CATALYTIC PYROLYSIS OF DISCARDED COVID-19 MASKS OVER SEPIOLITE

This research aims to develop a new strategy to valorize wasted COVID-19 masks based on pyrolysis to convert them into useful products. First, surgical and FFP2 masks were thermally pyrolyzed at temperatures of 450–550 ºC with the purpose of determining gas, liquid (oil) and solid (char) yields. At low temperatures, solid yield was high, while at high temperatures the gas product was enhanced. The highest yield of liquid was found at an operating temperature of 500 ºC in both surgical and FPP2 masks pyrolysis. The liquid product yields were 59.08% and 58.86%, respectively. Then, the volatiles generated during thermal pyrolysis of residual masks were cracked over sepiolite as catalyst at a temperature of 500 ºC. The catalytic pyrolysis increased the yield of gas product (43.89% against 39.52% for surgical masks and 50.53% against 39.41% for FFP2 masks) and decreased the viscosity of the liquid product. Finally, the effect of sepiolite regeneration and reuse in consecutive pyrolysis tests was examined. Results showed that, with the higher regeneration-reuse of sepiolite, the catalyst was degraded obtaining a liquid product with higher molecular mass. This effect was hardly noticeable in the case of FFP2 masks. © 2022 International Multidisciplinary Scientific Geoconference. All rights reserved.

Valorization of hazardous plastic wastes into value-added resources by catalytic pyrolysis-gasification: A review of techno-economic analysis

Plastic waste pollution has grown exponentially since the 1950s. This situation was exacerbated when the volume of personal protective equipment (PPE)-based plastic waste surged after the COVID-19 pandemic. Plastic waste management such as landfills and incineration have adverse effects on the environment and human health due to the leaching of hazardous chemicals and the emission of toxic gases. Modern solutions such as biodegradable plastics and green brick technology are expensive and not well developed to valorize the current accumulation of plastic waste. This has led to the emergence of thermal degradation processes, which is faster and more realistic to solve the PPE-based plastic waste buildup. Pyrolysis and gasification systems to valorize plastic waste into hydrocarbons and fuels are discussed and compared with examples respectively. Scoping review approach is employed to conduct this study. To further increase the value of the final product of plastic waste management, the integrated pyrolysis system to upcycle plastic waste to carbon nanomaterials (CNMs) and the factors affecting the production of non-condensable gases are critically reviewed. The importance of feedstock composition, catalyst type, pyrolysis operating condition (including gas condition and temperature profiles) based on various studies is discussed. The potential and limitation of an integrated pyrolysis system are assessed from kinetic analysis, economic analysis and life-cycle assessment. This review is expected to contribute to the industrial-scale development of sustainable upcycling of plastic waste and enhance the production of desirable gas components for CNM synthesis for environmental sustainability.

Strategic use of thermo-chemical processes for plastic waste valorization

Plastic is one of the most widely used materials in industries including packaging, building, and construction due to its lightweight, low cost, durability, and versatility. However, the mass production of plastics has exacerbated plastic pollution. Globally, plastic waste is predominantly incinerated, landfilled, or released into the environment;only 5-6% is recycled in the United States. Although conventional management protocols such as incineration and landfilling are evidently effective for plastic waste disposal, they are associated with significant environmental and societal challenges. In addition, most recycled plastic is downcycled, and thus does not provide sufficient incentive to use recycled materials instead of virgin materials. This review discusses thermo-chemical upcycling processes such as (catalytic) pyrolysis and heterogeneous catalysis. Furthermore, we present the recent progress in the thermo-chemical upgrading of single-type plastic waste, heterogeneous plastic mixtures, and post-consumer plastic waste obtained from different locations and, finally, suggest future research directions.

