Full Utilization of Hard-to-Recycle Mixed Plastic Waste by Conversion toward Pyrolysis Oil and BTX Aromatics on a Pilot Scale
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High Resolution Image Download MS PowerPoint Slide This study investigates the technological feasibility of recycling mixed plastic waste streams into chemical building blocks on a pilot scale. Postconsumer-separated DKR-350 mixed plastic waste was first separated into two fractions by using a two-step negative near-infrared (NIR) optical sorting process. The resulting two fractions (polyolefin-rich and polyolefin-poor) were subjected to thermal and ex situ catalytic pyrolysis, respectively. Both types of pyrolysis were performed in a fluidized bed pilot plant, continuously operated at feed rates of 5 kg h –1 and temperatures ranging from 460 to 550 °C. The polyolefin (PO)-rich fraction (∼81 wt % PE + PP) resulted in a maximum aliphatic-rich oil yield of 48 wt % and 26 wt % gas yield based on dry material intake. The PO-poor fraction, characterized by a lower PE/PP content (∼13 wt %) and high in PET and PS (43.5 and 14.4 wt %, respectively) normally unsuitable for efficient thermal pyrolysis, was processed through integrated cascading catalytic pyrolysis (ICCP) using a proprietary zeolite-based catalyst. This allowed for the successful transformation to 37 wt % aromatic-rich oil, with a total benzene, toluene, and xylenes (BTX) yield of 17 wt %, and 42 wt % gas. The high PET and PS content in the PO-poor fraction contributed to a significant increase in aromatic yields compared to the expected yield of a mixed plastic waste stream. This study thus demonstrates the potential to produce a full range of petrochemical building blocks, i.e., olefins and aromatics, from low-quality, hard-to-recycle plastic waste streams. Importantly, this work highlights that catalytic pyrolysis of the PO-poor residue stream, postsorting to yield PO-enriched streams, can effectively valorize this fraction, underscoring the technological viability of improved plastic recycling through targeted sorting and pyrolysis.
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Liquid oil yields from mixed waste plastic pyrolysis can be approximately 48-75 wt.%, heavily influenced by feedstock composition, process temperature, residence time, reactor design, catalysts, and pre-treatment such as sorting to remove PVC and PET.
“Typical product yield ranges from mixed waste plastic pyrolysis can vary significantly; for instance, liquid oil yields can be approximately 48-75 wt.%, and these are heavily influenced by feedstock composition (with polyolefins favoring higher oil yields), process temperature, residence time, reactor design, and the application of catalysts, as well as pre-treatment methods like sorting to remove”
From Biofuels, E-Fuels, and Waste-Derived Fuels: Advances, Challenges, and Future Directions (2025) · cites this paper as [331]
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Biofuels, E-Fuels, and Waste-Derived Fuels: Advances, Challenges, and Future Directions
Yılbaşı, Z. (2025) · Sustainability · doi:10.3390/su17136145 · Cited by 41 · see citing works
- Authors
- van Akker, M., Strien, J. R. J., Genuino, H. C., van Eijk, M. C. P., Schenk, N. J., Heeres, H. J., & Deuss, P. J.
- Affiliations
- BioBTX B.V., Zernikelaan 17, 9747 AA Groningen, The Netherlands
- University of Groningen (NL)
- NTCP, Duitslanddreef 7, 8447 SE Heerenveen, The Netherlands
- Corresponding author
- Deuss, Peter J.
- ORCID
- Venue
- Energy & Fuels
- Publisher
- American Chemical Society (ACS)
- Published
- 2025-03-14
- Volume
- 39
- Issue
- 13
- Pages
- 6438-6451
- ISSN
- 0887-0624 (ISSN-L)
- 1520-5029
- OpenAlex
- W4408453720
- Cited by
- 25
- References
- 50
- Citations by year
- 2026: 20 · 2025: 5
- FWCI
- 6.10
- Type
- journal article
- Language
- en
- Open access
- hybrid
- doi.org
- Locations
- Energy & Fuels (publishedVersion, cc-by)
- Research Publications (Maastricht University) (publishedVersion, cc-by)
- University of Groningen research database (University of Groningen / Centre for Information Technology) (submittedVersion, cc-by)
- Funders
- Ministry of Climate Policy and Green Growth of the Netherlands
- Topics
- Physical Sciences › Engineering › Biomedical Engineering › Thermochemical Biomass Conversion Processes
- Physical Sciences › Environmental Science › Waste Management and Disposal › Recycling and Waste Management Techniques
- Physical Sciences › Environmental Science › Waste Management and Disposal › Municipal Solid Waste Management
- Keywords
- mixed plastic waste, plastic recycling, catalytic pyrolysis, BTX aromatics, polyethylene, polypropylene, polyethylene terephthalate, polystyrene, zeolite catalysts, bio-oil, fluidized bed reactor
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