Chemical recycling of polyolefin waste: from the perspective of efficient pyrolysis reactors

doi:10.1007/s11705-024-2498-x

Front. Chem. Sci. Eng.

2024, Vol. 18

Issue (12) : 147 https://doi.org/10.1007/s11705-024-2498-x

Chemical recycling of polyolefin waste: from the perspective of efficient pyrolysis reactors

Weiqiang Gao^1,², Yinlong Chang^1,², Qimin Zhou^1,², Qingyue Wang^1,²(

), Khak Ho Lim^1,², Deliang Wang^1,², Jijiang Hu^1,², Wen-Jun Wang^1,², Bo-Geng Li^1,², Pingwei Liu^1,²(

)

¹. State Key Laboratory of Chemical Engineering, College of Chemical and Biological Engineering, Zhejiang University, Hangzhou 310058, China
². Institute of Zhejiang University-Quzhou, Quzhou 324000, China

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Abstract

Polyolefins, widely used for packaging, construction, and electronics, facilitate daily life but cause severe environmental pollution when discarded after usage. Chemical recycling of polyolefins has received widespread attention for eliminating polyolefin pollution, as it is promising to convert polyolefin wastes to high-value chemicals (e.g., fuels, light olefins, aromatic hydrocarbons). However, the chemical recycling of polyolefins typically involves high-viscosity, high-temperature and high-pressure, and its efficiency depends on the catalytic materials, reaction conditions, and more essentially, on the reactors which are overlooked in previous studies. Herein, this review first introduces the mechanisms and influencing factors of polyolefin waste upcycling, followed by a brief overview of in situ and ex situ processes. Emphatically, the review focuses on the various reactors used in polyolefin recycling (i.e., batch/semi-batch reactor, fixed bed reactor, fluidized bed reactor, conical spouted bed reactor, screw reactor, molten metal bed reactor, vertical falling film reactor, rotary kiln reactor and microwave-assisted reactor) and their respective merits and demerits. Nevertheless, challenges remain in developing highly efficient reacting techniques to realize the practical application. In light of this, the review is concluded with recommendations and prospects to enlighten the future of polyolefin upcycling.

Keywords polyolefins chemical recycling thermal pyrolysis catalytic pyrolysis reactors

Corresponding Author(s): Qingyue Wang,Pingwei Liu

Just Accepted Date: 27 June 2024 Issue Date: 18 September 2024

Cite this article:

Weiqiang Gao,Yinlong Chang,Qimin Zhou, et al. Chemical recycling of polyolefin waste: from the perspective of efficient pyrolysis reactors[J]. Front. Chem. Sci. Eng., 2024, 18(12): 147.

URL:

https://academic.hep.com.cn/fcse/EN/10.1007/s11705-024-2498-x
https://academic.hep.com.cn/fcse/EN/Y2024/V18/I12/147

Fig.1 Global primary plastic waste generation by polymer in 2019 (date source: OECD 2022). Reprinted with permission from Ref. [4], copyright 2023, Our world in data. Note: Polymers are color-coded to indicate recyclability: widely recycled (green), moderately recycled (blue), limited recyclability (orange), usually non-recycled (red), and unknown recyclability (violet). Polymer types: ABS, acrylonitrile butadiene styrene; ASA, acrylonitrile styrene acrylate; SAN, styrene acrylonitrile; PUR, polyurethane; PVC, polyvinyl chloride; PS, polystyrene; LLDPE, linear LDPE; PET, polyethylene terephthalate.

Tab.1 Product distribution of polyolefin thermal pyrolysis under different reaction conditions

Tab.2 Catalytic performance of different polyolefin wastes under different reaction conditions

Fig.3 (a) Reaction pathways for conversion of model compound in polyolefin plastic pyrolysis oil (1-octene) over zeolites, (b) its relation between BTX yield and paraffin yield, molar hydrogen selectivity, and the hydrogen transfer rate associated with the average zeolite pore size. Reprinted with permission from Ref. [79], copyright 2024, Elsevier. (c) Proposed mechanism of catalytic pyrolysis of LDPE over Zn-P/HZSM-5. Reprinted with permission from Ref. [83], copyright 2024, Elsevier BV.

