Pyrolysis: Transforming Plastic Waste into Future Fuel

Humans have always excelled at utilizing innovation and creativity to turn the unwanted into something valuable. Today, this is happening with plastic waste.

We all recognize that this waste, occurring across various industries from food to fashion, is having increasingly negative impacts. Due to the waste comprising multiple types of plastics, it is typically too difficult to recycle. However, the good news is that plastic waste can be broken down and recycled back into gas and oil.

The Power of Pyrolysis

Recycling plastic waste is achieved through pyrolysis, a thermal process of heating plastics to high temperatures (typically between 450-650°C) in the absence of oxygen. This occurs in a fluidized bed reactor at a fixed reaction temperature and atmospheric pressure. During this process, the long polymer chains of plastics are broken down into shorter liquid and gaseous hydrocarbons.

The result includes several byproducts, such as pyrolysis oil, char, and gas. The composition of this oil depends on the type of plastic waste it comes from and the specific pyrolysis conditions. Nonetheless, it is always a complex mix of compounds, including additives, fillers, colorants, pigments, dust, condensable, and non-condensable gases.

Transforming Waste into Practical New Products

Since pyrolysis occurs without oxygen, it prevents combustion, and the pyrolysis oil can be converted into useful products such as new plastics, hydrogen, and fuels. For instance, pyrolysis oil shows potential as a more cost-effective and less environmentally impactful alternative to diesel. The char byproduct of pyrolysis can also be used in soil, carbon sequestration, and filtration.

In short, pyrolysis helps manufacturers reduce plastic pollution, enable plastic recycling, and create valuable products while lessening their environmental impact. And many companies are increasingly recognizing this potential. For example, it is expected that Shell, SABIC, and Dow will process over 100,000 tons per year of pyrolysis oil from plastic waste at steam crackers in the Netherlands by 2025.

Perfecting Pyrolysis with Advanced Analytics

To maximize the benefits of pyrolysis oil, the process must be carefully optimized for its intended use. With Malvern Panalytical, it is possible.

Our Epsilon 1 XRF solutions help detect numerous toxic elements in plastic waste feedstock right from the start. Our unique reference materials provide reliable results, including our TOXEL, ADPOL, and RoHS calibration standards for XRF. Next, during the pyrolysis process, using the Mastersizer and Aeris, you can analyze particle size, crystallinity, and atomic structure of catalysts inside the pyrolysis fluidized bed reactor. Finally, equipment such as Epsilon 1 and Epsilon Xflow allow the elemental composition analysis of pyrolysis oil to strictly control pyrolysis oil products.

Turning Waste to Value

In addition to our solutions, we are proud to collaborate with various organizations exploring the potential of pyrolysis. For instance, we participate in several ISO committees dealing with test methods, such as ISO TC 28, to identify important chemical elements like chlorine in pyrolysis oil. We are also members of the Circular Plastics NL program within the Dutch National Growth Fund, working to make plastics entirely circular.

Finally, we are members of the ASTM International Committee D20 on Polymers and Plastics. Here, we act as a liaison among various organizations, including ISO, CEN, NEN, and DIN, involved in developing standards for plastic recycling and microplastics.

With this network and our analytical solutions, we are ready to help turn lemons into lemonade, and plastics into pyrolysis oil, driving a more sustainable future for the petrochemical industry and beyond.

Curious how we can support plastic recycling? Contact us below or explore the solutions on our Plastics and Polymers Page.