Thermal cracking of oils from waste plastics

Thermal cracking of decomposed waste plastic oil produces a good yield of olefins. The solvent extraction of such waste plastic oil seems to be efficient for increasing gas yields and recycling monomers. To assess the potential of monomer recovery from municipal waste plastics, the oils were cracked using a laboratory-scale quartz-tube reactor. The waste plastic oils were provided by two commercial plants of the Sapporo Plastic Recycle Co. and the Dohoh Recycle Center Co. in Japan. A model waste plastic oil made in a laboratory was also examined. Yields of ethene, propene, and other products were measured at different temperatures. Two-step pyrolysis reduces coking compared with the direct thermal degradation of plastics. The raffinates from waste plastic oils extracted by sulfolane were also cracked. The primary products were almost the same as those from nontreated oils. The maximum total gas yield was 78wt%–85wt% at 750°C, an increase of about 20wt% compared with that of nonextracted oil. Solvent extraction removes stable aromatic hydrocarbons such as styrene, which is more coked than cracked.     

Development of a catalytic cracking process for converting waste plastics to petrochemicals

The catalytic degradation of polyolefin using H-gallosilicates was examined using a bench-scale reactor (0.8kg/h) with semicontinuous feeding and the following plastics: (1) low-density polyethylene (LDPE) pellets; (2) linear low-density polyethylene (L-LDPE) pellets; (3) high-density polyethylene (HDPE) pellets; (4) polypropylene (PP) pellets; (5) polyolefin obtained from pulverized industrial waste plastics. The yields of liquid compounds from these materials, which were aromatics in most cases, ranged from 55wt% to 68wt%. With an increase in the ratio of total reactant to catalyst, the liquid yield remained the same. Yields of benzene, toluene, and xylenes (BTXs) decreased rapidly to below 50wt% at a ratio of more than 30. Differences in this ratio for BTXs were always small and were independent of the material. Only about half of the gas product was propane with a fresh catalyst. When the experiments were repeated, propylene, isobutane, and isobutene were found to increase.     

Postconsumer polyethylene terephthalate (PET)/polyolefin blends through reactive processing

Increasing awareness of environmental and energy problems has promoted greater governmental interest in selected waste collection and consequently has attracted the interest of several research groups to the challenge of converting recovered plastics into useful materials. The reactive blending of postconsumer polyethylene terephthalate (PET) with different polyolefins (PO) was studied in attempts to obtain a new material with enhanced properties with respect to the starting materials. The success of the project depends mainly on the possibility of obtaining a compatibilized blend between two starting polymers that, from chemical and thermomechanical viewpoints, are very different. This was approached by employing polyolefins bearing functional groups capable of specific interaction or chemical reaction with PET end groups. Ternary blends of very low density polyethylene (VLDPE)/PET/functionalized polyolefin (FPO) in a weight composition of 70/20/10 and binary blends of FPO/PET in a weight composition of 90/10 were prepared and studied to obtain reinforced polyolefin thermoplastic materials. Reactive blending was achieved in a Brabender Plastograph with a mixing chamber of 30 or 50cm³, at 250°C, and 40rpm for 10min. Differential scanning calorimetry, scanning electron microscopy, and tensile tests were used to investigate the phase behavior, the efficiency of compatibilization, and the mechanical properties of the blends.     

Pore structure and adsorption properties of activated carbon prepared from granular molded waste paper

We have previously manufactured activated carbon using waste paper board, which was prepared by adding 8% phenol resin adhesive to torn waste newspaper and hot-pressing. In this study, the pretreatment process of the raw material was simplified; the waste paper was extruded to form granules. The activated carbon was manufactured by the carbon dioxide activation method using the granules as the raw material. The properties of the activated carbon were evaluated based on the pore structure, the iodine adsorption number, and the adsorption of toluene vapor in a sealed chamber. The activated carbon, which was manufactured at an activation temperature of 1100°C and a treatment time of 60min, exhibited a specific surface area of 1241m²/g and an iodine adsorption number of 1120mg/g. These results were similar to those obtained for two commercially available activated carbons. The extent of toluene vapor adsorption by this activated carbon was similar to that observed for the two commercial activated carbons over a period of 130min.     

