Materials Today: Proceedings 45 (2021) 7216–7221

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Materials Today: Proceedings

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Experimental study on catalytic pyrolysis of plastic waste using low cost

catalyst
Premdasu Nalluri a, P. Prem Kumar b, M.R. Ch Sastry a
a
Gudlavalleru Engineering College, Gudlavalleru, India
b
Annamalai University, Chidambaram, India

a r t i c l e i n f o a b s t r a c t

Article history: Energy generation and utilization become an index of country development. The currently using
Received 2 December 2020 conventional energy sources are depleting at faster rate, thereby researchers are searching for a viable
Received in revised form 12 February 2021 alternative to generate the energy. The source should be compatible with the existing engines to run
Accepted 16 February 2021
and sustain eco-balance. The two severe problems facing across the world are continuous raise of plastic
Available online 11 March 2021
usage and depletion of fossil fuels. The major hurdles with the plastic waste are disposal and recycling.
The disposal for land filling may cause soil contamination, environmental disturbance due to incineration
Keywords:
both are leads to social resistance. Pyrolysis is the one effective solution to resolve the plastic waste
Robots
Pyrolysis
disposal is converting the energy a Though, pyrolysis is an effective approach to extract fuel oil from
Waste plastic waste plastic, it suffers from expensive of catalysts. In the present work, an attempt has made to address
Low cost catalyst it by utilizing low cost catalyst like fly ash for pyrolysis of HDPE and LDPE plastic. Experiments were con-
HDPE and LDPE ducted on pyrolysis unit by varying the mass fraction of catalyst at 5%, 10% and 15%. It is observed that
yield of maximum at 5% and it is decline with the further addition of catalyst. In contra, increase in mass
fraction of catalyst reduces the reaction temperatures as well as retention times. The physiochemical
properties of collected oil were measured and compared against the diesel and gasoline fuels bides in
polymerized links into usable form. It offers dual solution in environmental aspects and addressing the
verge fossil fuels.
Ó 2020 Elsevier Ltd. All rights reserved.
Selection and peer-review under responsibility of the scientific committee of the International Confer-
ence on Mechanical, Electronics and Computer Engineering 2020: Materials Science.

1. Introduction in either of catalytic or thermal approach. In thermal pyrolysis,

For most of the plastics, biodegradation is very slow and remain
as solid mass for years together [1]. The existing recycling tech-
niques like grinding and sorting are able to crunch a minor portion
of total waste. [2,3]. Therefore, few environmental friendly energy
recovery approaches like gasification, plasma arc gasification and
pyrolysis are attracting the researchers [4]. Among the above men-
tioned techniques, pyrolysis is the simple, economical and effective
method for treating waste plastic Figs. 1–6.
Pyrolysis is the thermo-chemical process which converts waste
plastic into solid, gas and liquid forms. As plastic are polymerized
combinations of hydrocarbons the obtained liquid and gases can be
utilized as alternative fuel in IC engines and thermal power plants
after examining the fuel properties. The solid residue that remains
after degradation of waste plastic could be utilized in waste water
treatment plants as an active element. Pyrolysis can be carried out
degradation of waste plastic takes place at high temperatures
(300-900oC) [5] whereas catalytic pyrolysis can degrade the waste
plastic even at lower temperatures (150-500oC). The limitations
associated with thermal pyrolysis are, whole process is tempera-
ture dependent, demands more energy input and collected oil
may have contaminated with Sulphur and chlorine [6-8]. There-
fore, catalytic pyrolysis predominated by defeating the limitations
associated with thermal pyrolysis [9].
Many authors have done research work on natural as well as
treated catalysts for converting waste plastic into usable products.
Renowned catalysts using by the researchers are HZSM-5 [10], FCC
[11], ZSM-5 [12,13], spent FCC [14], Zeolite-ß [15] CoMo/Z [16],
Cu-Al2O3 [17], natural zeolite NZ [18], Al(OH)3 Ca(OH)2 [19] Red
Mud [9], Fe2O3[20] and Activated Carbons [21] have been used
extensively to enhance the yield and quality of the products.
However, the above mentioned catalysts are expensive therefore

https://doi.org/10.1016/j.matpr.2021.02.478
2214-7853/Ó 2020 Elsevier Ltd. All rights reserved.
Selection and peer-review under responsibility of the scientific committee of the International Conference on Mechanical, Electronics and Computer Engineering 2020:
Materials Science.
P. Nalluri, P. Prem Kumar and M.R. Ch Sastry Materials Today: Proceedings 45 (2021) 7216–7221

