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J. Anal. Appl.

Pyrolysis 74 (2005) 282289


www.elsevier.com/locate/jaap

Thermal and catalytic decomposition behavior of PVC


mixed plastic waste with petroleum residue
Mohammad Farhat Ali, Mohammad Nahid Siddiqui *
Department of Chemistry, King Fahd University of Petroleum & Minerals, Dhahran 31261, Saudi Arabia

Received 24 June 2004; accepted 17 December 2004


Available online 9 March 2005

Abstract

The pyrolysis and hydropyrolysis of PVC mixed plastic waste alone and with petroleum residue was carried out at 150 and 350 8C under
N2 gas and at 430 8C under 6.5 MPa H2 gas pressure. The behavior of plastic waste during thermal and catalytic decomposition has also been
studied in single- and two-stage reaction processes. In the individual pyrolysis process, both the petroleum residue and polystyrene (PS)
undergo more than 90% conversion to liquid and gaseous products, whereas low-density polyethylene (LDPE) and high-density polyethylene
(HDPE) yielded lower conversions products, and polypropylene (PP) and polyvinyl chloride (PVC) afforded somewhere a moderate to high
conversion products.
In a single-stage pyrolysis reaction, PVC was processed with petroleum residue at 150 and 430 8C, under N2 gas for 1 h at each
temperature in a glass reactor. The model PVC and waste PVC showed slight variations in the products distribution obtained from the glass
reactor. In two-stage process, model PVC, vacuum gas oil (VGO) and a number of different catalysts were used in a stainless steel autoclave
micro tubular reactor at 350 8C under the stream of N2 gas for 1 h and at 430 8C under 950 psi (6.5 MPa) H2 pressure for the duration of 2 h.
Significantly, different products distributions were obtained. Among the catalysts used, fluid catalytic cracking (FCC) and hydrocracking
catalysts (HC-1) were most effective in producing liquid fuel (hexane soluble) materials. The study shows that the catalytic coprocessing of
PVC with VGO is a feasible process by which PVC and VGO materials can be converted into transportation fuels.
# 2005 Elsevier B.V. All rights reserved.

Keywords: PVC; Thermal and catalytic degradation; Fuel oils; Coprocessing; Residue upgrading

1. Introduction such as nitrous oxide, sulfur oxides, dusts, dioxins and other
toxins. The option of secondary recycling or mechanical
The disposal of waste plastics has become a major recycling, which is the reprocessing of plastic waste into
environmental problem all over the world. USA, Europe and new plastic products with a lower quality level, is not
Japan generate about 50 million tons of post consumer showing any signs of growth in the recycling industry.
plastic waste material. Saudi Arabia is one of the major Tertiary recycling, which returns plastics to their constituent
producers of plastic in the world with total production monomers or to their higher value hydrocarbon feed stock
capacity of around six million metric tons per year. The and fuel oil, is gaining momentum as an alternative method.
amount of plastic wastes in Saudi Arabia is about 15 wt% in Tertiary recycling includes all those processing which
the composition of domestic municipality waste [1]. The attempt to convert the plastic wastes to basic chemicals by
number of landfill sites is decreasing. Also land filling could the use of chemical reactions such as hydrolysis, metha-
result in plastic additives such as phthalates and various dyes nolysis and ammonoloysis for condensation polymers and to
polluting ground water. Incineration is an alternative to fuels with conventional refinery processes such as pyrolysis,
landfill disposal of plastic wastes, but this practice could gasification, hydrocracking, catalytic cracking, coking and
result in the formation of unacceptable emissions of gases visbreaking for addition polymers excluding PVC. Pyrolysis
of waste plastic affords high rates of conversion into liquid
* Corresponding author. Tel.: +966 3860 2529; fax: +966 3860 4277. fuels that can be used as feedstock in refinery. There has
E-mail address: mnahid@kfupm.edu.sa (M.N. Siddiqui). been a lot of research work on the pyrolysis of individual