Development of a catalytic dehalogenation (Cl,Br) process for municipal waste plastic-derived oil

Dehalogenation is a key technology in the feedstock recycling of mixed halogenated waste plastics. In this study, two different methods were used to clarify the effectiveness of our proposed catalytic dehalogenation process using various carbon composites of iron oxides and calcium carbonate as the catalyst/sorbent. The first approach (a two-step process) was to develop a process for the thermal degradation of mixed halogenated waste plastics, and also develop dehalogenation catalysts for the catalytic dehydrochlorination of organic chlorine compounds from mixed plastic-derived oil containing polyvinyl chloride (PVC) using a fixed-bed flow-type reactor. The second approach (a single-step process) was the simultaneous degradation and dehalogenation of chlorinated (PVC) and brominated (plastic containing brominated flame retardant, HIPS–Br) mixed plastics into halogen-free liquid products. We report on a catalytic dehalogenation process for the chlorinated and brominated organic compounds formed by the pyrolysis of PVC and brominated flame retardant (HIPS–Br) mixed waste plastics [(polyethylene (PE), polypropylene (PP), and polystyrene (PS)], and also other plastics. During dehydrohalogenation, the iron- and calcium-based catalysts were transformed into their corresponding halides, which are also very active in the dehydrohalogenation of organic halogenated compounds. The halogen-free plastic-derived oil (PDO) can be used as a fuel oil or feedstock in refineries.     

The contemporary Oceania zinc cycle: one-year stocks and flows

The material flow approach provides a framework from which to address resource management and estimate gross environmental impacts, both spatially and temporally. In this article, the major flows of zinc in Oceania over its entire life-cycle are examined; these include production (mining, milling, and refining), fabrication and manufacturing of semi- and finished products, use, and the waste management system. Comprehensive mass balances were applied to determine the zinc flows, including the quantities of zinc entering stocks in waste and in-use reservoirs. The Oceania cycle shows that substantial amounts of zinc (about 1120Gg/year) are mined on the continent. The total flow of zinc in finished products entering the use stage is about 8.6kg/(capita.year), substantially exceeding the zinc flow in discarded products. This difference, about 7.2kgZn/(capita.year) on average, is added to the in-use reservoir, largely for galvanizing applications in domestic construction and transportation. Less than 60% of all discarded zinc entering the waste management system is recycled. Much of the remaining discarded zinc is diluted into other waste streams, where recovery and recycling are probably not economically feasible.     

Decomposition reactions of epoxy resin and polyetheretherketone resin in sub- and supercritical water

Epoxy resin and polyetheretherketone (PEEK) resin were decomposed into their monomers such as phenol, cresols, and their analogues by thermal treatment in sub- and supercritical water in a 10-ml tubing bomb reactor. The addition of basic compounds such as Na₂CO₃ was effective in promoting the decomposition reaction of the resins. In the reaction of epoxy resin, the yield of identified products reached 10% for the reaction at 703K over 1h. In the reaction of PEEK resin, the total yield of phenol and dibenzofuran reached 88% for the reaction at 703K over 3h. Chemical participation of water in the decomposition reaction was confirmed by the reaction of dinaphthylether.     

Catalytic decomposition of hydrocarbon into hydrogen and carbon in a spouted-bed reactor as the second-stage reactor of a plastic recycling process

A two-stage process for the chemical recycling of plastics is proposed. In this process, which consists of two reactors, plastics are converted into hydrogen and carbon. In the first reactor, plastic chips are thermally decomposed into hydrocarbons. In the second reactor, the hydrocarbons formed in the first reactor are catalytically decomposed into carbon and hydrogen. In this study, in order to obtain basic data for the second reactor, propene was catalytically decomposed in a laboratory-scale spouted-bed reactor (600mm high, 21.6mm internal diameter, made of SUS304). The effect of the type of spouting medium used on the decomposition behavior of propene was investigated using four types of spouting medium (nickel-plated -alumina, palladium-plated -alumina, nickel-impregnated -alumina, and -alumina). The nickel-impregnated -alumina gave the best propene conversion and hydrogen yield.     