Fig. 1. Block diagram of Experimental setup.

Fig. 2. Experimental setup.

Fig. 3. Plastic tub pieces.

Fig. 4. Waste saline bottle pieces.

utilization of such catalysts may increase the overall cost of
process. Moreover, researchers are focusing over low cost and
naturally available form of catalysts [22].
Fly ash (FA)- the moneyed source of alumina and silicon, which
is the bi product of thermal plants, can be used as catalysts for
pyrolysis [23]. It is a measure of colossal of fly ash from power
plants across all developing and developed countries [24]. The
major quantity of fly ash is using for land filling as the scientific
applications are limited to it. Though there are substantial miner-
als which can open new gate ways by the researchers for various
engineering and scientific applications, which is the better way
of addressing the disposal issue of fly ash. From the statistics India

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P. Nalluri, P. Prem Kumar and M.R. Ch Sastry Materials Today: Proceedings 45 (2021) 7216–7221

Table 1
Fly ash generation and utilization during the year 2018–19 [25]

Sl.No. Description Year 2018–19

1 No. of thermal power stations considered 195
for the study
2 Installed capacity of each plant (MW) 197966.50
3 Coal consumption (MT) 667.43
4 Generation of FA (MT) 217.04
5 Uutilization of FA (MT) 168.40
6 Utilization percentage (%) 77.59

Table 2
Modes of FA utilization in India during the year 2018–19 [25]
Fig. 5. Fly ash catalyst.
Sl. No. Mode of utilization Quantity of FA utilization
Million ton Percentage (%)
alone generating about 200MT of fly ash per year. For instance, fly
1 Cement 58.34 26.88
ash utilization in the recent year is presented in Table 1. [26]. How- 2 Mine filling 10.10 4.65
ever, recent years are the evidence for rising the fly ash utilization 3 Bricks and tiles 21.61 9.96
to solve environmental problems by using it as an active ingredient 4 Reclamation of low lying area 29.31 13.51
in brick making and cement manufacturing domains. Nevertheless, 5 Ash dyke raising 21.57 9.94
6 Roads and flyovers 9.72 4.48
its contribution is minimal and it is presented in Table 2 [25].
7 Agriculture 1.3769 0.63
Among many of pyrolysis processes, in-situ process proposed 8 Concrete 1.7742 0.82
by Pramendra et al., [24] categorized the FA into A and B types 9 Others 14.58 6.72
based on silicon enrichment and activeness in reaction to synthe- 10 Unutilized FA 48.64 22.41
size the plastic waste. Y. C. Rotliwala1et al., [26] investigated with Total 217.038 100.00

versatile FAs for pyrolysis such as bagasse fly ash, deoiled cake of
jatropha, bituminous coal FA to decompose the high density poly-
ethylene in a batch reactor at 4500C in nitrogen atmosphere. Table 3
Chemical composition of FA.
In the current study proposed to utilize economically feasible
catalyst like FA to do the pyrolysis of waste LDPE plastics and HDPE Sl.No Components Wt. (%)
plastics systematically investigate the effect of mass fraction of 1 SiO2 53.56
catalyst of 5%,10% and 15% on different process parameters e.g., 2 Al2O3 27.71
oil yield, gas yield, reaction temperature, retention time. the oil 3 Fe2O3 5.53
4 MgO 0.91
samples obtained were characterized by testing the basic proper-
5 CaO 4.50
ties such as Viscosity, flash and fire points, Specific gravity, and 6 K2O 0.94
calorific values to compare with Euro standards to know the suit- 7 Na2O 0.37
able usage domain of it. The novelty of our work is varying the 8 Others 6.48
mass fraction of catalyst at 5%, 10% and 15% to conduct a pyrolysis 9 Ignition loss 5.88

