Catalytic microwave-assisted pyrolysis of plastic waste to produce naphtha for a circular economy

Leilei Dai; Hailong Zhao; Nan Zhou; Kirk Cobb; Paul Chen; Yanling Cheng; Hanwu Lei; Rongge Zou; Yunpu Wang; Roger Ruan

doi:10.1016/j.resconrec.2023.107154

Catalytic microwave-assisted pyrolysis of plastic waste to produce naphtha for a circular economy

Leilei Dai, Hailong Zhao, Nan Zhou, Kirk Cobb, Paul Chen, Yanling Cheng, Hanwu Lei, Rongge Zou, Yunpu Wang, Roger Ruan

Research output: Contribution to journal › Article › peer-review

8 Scopus citations

Abstract

Catalytic cracking of plastics into naphtha as a substitute for new plastic production has the potential to contribute to the plastic circular economy. However, mitigating catalyst deactivation in large-scale processes poses a significant challenge. Here, we demonstrate a remarkable improvement (4.3 × to 12.3 ×) in catalyst lifetime by utilizing hierarchical ZSM-5 catalysts compared to conventional analogues. Increasing the Brønsted acid concentration from 0 to 302 µmol/g enhances catalyst lifetime by over 46 × and boosts cumulative aromatic selectivity from 6 to 73%. Catalyst characterization reveals the development of significant voids after modification, enhancing molecular transport within the hierarchical ZSM-5. Economic analysis shows a pilot system with a 10 ton/day capacity yielding an annual profit of $344,999 and an 11.5% return on investment. Life cycle assessment indicates a reduction of 817.6 kg CO₂ eq compared to traditional plastic-to-fuels technology. These findings advance the plastic circular economy and bring us closer to commercial implementation.

Original language	English
Article number	107154
Journal	Resources, Conservation and Recycling
Volume	198
DOIs	https://doi.org/10.1016/j.resconrec.2023.107154
State	Published - Nov 2023
Externally published	Yes

Funding

We acknowledge the financial support from the National Natural Science Foundation of China ( 52170141 , 21878137 ), China Scholarship Council (CSC), Resynergi, the University of Minnesota MnDrive Environment Program MNE12, and the University of Minnesota Center for Biorefining. Parts of this work were carried out in the Characterization Facility, University of Minnesota, which receives partial support from NSF through the MRuSEC program.

Funders	Funder number
National Science Foundation
University of Minnesota
National Natural Science Foundation of China	52170141, 21878137
National Natural Science Foundation of China
China Scholarship Council

Keywords

Catalytic cracking
Hierarchical
Naphtha
Plastic waste
ZSM-5

UN SDGs

This output contributes to the following UN Sustainable Development Goals (SDGs)

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10.1016/j.resconrec.2023.107154

Cite this

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title = "Catalytic microwave-assisted pyrolysis of plastic waste to produce naphtha for a circular economy",

abstract = "Catalytic cracking of plastics into naphtha as a substitute for new plastic production has the potential to contribute to the plastic circular economy. However, mitigating catalyst deactivation in large-scale processes poses a significant challenge. Here, we demonstrate a remarkable improvement (4.3 × to 12.3 ×) in catalyst lifetime by utilizing hierarchical ZSM-5 catalysts compared to conventional analogues. Increasing the Br{\o}nsted acid concentration from 0 to 302 µmol/g enhances catalyst lifetime by over 46 × and boosts cumulative aromatic selectivity from 6 to 73%. Catalyst characterization reveals the development of significant voids after modification, enhancing molecular transport within the hierarchical ZSM-5. Economic analysis shows a pilot system with a 10 ton/day capacity yielding an annual profit of $344,999 and an 11.5% return on investment. Life cycle assessment indicates a reduction of 817.6 kg CO2 eq compared to traditional plastic-to-fuels technology. These findings advance the plastic circular economy and bring us closer to commercial implementation.",

keywords = "Catalytic cracking, Hierarchical, Naphtha, Plastic waste, ZSM-5",

author = "Leilei Dai and Hailong Zhao and Nan Zhou and Kirk Cobb and Paul Chen and Yanling Cheng and Hanwu Lei and Rongge Zou and Yunpu Wang and Roger Ruan",

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year = "2023",

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doi = "10.1016/j.resconrec.2023.107154",

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T1 - Catalytic microwave-assisted pyrolysis of plastic waste to produce naphtha for a circular economy

AU - Dai, Leilei

AU - Zhao, Hailong

AU - Zhou, Nan

AU - Cobb, Kirk

AU - Chen, Paul

AU - Cheng, Yanling

AU - Lei, Hanwu

AU - Zou, Rongge

AU - Wang, Yunpu

AU - Ruan, Roger

PY - 2023/11

Y1 - 2023/11

N2 - Catalytic cracking of plastics into naphtha as a substitute for new plastic production has the potential to contribute to the plastic circular economy. However, mitigating catalyst deactivation in large-scale processes poses a significant challenge. Here, we demonstrate a remarkable improvement (4.3 × to 12.3 ×) in catalyst lifetime by utilizing hierarchical ZSM-5 catalysts compared to conventional analogues. Increasing the Brønsted acid concentration from 0 to 302 µmol/g enhances catalyst lifetime by over 46 × and boosts cumulative aromatic selectivity from 6 to 73%. Catalyst characterization reveals the development of significant voids after modification, enhancing molecular transport within the hierarchical ZSM-5. Economic analysis shows a pilot system with a 10 ton/day capacity yielding an annual profit of $344,999 and an 11.5% return on investment. Life cycle assessment indicates a reduction of 817.6 kg CO2 eq compared to traditional plastic-to-fuels technology. These findings advance the plastic circular economy and bring us closer to commercial implementation.

AB - Catalytic cracking of plastics into naphtha as a substitute for new plastic production has the potential to contribute to the plastic circular economy. However, mitigating catalyst deactivation in large-scale processes poses a significant challenge. Here, we demonstrate a remarkable improvement (4.3 × to 12.3 ×) in catalyst lifetime by utilizing hierarchical ZSM-5 catalysts compared to conventional analogues. Increasing the Brønsted acid concentration from 0 to 302 µmol/g enhances catalyst lifetime by over 46 × and boosts cumulative aromatic selectivity from 6 to 73%. Catalyst characterization reveals the development of significant voids after modification, enhancing molecular transport within the hierarchical ZSM-5. Economic analysis shows a pilot system with a 10 ton/day capacity yielding an annual profit of $344,999 and an 11.5% return on investment. Life cycle assessment indicates a reduction of 817.6 kg CO2 eq compared to traditional plastic-to-fuels technology. These findings advance the plastic circular economy and bring us closer to commercial implementation.

KW - Catalytic cracking

KW - Hierarchical

KW - Naphtha

KW - Plastic waste

KW - ZSM-5

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DO - 10.1016/j.resconrec.2023.107154

M3 - Article

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SN - 0921-3449

VL - 198

JO - Resources, Conservation and Recycling

JF - Resources, Conservation and Recycling

M1 - 107154

ER -

Catalytic microwave-assisted pyrolysis of plastic waste to produce naphtha for a circular economy

Abstract

Funding

Keywords

UN SDGs

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