Utilization of red mud as catalyst in conversion of waste oil and waste plastics to fuel

The aim of this study was to investigate the possibilities of using a by-product (red mud) from alumina production as a catalyst for recovery of waste. The conversion of waste mineral oil (WMO) and waste mineral oil/municipal waste plastic (WMO/MWP) blends over red mud (RM), a commercial hydrocracking catalyst (silica–alumina), and a commercial hydrotreating catalyst (Ni–Mo/alumina) to fuel has been studied. The effect of the catalyst and the temperature on the product distribution (gas, liquid, and wax) and the properties of liquid products were investigated. In the case of hydrotreatment of WMO, the liquids obtained over RM at both 400° and 425°C had larger amounts of low-boiling hydrocarbons than that of thermal or catalytic treatment with hydrotreating catalyst. Gas chromatography and nuclear magnetic resonance analysis of the liquid products showed that RM had hydrogenation and cracking activity in hydrotreatment of WMO. In coprocessing of WMO with municipal waste plastics, temperature had an important effect as well as the amount of MWP in the blend and the catalyst type. The hydrocracking at 400°C produced no liquid product. In hydrocracking at 425°C, the product distribution varied with catalyst type and MWP amount. The commercial hydrocracking catalyst had more cracking ability in the conversion of WMO/MWP to liquid and gas fuel than RM. In the case of hydrocracking over RM, the largest amount of liquid having satisfactory quality was obtained only from the blend containing 20% MWP.     

Decomposition of mixed plastics consisting of polypropylene and polyethylene terephthalate into oils over titania/silica catalysts

The catalytic decomposition of mixed plastics consisting of polypropylene (PP) and polyethylene terephthalate (PET) has been investigated over titania/silica catalysts at 698 K. The yield of oil produced was about 70%, and the large amounts of C₁₈₊ hydrocarbons this contained was from the aromatics in PET. Gas was also produced, including C₃–C₅ hydrocarbons. The carbon-number fractions in the oil was influenced by the PET/(PP + PET) ratios and the catalyst weight. The titania/silica catalysts could be used repeatedly, and after they had been fouled, could be regenerated. From the Fourier Transform Infrared (FT–IR) spectroscopic data of adsorbed pyridine on the catalyst surface, most of the acid sites of the titania/silica catalysts were found to be Lewis sites where the hydride abstracted from PP pyrolysates react with PET pyrolysates to form oil and gas. Received: July 19, 2000 / Accepted: October 20, 2000     

Multiple use of waste catalysts with and without regeneration for waste polymer cracking

Waste plastics contain a substantial number of valuable chemicals. The wastes from post-consumer as well as from industrial production can be recycled to valuable chemical feedstock, which can be used in refineries and/or petrochemical industries. This chemical recycling process is an ideal approach in recycling the waste for a better environment. Polymer cracking using a laboratory fluidised bed reactor concentrated on the used highly contaminated catalyst, E-Cat 2. Even though E-Cat 2 had low activity due to fewer acid sites, the products yielded were similar with amorphous ASA and were far better than thermal cracking. The high levels of heavy metals, namely nickel and vanadium, deposited during their lifetime as an FCC catalyst, did not greatly affect on the catalyst activity. It was also shown that E-Cat 2 could be used with and without regeneration. Although there was more deactivation when there was no regeneration step, the yield of gases (C₂-C₇) remained fairly constant. For the first time, these results indicate that “waste” FCC catalyst (E-Cat) is a good candidate for future feedstock recycling of polymer waste. The major benefits of using E-Cat are a low market price, the ability to tolerate reuse and regeneration capacity.     

Catalytic degradation of PP with an Fe/activated carbon catalyst

We investigated the function of Fe and activated carbon (AC) as a catalyst by comparing Fe/AC with Fe/SiO₂ or AC, and also the effect of H₂ as a reaction gas on the product distribution in the catalytic degradation of polypropylene. Supported Fe promotes H₂ consumption to decompose solid residues, and AC support degrades heavy oil to produce light oil. As a result, using Fe/AC as a catalyst gives the maximum yield of the liquid product. For the reaction conditions, with a high reaction temperature or a long reaction time, the product distribution is more influenced by the thermal degradation than by the catalytic degradation. For the amount of Fe to load, 5wt% is the optimum condition in our reaction system. We demonstrated the mechanism of the degradation of polyolefins with hydrogen-capping catalysts.     