0165-2370/$ see front matter # 2005 Elsevier B.V. All rights reserved.
doi:10.1016/j.jaap.2004.12.010
M.F. Ali, M.N. Siddiqui / J. Anal. Appl. Pyrolysis 74 (2005) 282289 283

and mixed plastics with and without PVC into liquid fuels atmospheric bottoms sample was charged to a wiped-film
[24]. molecular still (Pope Scientific, Menomonee Fall, WI, USA)
One of the main problems in the pyrolysis of PVC and and more volatile part of the feed was progressively
mixed plastics containing PVC is the production of vaporized to remove the material boiling below 350 8C. This
hydrogen chloride, chloro organic and inorganic com- atmospheric bottom petroleum residue (350 8C+) was used
pounds during the early stages of pyrolysis process. The with plastics in single-stage coprocessing reactions whereas
presence of such chloro compounds in the liquid products a distillate fraction of the same petroleum residue with
of pyrolysis are highly undesirable; therefore efforts were boiling range of 325500 8C, called vacuum gas oil (VGO),
made to remove these halogen contents prior to pyrolysis was used in the two-stage coprocessing reactions.
of the waste plastics into liquid fuel products [57]. The
behavior and the chemical nature of mixed plastics 2.1.3. Catalysts
containing PVC are very important parameters to be The following eight different catalysts were obtained
known before carrying out dechlorination process. The from the manufacturers and used in this work: hydro
kinetic studies on the decomposition of various individual cracking catalysts (HC-1, HC-2 and HC-3), ZSM-5 zeolite
and mixed plastics revealed that different molecular catalyst, FCC catalyst, presulfided NiMo/Al2O3 (NiMo)
structures of the plastics undergo different reaction catalyst and iron oxide carbon composite catalyst. Selection
mechanisms of decomposition, follow different reaction of suitable catalysts for the cracking reactions was the
rates and shows a different and great temperature difficult task due to limitations in terms of operating
dependency of the decomposition rate [8,9]. These studies conditions, feedstock properties, catalyst performance and
suggest that the dechlorination of PVC occurs at relatively desired products. The suitability of catalysts was based on
low temperatures via free radical mechanism. This these essential characteristics: activity, selectivity, ease of
tendency prompts the use of a combination of separation regeneration and mechanical strength. The catalyst selection
and decomposition of plastic waste in stepwise pyrolysis for this study is based mainly on the results obtained in our
with different temperatures in the preliminary step for the previous work [2].
dechlorination of PVC. During the dechlorination step, the
rechlorination of other components of the product mixture 2.2. Analytical procedure
must also be checked and avoided.
In this work, we report the pyrolysis of PVC mixed The procedure can be explained in two parts: first to
plastic waste alone and coprocessed with petroleum residue. determine the HCl contents in PVC and secondly the fuel oil
The behavior of plastic waste during thermal and catalytic formation in the form of hexane, toluene and THF solubles
decomposition has also been studied in single- and two- in the reaction material.
stage reaction processes. The product distributions and the A stock solution of 1 M NaOH was prepared and
effect of catalyst types on percent conversion of plastics into standardized using potassium hydrogen phthalate solution in
liquid fuels are discussed. order to obtain the exact concentration of NaOH solution
that was found to be 0.96 M.
Fig. 1 shows the schematic of a fixed-bed pyrolytic gas-
2. Experimental purged glass reactor used to pyrolyze the PVC plastics.
The reactor is a Pyrex glass tube with 32 cm length and
2.1. Materials 2 cm i.d. The samples were placed inside the tube before
reaction started. A programmable temperature controller
2.1.1. Polymers controlled the furnace. This enabled the samples to be
The model plastic compounds, polystyrene (PS), low heated slowly at the rate of 5 8C/min until temperature
density polyethylene (LDPE), high density polyethylene reaches to 150 8C. This temperature was maintained for 1 h
(HDPE), polypropylene (PP), polyethylene terephthalate to ensure that all HCl gas was evolved. Then heating was
(PET) and polyvinyl chloride (PVC) used in this study were increased at the same rate to the final pyrolysis temperature
obtained from Saudi Basic Industries Corporation (SABIC), of 430 8C. The sample was held at 430 8C for another hour
Riyadh, Saudi Arabia, and were used as received. Municipal or until there was no significant evolution of gases. The
waste plastic (MWP) for PVC was collected locally as used liquid oil phase was trapped in a cylindrical flask using a
water pipes and prepared in the laboratory by chopping and cold-water spiral condenser. Nitrogen gas was used as the
mixing for the reactions. carrier gas at a fixed flow rate to sweep the evolved gaseous
products quickly. The gases evolved, except HCl, were not
2.1.2. Petroleum residue collected so no gas analysis was performed. Initially,
It is an atmospheric bottom residue from Arab light crude 200 ml of standard NaOH solution was used to trap and
oil supplied by Saudi Aramcos Ras Tanura refinery. Arab determine the amount of HCl gas produced from the
light crude was found to contain a substantial amount of low pyrolysis. At the end of the reaction, the glass reactor was
boiling material (about 8% of <350 8C distillate). The cooled and weight of the reactor and the cylindrical flask
284 M.F. Ali, M.N. Siddiqui / J. Anal. Appl. Pyrolysis 74 (2005) 282289