Fig.4 A graphical illustration of the thermo-catalytic pyrolysis of LDPE in one-step (in situ) and two-step (ex situ) processes. Reprinted with permission from Ref. [92], copyright 2022, Elsevier BV.

Reactor types	Applicable processes	Advantages	Disadvantages	Ref.
Batch/semi-batch reactor	Thermal/catalytic pyrolysis	Simple design, easy to control the operating parameters, no limitation on particle size	High reaction times, low heat transfer rate, more secondary reactions leading to coke formation, wide product distribution, low production capacity	[103?107]
Fixed bed reactor	Thermal/catalytic pyrolysis	Simple design, easy to control, no limitation on particle size	Long residence time, uneven temperature distribution, low heat transfer rate, difficulty to continuously operated	[42,51,104,108?113]
FBR	Thermal/catalytic pyrolysis	High efficiency of heat and mass transfer, continuous operation, large scale operating, narrow product distribution, allows for catalysts circulation, efficient contact with catalysts	Defluidization may occur, catalysts attrition, high investment in equipment	[2,54,114?120]
CSBR	Thermal/catalytic pyrolysis	High efficiency of heat and mass transfer, accommodate a broad particle size distribution, bigger particles and different particle densities, narrow product distribution, efficient contact with catalysts	Problems with catalyst feeding and entrainment and collection of pyrolysis products, catalysts attrition, high investment in equipment, difficulties for catalyst circulation	[49,75,121?127]
Screw reactor	Thermal/catalytic pyrolysis	Efficient blending between plastics and catalysts, treatment of high viscosity materials, residence time controllable, conveying raw material, no limitation on particle size	Wear and tear of the screw over prolonged operation, low heat efficiency	[58,103,128,129]
Molten metal bed reactor	Thermal pyrolysis	Uniform temperature distribution, high heat transfer efficiency, no limitation on particle size	High cost of equipment, possible metal pollution, difficulty of scale-up	[130?132]
Vertical falling film reactor	Thermal pyrolysis	Uniform heating way, no limitation on particle size	Complexity in large-scale manufacturing	[133?135]
Rotary kiln reactor	Thermal/catalytic pyrolysis	No limitations on raw material type and particle size, efficient blending between plastics and catalysts, simple design, continuous mixing of incoming wastes	High energy consumption, high equipment cost, difficult to guarantee reaction uniformity	[136?140]
Microwave-assisted reactor	Thermal/catalytic pyrolysis	Fast and uniform heating, selective heating, easy control of the operating parameters	High equipment cost, requires a large amount of microwave absorbing materials, cannot be applied on a large scale	[41,67,69,141?147]

Tab.3 The applicable process, advantages and disadvantages of different pyrolysis reactors

Fig.5 (a) Schematic diagram of two-step fixed bed reactor; yields of selected aromatic compounds in (b) noncatalyzed; (c) catalyzed product oil from processing of real-world plastics (MP), the simulated mixture of plastics (SMP), and virgin plastics (PE, PP, PS, PET). Reprinted with permission from Ref. [157], copyright 2015, American Chemical Society; (d) schematic flow diagram of the novel pyrolysis reactor system. Reprinted with permission from Ref. [51], copyright 2019, Institution of Chemical Engineers.

Fig.7 (a) Schematic diagram of CSBR. Reprinted with permission from Ref. [127], copyright 2021, Wiley-VCH Verlag. (b) Double-bed CSBR. Reprinted with permission from Ref. [173], copyright 2014, Elsevier.

Fig.10 Schematic diagram of two-step pyrolysis reactor. (a) Combined with CSBR and fixed bed reactor. Reprinted with permission from Ref. [48], copyright 2012, American Chemical Society. (b) Combined with microwave reactor and fixed bed reactor. Reprinted with permission from Ref. [190], copyright 2023, Elsevier Ltd.

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