Pyrolysis of polyolefins for increasing the yield of monomers' recovery

Pyrolysis of plastic waste is an alternative way of plastic recovery and could be a potential solution for the increasing stream of solid waste. The objective of this work was to increase the yield the gaseous olefins (monomers) as feedstock for polymerization process and to test the applicability of a commercial Ziegler-Natta (Z-N): TiCl(4)/MgCl(2) for cracking a mixture of polyolefins consisted of 46%wt. of low density polyethylene (LDPE), 30%wt. of high density polyethylene (HDPE) and 24%wt. of polypropylene (PP). Two sets of experiments have been carried out at 500 and 650°C via catalytic pyrolysis (1% of Z-N catalyst) and at 650 and 730°C via only-thermal pyrolysis. These experiments have been conducted in a lab-scale, fluidized quartz-bed reactor of a capacity of 1-3kg/h at Hamburg University. The results revealed a strong influence of temperature and presence of catalyst on the product distribution. The ratios of gas/liquid/solid mass fractions via thermal pyrolysis were: 36.9/48.4/15.7%wt. and 42.4/44.7/13.9%wt. at 650 and 730°C while via catalytic pyrolysis were: 6.5/89.0/4.5%wt. and 54.3/41.9/3.8%wt. at 500 and 650°C, respectively. At 650°C the monomer generation increased by 55% up to 23.6%wt. of total pyrolysis products distribution while the catalyst was added. Obtained yields of olefins were compared with the naphtha steam cracking process and other potentially attractive processes for feedstock generation. The concept of closed cycle material flow for polyolefins has been discussed, showing the potential benefits of feedstock recycling in a plastic waste management.     

Solid State Reactions of Potato Starch with Urea and Biuret

Reaction of granular potato starch with urea and biuret resulted in the formation of products, which were soluble neither in cold nor boiling water. The net reaction was a monosubstitution of the hydrogen atom in one hydroxyl group in each D-glucose unit of starch with the either CO–NH₂ or CO–NH–CO–NH₂ moiety, respectively. Properties of the products, particularly these with urea, depended on the mode of reaction. Reactions were carried out in the microwave oven as well as with convection heating. The products retained the granular form of starch but a vast majority of granules were damaged. -Amylolysis of those materials revealed that their susceptibility to the enzyme increasing in the order: starch-amylolysis with simultaneous insolubility in water make these products suitable as ruminant fodder and, eventually, biodegradable material.     

Methane generation from corncobs treated with xylanolytic consortia

Consortia were developed for the treatment of corncobs for use as a feedstock in a biogas fermentor. The treatment of corncobs with xylanolytic consortia enhanced the production of methane and biogas. All five consortia developed produced the maximum biogas and methane at a 6% loading rate and 20 days hydraulic retention time (HRT). The maximum biogas yield of 0.59m³/kg volatile solids (VS) with a methane content of 62% was produced with the KK-10 consortium. This was apparently due to a maximum hemicellulose degradation of 88%.     

Effects of Temperature and Relative Humidity on Polylactic Acid Plastic Degradation

Three high molecular weight (120,000 to 200,000 g mol^–1) polylactic acid (PLA) plastic films from Chronopol (Ch-I) and Cargill Dow Polymers (GII and Ca-I) were analyzed for their degradation under various temperature and relative humidity (RH) conditions. Two sets of plastic films, each containing 11 samples, were randomly hung in a temperature/humidity-controlled chamber by means of plastic-coated paper clips. The tested conditions were 28, 40, and 55°C at 50 and 100% RH, respectively, and 55°C at 10% RH. The three tested PLA films started to lose their tensile properties when their weight-average molecular weight (M _w) was in the range of 50,000 to 75,000 g mol^–1. The average degradation rate of Ch-I, GII, and Ca-I was 28,931, 27,361, and 63,025 M _w/week, respectively. Hence, GII had a faster degradation rate than Ch-I and Ca-I under all tested conditions. The degradation rate of PLA plastics was enhanced by the increase in temperature and relative humidity. This trend was observed in all three PLA plastics (Ca-I, GII, and Ch-I). Of the three tested films, Ch-I was the first to lose its mechanical properties, whereas Ca-I demonstrated the slowest loss, with mechanical properties under all tested conditions.     

