogen from biomass and coal. To date, there are few studies focusing on the water footprint of biomass-to-hydrogen and coal-to-hydrogen processes. This research conducted a life cycle water use analysis on wheat straw biomass and coal to hydrogen via pyrolysis gasification processes. The results show that the water consumption of the entire biomass-to-hydrogen process was 76.77 L/MJ, of which biomass cultivation was the dominant contributor (99%). Conversely, the water consumption of the coal-to-hydrogen process was only 1.06 L/MJ, wherein the coal production stage accounted for only 4.15% for the total water consumption, which is far lower than that of the biomass-to-hydrogen process. The hydrogen production stage of biomass hydrogen production accounted for 76% of the total water consumption when excluding the water consumption of straw growth, whereas that of the coal hydrogen production stage was 96%. This research provides the associated water consumption, within a specified boundary, of both hydrogen production processes, and the influence of major factors on total water consumption was demonstrated using sensitivity analysis.

Study of waste tire pyrolysis in a rotary kiln reactor in a wide range of pyrolysis temperature

Thermal pyrolysis of waste tires without metals has been studied in a rotating kiln reactor under nitrogen atmosphere. The pyrolysis temperature was varied in a wide range from 400 up to 1050 °C to investigate the effect of temperature on pyrolysis products. The pyrolytic oil during each pyrolysis process was reported in different pyrolysis times. It was found that the maximum yield of pyrolytic oil was 44 wt% in 550 °C. However, by raising the temperature of the pyrolysis process, the yield of produced gas increased, while the yield of produced char decreased. In addition, Fourier transform infrared spectroscopy (FT-IR) was performed in order to specify functional groups and types of bonds at different temperatures. FT-IR analysis showed the presence of some undesired compounds with sulphur and nitrogen functionalities in pyrolytic oil. Also, the properties of maximum produced oil were analyzed. The distillation data of maximum pyrolytic oil revealed that there was 14%, 4%, and 36% of light naphtha (>160 °C), heavy naphtha (160-200 °C) and middle distillate (200-350 °C), respectively and the fraction of VGO (<350 °C) was 46%.

Influence of pyrolysis temperature on properties and environmental safety of heavy metals in biochars derived from municipal sewage sludge

Dried raw sludge was pyrolyzed at temperatures ranging from 400 to 600°C at the increase of 50°C intervals to investigate the influence of pyrolysis temperature on properties and environmental safety of heavy metals in biochar derived from municipal sewage sludge. The sludge biochar yield decreased significantly with increasing pyrolysis temperature but the pH, ash content and specific surface area increased. Conversion of sludge to biochar markedly decreased the H/C and N/C ratios. FT-IR analysis confirmed a dramatic depletion of H and N and a higher degree of aromatic condensation in process of biochar formation at higher temperatures. The total concentrations of Cu, Zn, Pb, Cr, Mn, and Ni increased with conversion of sludge to biochar and increasing pyrolysis temperature. However, using BCR sequential extraction and analysis, it was found that most of the heavy metals existed in the oxizable and residual forms after pyrolysis, especially at 600°C, resulting in a significant reduction in their bioavailability, leading to a very low environmental risk of the biochar. The present study indicates pyrolysis is a promising sludge treatment method for heavy metals immobilization in biochar, and highlights the potential to minimize the harmful effects of biochar by controlling pyrolysis temperature.