experiment. It was noted that maximum yield was observed at 5%

Table 3.
2. Materials and methods
The pyrolysis unit consists of a Reactor, Water cooled
condenser, heating source (usually LPG), thermocouple, tempera-
ture indicator, safety valve, pressure gauge, ball type valve and
gas burner. The pyrolysis reactor is made from Stainless steel
316 grade sheet – 4feet
3feet and water cooled condenser coil
is made from Copper tube of outer diameter 6.35 mm with 10 feet
length. Reactor is the main element of the pyrolysis unit where cat-
alytic cracking of waste plastics takes place.it is equipped with a
pressure gauge and a safety valve. The function of pressure gauge
is to read the gauge pressure of reactor at the time of experimen-
tation similarly a safety valve is provided in order to safeguard the
reactor from high pressures. Furthermore, J-type thermocouple is
attached to the reactor for continuous measuring of reaction
temperature.
Pyrolysis is a tertiary recycling process in which organic poly-
mers are converted into oil, char and gases. The prepared waste

Fig. 6. Mass balance for HDPE plastic.

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P. Nalluri, P. Prem Kumar and M.R. Ch Sastry Materials Today: Proceedings 45 (2021) 7216–7221

Plastics are fed into the reactor with or without catalyst. Heat is Table 4
supplied to reactor with the help of any heat source. As a result oil yield and gas yield (by % of mass) for HDPE plastics.

of heating organic polymers is converted into vapors, these Particular C/p C/p C/p
vapours are condensed in a specially designed condenser; oil is col- ratio = 0.05 ratio = 0.1 ratio = 0.15
lected at the end. The step by step procedure to get oil from the (C5%) (C10%) (C15%)

waste plastics is given below. Mass of HDPE plastic, mp 1 kg 1 kg 1 kg

Mass of catalyst, mc 0.05 kg 0.1 kg 0.15 kg
Mass of total charge, mt 1.05 kg 1.1 kg 1.15 kg
(a) Preparation of plastic and catalyst
Mass of oil obtained , mo 0.5084 kg 0.464 kg 0.44 kg
Mass of solid residue (after 0.25 kg 0.2 kg 0.15 kg
In the present work, waste plastic tub pieces (HDPE) and waste subtracting mass of catalyst
Saline bottles (LDPE) were used as a feed to the pyrolysis reactor. from total residue)
The waste tubs were collected from the nearby village and waste Mass of gas obtained, mg 0.2416 kg 0.336 kg 0.41 kg
Oil yield (by % of mass) 50.84% 46.4% 44%
saline bottles were collected from the Government hospital, Gas yield (by % of mass) 24.16% 33.6% 41%
Machilipatnam. Firstly, collected Waste plastic is cut into small Solid residue (Char) (by % mass) 25% 20% 15%
pieces of nearly one-inch size. Secondly, the pieces are washed
with water to remove impurities and later they were dried. In
the end the prepared pieces are fed to the reactor with Catalyst Gas yield (by % of mass) = (mass of gas obtained / mass of
(C5%, C10% and C15%) as required by the experiment. plastic)
100

(b) Feeding mg
¼ x100
mP
The plastic pieces along with catalyst in required ratio is fed into Where,
the reactor through bottom feeding arrangement, wound thread Mass of gas obtained mg = Mass of plastic - (mass of oil + mass
and applied shellac to ensure no leakage and screwed cap over it. of Char)