In-depth study of kinetics, thermodynamics, and reaction mechanism of catalytic pyrolysis of disposable face mask using spent adsorbent based catalysts

Millions of face mask has been converted to waste since the onset of COVID-19 virus. Hence, present study explores the feasibility of converting disposable face masks to energy through catalytic pyrolysis process using a low-cost waste (spent aluminum hydroxide/oxide nanoparticle adsorbent) derived catalyst. Thermogravimetric analysis of the non-catalytic and catalytic pyrolysis of disposable face mask was conducted at varied heating rates of 10 °C/min, 20 °C/min, 30 °C/min, 40 °C/min, and 50 °C/min, respectively. Iso-conversional methods, Kissinger Akahira Sunose (KAS) and Ozawa Flynn Wall (OFW) were used for the kinetic study. The reaction mechanism was analyzed using Criado's z-master plot (CZMP) method along with the determination of thermodynamic parameters of the process. Results found that the addition of a catalyst to the process benefits the overall efficacy of the process by reducing the activation energy (Ea) (without catalyst;OFW-Ea: 188.7 kJ/mol, KAS-Ea: 186.2 kJ/mol) as well as lowering the disordered state of the process. Metal doped catalyst (Ni/ γ-Al2O3) (OFW-Ea: 168.4 kJ/mol, KAS-Ea: 167.8 kJ/mol) shows a larger reduction in activation energy in comparison to bare alumina (γ-Al2O3) (OFW-Ea: 183.2 kJ/mol, KAS-Ea: 180.4 kJ/mol). The current study presented disposable face masks as reclaimable in terms of energy and waste-derived catalyst as a potent solution to be explored in place of high-cost commercial catalysts. © 2023 Energy Institute

CO2-mediated thermal treatment of disposable plastic food containers

In accordance with global economic prosperity, the frequencies of food delivery and takeout orders have been increasing. The pandemic life, specifically arising from COVID-19, rapidly expanded the food delivery service. Thus, the massive generation of disposable plastic food containers has become significant environmental problems. Establishing a sustainable disposal platform for plastic packaging waste (PPW) of food delivery containers has intrigued particular interest. To comprise this grand challenge, a reliable thermal disposable platform has been suggested in this study. From the pyrolysis process, a heterogeneous plastic mixture of PPW was converted into syngas and value-added hydrocarbons (HCs). PPW collected from five different restaurants consisted of polypropylene (36.9 wt%), polyethylene (10.5 wt%), polyethylene terephthalate (18.1 wt%), polystyrene (13.5 wt%), polyvinyl chloride (4.2 wt%), and other composites (16.8 wt%). Due to these compositional complexities, pyrolysis of PPW led to formations of a variety of benzene derivatives and aliphatic HCs. Adapting multi-stage pyrolysis, the different chemicals were converted into industrial chemicals (benzene, toluene, styrene, etc.). To selectively convert HCs into syngas (H2 and CO), catalytic pyrolysis was adapted using supported Ni catalyst (5 wt% Ni/SiO2). Over Ni catalyst, H2 was produced as a main product due to C[sbnd]H bond scission of HCs. When CO2 was used as a co-reactant, HCs were further transformed to H2 and CO through the chemical reactions of CO2 with gas phase HCs. CO2-assisted catalytic pyrolysis also retarded catalyst deactivation inhibiting coke deposition on Ni catalyst. © 2022 Elsevier B.V.

Thermo-Chemical conversion of polyolefin-based facemask using bench-scale pyrolysis system

The generation of personal protective equipment (PPE) waste due to the impact of COVID has increased multi-fold globally. In this study, pyrolysis of polyolefin-based PPEs was carried out using a bench-scale reactor of 2 kg per batch capacity. Thermogravimetric (TGA) analysis of face masks was carried out to identify the optimal parameters for the pyrolysis process. Different combinations of catalysts (ZSM-5 and montmorillonite), catalyst to feed ratio (2.5% and 5%), experiment duration (2 h and 3 h), and process temperature (450 degrees C and 510 degrees C) were tested to determine the maximum yield of the pyrolysis oil. The oil and char obtained from the pyrolysis of PPEs were analyzed for its gross calorific value (GCV), elemental analysis (CHNS), and chemical composition. Based on the experiments conducted, the optimum pyrolysis temperature, catalyst, catalyst to feed ratio, and batch time for maximum oil yield (55.9% w/w) were determined to be 510 degrees C, ZSM-5, 5%, and 2 hours, respectively. Oil was free of sulfur and had a calorific value of 43.7 MJ/kg, which is comparable to commercial diesel fuel and makes it a suitable alternative fuel for ships, boilers, and furnaces.