Fig. 1. Schematic experimental setup of glass reactor.

were recorded. Then the liquid product was dissolved in called dechlorination step. There was no significant
three different solvents successively hexane, toluene and evolution of gases after 1 h of reaction. Then the reactor
THF. A separation procedure for the product distribution of was cooled to room temperature keeping under nitrogen.
reactions is shown in Fig. 2. The air trap and NaOH trap solution were removed from
Two-stage reactions were carried out in a 25 cm3 the reactor assembly and the nitrogen flow was cut off for
stainless steel tubular micro reactor with a programmable the second-stage reaction as shown in Fig. 4. At this stage,
temperature controller obtained from the Parr Scientific, the dechlorinated reactor contents were pressurized at
USA. The reactor was gradually heated at the rate of 5 8C/ ambient temperature to 6.5 MPa (950 psi) with hydrogen
min and temperature was kept at 350 8C for 1 h under the gas. The reactor was heated to 430 8C and the temperature
nitrogen and gases evolved were purged into standard maintained for 2 h. The micro reactor was agitated by a
NaOH trap solution. Fig. 3 shows the schematic of built-in mechanical stirrer and heated with a temperature
experimental setup used for the first-stage that is also controlled built-in heater. Different ratios of PVC, VGO
and catalysts were charged to the reactor and reactions
were performed using single and double components to
evaluate the reactivity and interactive effects among the
reactants. The single reactions were studied for: LDPE,
HDPE, PS, PP, PET, PVC and petroleum residue while the
double component reactions were studied only for residue/
VGO and PVC mixtures. All reactions were run in
duplicate. The gaseous, liquid and solid products were
separated and analyzed by the solvent fractionation
methods.
The solubility and thermal analysis of each plastic was
carried out separately. The reactions of single and binary
systems using different plastics and residue/VGO were
experimented at different temperatures, under nitrogen gas
and hydrogen gas pressure and time duration. The best
results, based on the percent conversion to liquid products,
were obtained at 430 8C, 950 psi (6.5 MPa) and 120 min
duration in two-stage process. These optimum conditions
were used in our studies. After the reaction, liquid and solid
products were analyzed by solvent fractionation using a
series of solvents. The fractions obtained were hexane-
soluble materials (HXs); toluene-soluble, hexane-insoluble
Fig. 2. A separation scheme for the products distribution. material (TOLs); THF-soluble, toluene-insoluble material
M.F. Ali, M.N. Siddiqui / J. Anal. Appl. Pyrolysis 74 (2005) 282289 285

Fig. 3. Schematic experimental setup of micro reactor with continuous flow of N2 gas.