(c) Heating
Heat is supplied to the reactor by the burning of LPG and heat
rate can be varied with the help of adjustable burner where there
is a provision for the varying the distance between reactor and the
burner. In actual context waste heat from power plant could be uti-
lized as heat source.
(d) Condensation and liquid oil collection
As a result of heating the organic compounds of plastic get
evaporated and condensed using an indirect contact type heat
exchanger (water cooled). The condensed vapors are collected in
the vessel of known volume.
(e) Separation
In the end the crude oil obtained is fed to separating funnel
where light oil is separated due to difference in density. Further-
more, the crude oil has to be distilled at various temperatures so
as to get different oils (petrol, diesel and kerosene).
Oil yield and gas yield
Table 4 shows the mass balance (% of mass) for the typical HDPE
plastic derived samples, the maximum oil yield was obtained for
the 5% catalyst (C/P = 0.05) and maximum gas yield was obtained
for the 15% catalyst (C/P = 0.15).
Oil yield and gas yield were calculated from the following
expressions:
Oil yield (by % of mass) = (mass of oil obtained / mass of
plastic)
100
m0
¼ x100
mp
mg ¼ mP  m0 þ mc
The oil samples obtained in pyrolysis were tested for physio-
chemical properties such as density, viscosity and calorific value
with the aid of fuels and lubricants lab instruments. Furthermore,
properties of sample oils tabulated below and compared with the
conventional fuels. It is evident from the table 5 that, HDPE plastic
derived oil samples have the similar properties of diesel whereas
LDPE plastic derived oil samples have gasoline fuel properties
[27]. The properties of HDPE and LDPE plastic derived oil samples
were tabulated in table number 5 and 6 respectively.
3. Result and discussion
Tests were conducted on pyrolysis unit by taking waste HDPE
and LDPE plastics with coal FA as catalyst. Effects of percentage
of mass fraction of Catalyst on, reaction temperature, retention
time oil yield and gas yield was investigated experimentally. In
the present study pyrolysis process was carried out with three per-
centages of catalyst namely C5%, C10% and C15%. For instance,
C10% indicates one kg of plastic is fed with 0.1 kg of catalyst.
3.1. Effect of mass fraction of catalyst on physiochemical properties of
oil:
The use of a catalyst affects the physical properties of liquid oil
produced [28] such as the viscosity that is one of the important
parameters for any petroleum product. It is clear from the Table 5
and 6 that, viscosity of oil samples decreases with increase in cat-
alyst proportion. High viscous oil affects the engine performance as
it is hard to pump the oil into the engine during the operation.
Therefore, a pump is required to inject the fuel into atomizer,
hence making the process costly [29 30]. Feedstock composition

Table 5
Properties of HDPE derived oil samples.

Fuel properties Diesel C 5%oil C 10%oil C15%oil

3
Density(kg/m ) 820 800 800 800
Specific Gravity 0.82 0.8 0.8 0.8
Viscosity(cst) 3.36 0.65 0.4 0.145
Calorific Value(KJ/kg) 42,700 39914.16 40911.20 41932.97

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P. Nalluri, P. Prem Kumar and M.R. Ch Sastry Materials Today: Proceedings 45 (2021) 7216–7221

Table 6
Properties of LDPE derived oil samples.

Fuel properties Gasoline C 5%oil C 10%oil C15%oil

3
Density(kg/m ) 720 710 710 710
Specific Gravity 0.72 0.71 0.71 0.71
Viscosity(cst) 1.89 0.45 0.40 0.40
Calorific Value(KJ/kg) 43,600 40420.62 41500.87 41500.87

is another factor that affects the viscosity of liquid oil The Retention time(HDPE) Retention time(LDPE)
differences in viscosity results are due to the composition and 75
structure of feedstocks used [31]. 70

Retention time (minutes)