CO2-mediated thermal treatment of disposable plastic food containers

In accordance with global economic prosperity, the frequencies of food delivery and takeout orders have been increasing. The pandemic life, specifically arising from COVID-19, rapidly expanded the food delivery service. Thus, the massive generation of disposable plastic food containers has become significant environmental problems. Establishing a sustainable disposal platform for plastic packaging waste (PPW) of food delivery containers has intrigued particular interest. To comprise this grand challenge, a reliable thermal disposable platform has been suggested in this study. From the pyrolysis process, a heterogeneous plastic mixture of PPW was converted into syngas and value-added hydrocarbons (HCs). PPW collected from five different restaurants consisted of polypropylene (36.9 wt%), polyethylene (10.5 wt%), polyethylene terephthalate (18.1 wt%), polystyrene (13.5 wt%), polyvinyl chloride (4.2 wt%), and other composites (16.8 wt%). Due to these compositional complexities, pyrolysis of PPW led to formations of a variety of benzene derivatives and aliphatic HCs. Adapting multi-stage pyrolysis, the different chemicals were converted into industrial chemicals (benzene, toluene, styrene, etc.). To selectively convert HCs into syngas (H2 and CO), catalytic pyrolysis was adapted using supported Ni catalyst (5 wt% Ni/SiO2). Over Ni catalyst, H2 was produced as a main product due to CH bond scission of HCs. When CO2 was used as a co-reactant, HCs were further transformed to H2 and CO through the chemical reactions of CO2 with gas phase HCs. CO2-assisted catalytic pyrolysis also retarded catalyst deactivation inhibiting coke deposition on Ni catalyst.

Carbon Nanotube prepared by catalytic pyrolysis as the electrode for supercapacitors from polypropylene wasted face masks.

The massive global consumption and discarded face masks drove by the ongoing spread of COVID-19. Meantime, incineration and landfill discarded face masks would result in severe environmental pollution and infectious hazards. Herein a suggestion to recycle polypropylene waste masks into CNTs by an environmentally friendly and high-added value disposal process was proposed, and which was prepared as supercapacitor electrode materials for energy storage attempting. The CNTs were prepared from waste masks by catalysis pyrolysis with Ni-Fe bimetallic catalysts. Especially, the bamboo-like structure CNT was obtained with Ni/Fe molar ratio is 3. This structure owned a high specific capacitance compared to other standard CNTs. Its specific capacitance could reach 56.04 F/g (1 A/g) and has excellent cycling stability with a capacitance retention rate of the material is 85.41% after 10,000 cycles. Besides, the assembled capacitor possesses a good energy density of 4.78 Wh/kg at a power density of 900 W/kg. Thus, this work provides a sustainable and cost-effective strategy for disposing waste masks into high-valuable CNT, and their potential application for supercapacitors was also studied and exploited. It would provide a new idea for recycling and utilizing other polypropylene wastes such as medical devices.

Production of Hydrocarbon Liquid Fuels from waste Personal Protective Equipment (PPEs) through Pyrolysis

A novel coronavirus disease (Covid-19) epidemic identified in a capital of Hubei territory of China in the month of December 2019. Covid-19 was caused by severe acute respiratory syndrome coronavirus 2 (SARS-COV-2) and WHO announced it as pandemic. Health professionals were found at more risk due to frontline patronage during the pandemic. The only way to protect the health of frontliners is to appropriate utilization of PPEs. In this situation, there is always a concern about the shortage of PPEs;on the other hand, environmental consequence is the major issue because of its disposal. Plastic waste pyrolysis may play a major role to modify this waste. Pyrolysis is known as a tertiary recovery process which gives three recyclable end products: an oil, gas, and char. Generally, PPE waste has predominant hydrocarbon polymers which can be utilized as a fuel or feedstock by the synthetic enterprises. In this study, we have used pyrolysis method to transform 50gm PPE waste into hydrocarbons, which can be utilized either as powers or as feedstock in the petrochemical business. The maximum yield of fluid (35 %) was acquired at the reaction performed at 100 degrees C along with the cooling water at 17.59 degrees C. Maximum wax (11.02 %) was produced at 500 degrees C. The findings of this study indicate that non-biodegradable plastic waste may be transformed into useful products which may further be utilized in demanding segments. We have also tried to explore various potential applications of another product of this study i. e., oil.

