Pyrolysis of plastics: Challenges and solutions

Only a fraction of discarded plastics are recycled

The current state of plastics recycling is a significant challenge to our environment and society. Even though plastic is one of the most pervasive materials used in modern life, only 9.1% of all plastics in the US are ever recycled. Of this, most plastic waste ends up in landfills or incinerators, which can take centuries to break down. Moreover, due to the wide variety of different types of plastics present in waste streams, recycling facilities typically extract only high-value plastics for reuse. This means that re-processing techniques such as pyrolysis are required for lower-value plastic waste recycling.

The pyrolysis of plastics and chemical recycling

The pyrolysis of plastics process diagram.

The Pyrolysis process is particularly effective for waste plastics that may otherwise be difficult or impossible to recycle. This process converts these plastics into valuable chemicals and fuels, providing a viable pyrolysis solution for their reuse or disposal in an economically and environmentally responsible manner. Ultimately, pyrolysis can offer a sustainable way of managing plastic waste to reduce its impact on our environment while also providing a profitable opportunity for businesses. Although this process has a promising future, it's not without challenges, particularly regarding technology.

Unique challenges of pyrolysis recycling

Varied economical and technological challenges of pyrolysis.

Pyrolysis challenges are diverse and varied, with each one presenting unique difficulties. Difficulties include:

• Challenging fluids
• Corrosion and fouling
• Environmental factors
• Economics
• Scalability
• Water management

These issues are important for pyrolysis recycling facilities to address to ensure success of their operations. It is also important to know what solutions are available to these challenges.

Challenging feeds and fluids

Chemical recycling technologies, like pyrolysis, present unique challenges due to the varied and inconsistent feeds and fluids processed. Long-chain hydrocarbons must be broken down, wax and toxins removed, and contaminants treated with precision and accuracy to ensure product quality. These processes come with high risks of failure if not managed correctly.

Mixed plastic waste causes recycling and reuse challenges.

Corrosion and fouling

Corrosion and fouling are constant challenges in pyrolysis processing due to the acidic, oxygen-sensitive nature of pyrolysis oil. Its corrosive effects damage process equipment beyond repair. Furthermore, co-processing with contaminants like calcium, sodium, iron and magnesium lead to heavy fouling in catalysts and other process equipment. These issues lead to the need for costly replacements. But this goes beyond the cost of the equipment itself. Unreliable equipment causes disruptions in operations. Ultimately, this downtime is an additional cost. Regular maintenance reduces the need for replacements, but frequent maintenance can also be an issue, again costing time and money.

Damage from corrosion and fouling during the pyrolysis process can be extensive and costly.

The environmental impact of pyrolysis

Simply put, pyrolysis facilities are energy intensive. They can also emit carbon monoxide, nitrogen oxides and sulfur dioxide, leading to air and water pollution. These issues have significant financial implications for plant owners who must invest in proper pollution control equipment and regularly monitor emissions.

Investment in pollution control and environmental waste management is the key to the future.

Financial implications

Although pyrolysis is promising in managing environmental waste, the process often comes with substantial financial considerations. The cost of consistent feedstocks, cost-effectively upgrading pyrolysis oil and making pyrolysis oil production competitive against combustion are economic challenges all operations face. The availability and cost of feedstock vary greatly, making accurate forecasting of ROI challenging. To reduce both CAPEX and OPEX costs and make it more affordable for businesses to install within existing footprints, py-oil producers must make intelligent process integrations throughout the value chain. Modularization is one solution but still challenging as modularized solutions are only now beginning to become available, limiting options. Although subsidies and incentive availability will improve as the process matures, the current lack of subsidies or incentives is a definite barrier, as there needs to be more to offset the financial burdens. These economical challenges make breaking into the market unfeasible, raising questions about its long-term viability.

Py-oil producers must make intelligent process integration decisions throughout the value chain to address economical challenges of pyrolysis.

Scalability of operations

The demand for products derived from the pyrolysis of plastics is very high. Yet, suppliers cannot meet these demands due to the limited availability of consistent feedstock, limited technology for the industry and the high costs of both. Tight timelines further complicate this scalability challenge for launching new technologies, limited space for expansion in most plants and a need for flexible solutions that are only sometimes available. Ultimately, this has led to a situation where the sustainability of plastic chemical recycling operations is at risk before it even gets started. These challenges negatively impact production rates, energy consumption, waste management and budgeting.

Scalabilty of pyrolysis operations is necessary to meet growing demands.

Water management

Water management is also an essential part of pyrolysis recycling technologies, with energy use being just one of the issues. Access to water sources for cooling products also adds difficulties. The process uses large amounts of energy and water, which increases production costs. Also problematic is the issue of water pollution from waste streams. Careful management of hydrocarbons, minerals and oils is necessary to avoid environmental degradation and protect public health. This management comes at a high cost.

Water management is critical for both operational use and to ensure management of pollutants.

Solutions to pyrolysis challenges

Although there are many challenges to pyrolysis, technological solutions and consulting guidance are available to make the most of this promising new process. Alfa Laval is a trusted partner for businesses with pyrolysis challenges. We are equipped to handle your unique needs with a comprehensive range of solutions, holistic consulting and technical support. We understand that pyrolysis processes are complex and dynamic, so we provide up-to-date solutions for the ever-changing landscape.

Pyrolysis equipment to meet demand

Our plate heat exchangers and centrifugal separation solutions ensure consistent quality products and reliable, cost-effective technology for handling variable and inconsistent feeds. Our equipment is made of highly corrosion-resistant metals for longer service life while also helping boost process performance. Plus, our innovative solutions minimize capital and total installed cost by requiring less steel – allowing you to meet growing demand without taking up too much space. With Alfa Laval's efficient separation and water management solutions, you'll get the results you're after – on budget and schedule.

Alfa Laval’s pyrolysis solution portfolio.

Your partner in pyrolysis of plastics

Pyrolysis of plastics is a powerful tool for transitioning to a circular economy and solving the global plastic waste crisis. At Alfa Laval, we understand the importance of this process and are committed to helping you make it as efficient, cost-effective and safe as possible. Working together, we can take your pyrolysis process to the next level – allowing you to create products that meet your standards in an economically viable and sustainable way. Let's join forces and tackle these challenges together.