65
60
55
3.2. Effect of mass fraction of catalyst on reaction temperature: 50
45
It is considered as to be one of the most important factors
40
affecting both the quality and quantity of pyrolysis products [32].
35
Fig. 7 shows the effect of mass fraction of catalyst on reaction tem-
30
peratures for the both HDPE and LDPE plastics. It’s clear from the
C5% C10% C15%
fig. that with increase in catalyst percentage there is obviously Mass fraction of catalyst (%)
decrease in reaction temperatures which in turn decreases the
energy input to pyrolysis unit. Furthermore, It is evident from Fig. 8. Effect of mass fraction of catalyst on retention time.
the fig. that HDPE plastics required higher reaction temperatures
than LDPE plastics, for instance, reaction temperatures for the
HDPE and LDPE plastic at 5% catalyst proportion are 1500C and Oil Yield(HDPE) Oil Yield(LDPE)
1000C respectively. Therefore, degradation of HDPE plastics 640
requires moderately higher reaction temperatures due to stronger 620
intermolecular forces when compared to LDPE plastics. 600
Oil yield (ml)

580
560
540
520
3.3. Effect of mass fraction of catalyst on retention time:
500
480
Retention time is the time during which degradation of plastic 460
takes place in a reactor. It is a measure of energy input to system C5% C10% C15%
[33]. Fig. 8 shows the effect of mass fraction of catalyst on reten- Mass fraction of catalyst(%)
tion time for the both HDPE and LDPE plastics. It’s clear from the
fig. that with increase in catalyst percentage there is obviously Fig. 9. Effect of mass fraction of catalyst on Oil yield.
decrease in retention time which in turn decreases the process
energy input. For instance, retention time for C5%, C10% and
3.4. Effect of mass fraction of catalyst on oil yield and gas yield:
C15% HDPE plastics are 69,58 and 55 min respectively. The higher
concentration of FA catalyst in the reactor showed a high rate of C–
Oil yield is defined as the portion of plastic that is being
C cracking reaction due to presence of silica and alumina that leads
converted into oil which is a major product of pyrolysis. It is clear
to acceleration in the degradation of plastic. Lee et al., [33] have
from the Fig. 9 that; the mass fraction of catalyst has significant
observed the similar trend that, under catalytic conditions, rate
effect on oil yield as well as gas yield. As the concentration of
of cracking increases there by reducing the retention time.

Gas Yield(HDPE) Gas Yield(LDPE)

45
40
35
Gas Yield (%)

30
25
20
15
10
5
0
C5% C10% C15%
Mass fraction of catalyst (%)

Fig. 7. Effect of mass fraction of catalyst on reaction temperature. Fig. 10. Effect of mass fraction of catalyst on Gas yield.

7220
P. Nalluri, P. Prem Kumar and M.R. Ch Sastry
catalyst increases, the oil yield was decreased but a significant
improvement in gas yield was observed. The possible reason for
the decrease in oil yield is, when mass fraction of catalyst
increases, the rate of catalytic cracking also increases which pro-
duces more non condensable gasses instead of oil. Lopez et al.,
[9] reported the same results.Fig. 10
4. Conclusion
 Investigations are conducted by varying the mass fraction of
catalyst (C5%, C10%, C15%) to extract oil from HDPE and LDPE
plastics.
 Firstly, the effect of mass fraction of catalyst on oil yield was
investigated experimentally and it was observed that oil yield
gets reduced with increase in catalyst fraction therefore sample
C5% has more oil yield than other two samples (C10% & C15%).
 Secondly the effect of mass fraction of catalyst on reaction tem-
perature was investigated experimentally and it was observed
that increase in catalyst percentage decreases the reaction tem-
perature which ultimately reduces the process energy input.
 Thirdly the effect of mass fraction of catalyst on reaction time
was investigated experimentally and it was observed that
increase in Catalyst percentage reduces reaction time therefore
sample C15% has minimum reaction time as compared to other
two samples (C5% & C10%).
 Physiochemical properties of derived oil samples are tested and
compared with standard fuels. It is notices that oil derived from
HDPE plastic possess closer properties to diesel fuel, while the
oils derived from LDPE plastic have gasoline like properties.
Declaration of Competing Interest
The authors declare that they have no known competing finan-
cial interests or personal relationships that could have appeared
to influence the work reported in this paper.
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