A new strategy for butanol extraction from COVID-19 mask using catalytic pyrolysis process over ZSM-5 zeolite catalyst and its kinetic behaviour

This research aims to develop a new thermochemical strategy to extract butane from the billions of wasted Covid-19 masks that are generated every month. The experiments were conducted with 3-ply face masks (3PFM) over ZSM-5 zeolite with different ratios of ZSM-5 to 3PFM (w/w: 6, 12, 25, and 50 wt.%) using thermogravimetry (TGA) at different heating conditions. Also, the effect of ZSM-5 concentration and heating rates was examined using TG-FTIR and GC-MS measurements. Besides, the kinetics behaviour of the developed strategy was modelled using linear and nonlinear isoconversional modelling techniques, thus calculating the activation energy (Ea) for each conversion region. Finally, all required parameters to fit TGA and differential scanning calorimetry (DTG) experimental curves were estimated using the distributed activation energy (DAEM) and the independent parallel reactions (IPR) techniques, respectively. The results showed that the decomposed samples are very rich in aromatic and aliphatic (-C-H) compounds. Meanwhile, and based on GC-MS results, butanol compound was the basic component in the generated compounds with abundance of 31% at 25 wt.% of ZSM-5 at lowest heating rate (5 ˚C/min), whereas the average Ea at 25% of ZSM-5 (sample enriched with butanol) was estimated in the ranges 158-187 kJ mol−1 (linear methods with R2 > 0.96) and 167-169 kJ/mol (nonlinear methods with R2 > 0.98). Finally, DAEM and IPR succeeded to simulate TGA and DTG curves of ZSM-5/3PFM samples with very small deviation. Based on that, the catalytic pyrolysis strategy over ZSM-5 zeolite can be used effectively to dispose of Covid-19 masks and to convert them into butanol compound that can be used as a liquid fuel and lubricant.

Recent Trends in the Pyrolysis of Non-Degradable Waste Plastics.

Waste plastics are non-degradable constituents that can stay in the environment for centuries. Their large land space consumption is unsafe to humans and animals. Concomitantly, the continuous engineering of plastics, which causes depletion of petroleum, poses another problem since they are petroleum-based materials. Therefore, energy recovering trough pyrolysis is an innovative and sustainable solution since it can be practiced without liberating toxic gases into the atmosphere. The most commonly used plastics, such as HDPE, LDPE (high- and low-density polyethylene), PP (polypropylene), PS (polystyrene), and, to some extent, PC (polycarbonate), PVC (polyvinyl chloride), and PET (polyethylene terephthalate), are used for fuel oil recovery through this process. The oils which are generated from the wastes showed caloric values almost comparable with conventional fuels. The main aim of the present review is to highlight and summarize the trends of thermal and catalytic pyrolysis of waste plastic into valuable fuel products through manipulating the operational parameters that influence the quality or quantity of the recovered results. The properties and product distribution of the pyrolytic fuels and the depolymerization reaction mechanisms of each plastic and their byproduct composition are also discussed.

Kinetic Analysis for the Catalytic Pyrolysis of Polypropylene over Low Cost Mineral Catalysts

A kinetic analysis of non-catalytic pyrolysis (NCP) and catalytic pyrolysis (CP) of polypropylene (PP) with different catalysts was performed using thermogravimetric analysis (TGA) and kinetic models. Three kinds of low-cost natural catalysts were used to maximize the cost-effectiveness of the process: natural zeolite (NZ), bentonite, olivine, and a mesoporous catalyst, Al-MCM-41. The decomposition temperature of PP and apparent activation energy (Ea) were obtained from the TGA results at multiple heating rates, and a model-free kinetic analysis was performed using the Flynn–Wall–Ozawa model. TGA indicated that the maximum decomposition temperature (Tmax) of the PP was shifted from 464 °C to 347 °C with Al-MCM-41 and 348 °C with bentonite, largely due to their strong acidity and large pore size. Although olivine had a large pore size, the Tmax of PP was only shifted to 456 °C, because of its low acidity. The differential TG (DTG) curve of PP over NZ revealed a two-step mechanism. The Tmax of the first peak on the DTG curve of PP with NZ was 376 °C due to the high acidity of NZ. On the other hand, that of the second peak was higher (474 °C) than the non-catalytic reaction. The Ea values at each conversion were also decreased when using the catalysts, except olivine. At <0.5 conversion, the Ea obtained from the CP of PP with NZ was lower than that with the other catalysts: Al-MCM-41, bentonite, and olivine, in that order. The Ea for the CP of PP with NZ increased more rapidly, to 193 kJ/mol at 0.9 conversion, than the other catalysts.