Investigation on thermal dechlorination and catalytic pyrolysis in a continuous process for liquid fuel recovery from mixed plastic wastes

A continuous system (feeding rate >1 kg/h) consisting of thermal dechlorination pre-treatment and catalytic pyrolysis with Fe-restructured clay (Fe-RC) catalyst was developed for feedstock recycling of PVC-containing mixed plastic waste. The vented screw conveyor which was specially designed for continuous dechlorination was able to achieve dechlorination efficiency of over 90 % with a feedstock retention time longer than 35.5 min. The chlorine content of the pyrolytic oil obtained after dechlorination was in the range of 6.08–39.50 ppm, which meet the specification for reclamation pyrolytic oil in Japan. Fe-RC was found to significantly improve the yield of pyrolytic oil (achieved to 83.73 wt%) at the optimized pyrolysis temperature of 450 °C and catalyst dosage of 60 g. With the optimized parameters, Fe-RC showed high selectivity for the C₉–C₁₂ and C₁₃–C₁₉ oil fraction, which are the major constituents of kerosene and diesel fuel, demonstrating that this catalyst can be applied in the pyrolysis of mixed plastic wastes for the production of kerosene and diesel fuel. Overall, the continuous process exhibited high stability and consistently high-oil yield upon reaching steady state, indicating its potential up-scaling application in the industry.     

Landfill mining and waste characterization: a strategy for remediation of contaminated areas

This article describes landfill-mining tests, including excavation, screening, and fraction characterization, carried out in the Msalycke and Gladsax landfills for municipal solid waste (MSW) in Sweden. The excavated waste in these two sites was 17–22 and 23–25 years old, respectively. The main part of Msalycke was unaffected by degradation, and during excavations no substantial amount of biogas was detected. After screening, three size fractions were obtained: <18mm, 18–50mm, and >50mm. Soil amendment and anaerobic digestion with energy extraction are suggested for the first and second fraction, respectively. Incineration with energy recovery is possible with the third fraction after any coarse (inert) material is removed, and construction/demolition waste can easily be recycled provided that it is not contaminated by hazardous material. Excavated waste taken from different depths was also analysed and compared in relation to composition, calorific value, and leachate constituents.     

Biodegradability of degradable plastic waste.

Plastic waste constitutes the third largest waste volume in Malaysian municipal solid waste (MSW), next to putrescible waste and paper. The plastic component in MSW from Kuala Lumpur averages 24% (by weight), whereas the national mean is about 15%. The 144 waste dumps in the country receive about 95% of the MSW, including plastic waste. The useful life of the landfills is fast diminishing as the plastic waste stays un-degraded for more than 50 years. In this study the compostability of polyethylene and pro-oxidant additive-based environmentally degradable plastics (EDP) was investigated. Linear low-density polyethylene (LLDPE) samples exposed hydrolytically or oxidatively at 60 degrees C showed that the abiotic degradation path was oxidative rather than hydrolytic. There was a weight loss of 8% and the plastic has been oxidized as shown by the additional carbonyl group exhibited in the Fourier transform infra red (FTIR) Spectrum. Oxidation rate seemed to be influenced by the amount of pro-oxidant additive, the chemical structure and morphology of the plastic samples, and the surface area. Composting studies during a 45-day experiment showed that the percentage elongation (reduction) was 20% for McD samples [high-density polyethylene, (HDPE) with 3% additive] and LL samples (LLDPE with 7% additive) and 18% reduction for totally degradable plastic (TDP) samples (HDPE with 3% additive). Lastly, microbial experiments using Pseudomonas aeroginosa on carbon-free media with degradable plastic samples as the sole carbon source, showed confirmatory results. A positive bacterial growth and a weight loss of 2.2% for degraded polyethylene samples were evident to show that the degradable plastic is biodegradable.     

Degradation of poly(β-hydroxyalkanoates) and polyolefin blends in a municipal wastewater treatment facility

Six types of plastics and plastic blends, the latter composed at least partially of biodegradable material, were exposed to aerobically treated wastewater (activated sludge) to ascertain their biodegradability. In one study, duplicate samples of 6% starch in polypropylene, 12% starch in linear low-density polyethylene, 30% polycaprolactone in linear low-density polyethylene, and poly(-hydroxybutyrate-co-hydroxyvalerate) (PHB/V), a microbially produced polyester, were exposed to activated sludge for 5 months, and changes in mass, molecular weight average, and tensile properties were measured. None of the blended material showed any sign of degradation. PHB/V, however, showed a considerable loss of mass and a significant loss of tensile strength. In a second study, PHB/V degraded rapidly, but another type of microbial polymer which forms a thermoplastic elastomer, poly(-hydroxyoctanoate), did not degrade. These results illustrate the potential for disposal and degradation of PHB/V in municipal wastewater.