A multi-purpose pilot-scale molten metal & molten salt pyrolysis reactor.

This paper describes the design features and operational details of a molten metal pyrolysis reactor. Such a reactor allows pyrolysis experimentation on biomass, aluminium-laminated plastics, mixed plastics, carbon fibre materials, etc. Experimental results on biodegradable plastic, carbon fibre composites, biomass and printed circuit boards (PCBs) are presented.•The inner container can have a sloped or flat-bottom depending on the material.•The method can be used to pyrolyse composite and pure materials.

Recycling of aluminium laminated pouches and Tetra Pak cartons by molten metal pyrolysis - Pilot-scale experiments and economic analysis.

Aluminium laminated (AL) pouch packages and aluminium laminated Tetra-Pak cartons are considered unrecyclable, reducing their otherwise excellent lifecycle performance. This paper describes experimental results on pilot plant trials to recycle AL packages with a molten metal pyrolysis reactor. The experimental evidence shows that both package formats can be recycled and that clean aluminium can be recovered. However, the recovered aluminium from Al pouches may require mechanical cleaning as the consumer's information is printed onto the aluminium, leaving a carbon residue on the recovered aluminium. On the other hand, over 90% of the polypropylene plastic layer on the AL packaging pyrolysed into waxes, pointing to excellent kinetics. Moreover, an economic analysis of a 4,000 t/y commercial-scale plant demonstrates that a molten metal AL recycling plant is economically viable, achieving an internal rate of return (IRR) of over 20%.