(THFs); and THF-insoluble material called as insoluble The solubility of the unreacted materials was also
organic material (IOM). The masses of the gas, HXs, TOLs, obtained using solvent fractionation.
and THFs fractions were determined after the fractioning The recovery of the products from these reactions was
solvent was removed by rotary evaporation and the fractions defined as
were air-dried. The wt% of each of these fractions was  
g of output
determined and then the percent of the gas fraction was %Recovery  100 (1)
g of input
determined by difference as:
where, output = weight of gases + liquids + IOM products,
%Gas 100  HXs TOLs THFs IOM HCl input = weight of plastics + residue/VGO + catalyst

Fig. 4. Schematic experimental setup of micro reactor under H2 gas pressure.


286 M.F. Ali, M.N. Siddiqui / J. Anal. Appl. Pyrolysis 74 (2005) 282289

Percent conversion of plastics and residue was calculated materials, called asphaltenes, in hexane but was more than
from the following expression 99% soluble in toluene and THF solvents.
  Each available plastic used in this study was pyrolyzed
g of IOM
%Conversion 1   100 (2) individually at the optimum reaction conditions obtained
g of total charge
earlier. Table 2 shows the product distributions obtained
Percent conversion includes conversion of total charge from the thermal pyrolysis of the plastics and petroleum
(plastics + residue) into gases and liquids products that is residue. The conversion for the single component reactions
called pyrolysis oils. shows that under similar conditions of pyrolysis both
petroleum residue and PS undergo more than 90%
conversion to gaseous and liquid products whereas LDPE
3. Results and discussion and HDPE yielded lower conversions and PP remained in
the moderate to high conversion. PVC has highest
3.1. Properties of PVC conversion to gases that includes formation of hydrogen
chloride gas. PVC produces hydrogen chloride as a main gas
Plastics (LDPE, HDPE, PP, PS, and PET) in general and on pyrolysis. The CCl bond in PVC structure has relatively
PVC in particular are a major thermoplastic material used in lower bond energy than CC and CH bonds in the structure,
a very wide variety of applications and products. In physical hence on heating CCl bond dissociates first. As a result,
appearance PVC resin is a white, fairly inert powder at room thermal degradation of PVC begins around 150 8C, with the
temperature, although it is heat sensitive. The molecular evolution of hydrogen chloride gas due to the intermolecular
weight of the PVC polymer can be varied during the chain-transfer reaction. This process leads to the dehydro-
polymerization stage. The number average molecular chlorination of PVC. A virgin PVC plastic contains a total of
weight (Mn) range varies from between about 30,000 to 56.7% chlorine by weight and in our experiment it was
95,000. The properties of PVC are influenced by its average achieved 54.855.6% in virgin PVC and 53.3% in waste
molecular weight and its molecular weight distribution. PVC. It indicates that the reaction conditions followed in this
Some of the characteristics properties of the PVC provided experiment for the dechlorination were working satisfacto-
by the manufacturer are given here as: tensile strength rily. The dechlorination of PVC by a free radical chain
2.60 N/mm2, notched impact strength 2.045 kJ/m2, thermal mechanism occurs at relatively low temperatures. This
coefficient of expansion 80  106, Max Cont use tendency suggests a stepwise pyrolysis of mixed plastics at
temperature 60 8C and density 1.38 g/cm3. Commercial various temperatures using a combination of separation and
PVC polymers are essentially amorphous, but they also have decomposition in the single steps including dechlorination
a crystalline phase amounting to around 10% of the matrix. of PVC.
The glass transition temperature phase lies in the range of
7080 8C. 3.3. Reactions using glass reactor

3.2. Solubility and degradative properties of plastics The effects of temperature, time duration and hydrogen gas
pressure on the product distribution of coprocessing of PVC
Studies were performed to establish the solubility with petroleum residue were studied in single-stage reactions.
properties of unreacted materials. Table 1 shows the The reactions were performed at two different temperatures
solubility behavior of petroleum residue and six model (150 and 430 8C) for the durations of 1 h each and the results
plastics (LDPE, HDPE, PP, PET, PS and PVC) produced by are given in Table 3. The model PVC and waste PVC showed
SABIC, Saudi Arabia. Initially LDPE, HDPE, PET and PP slight variations in the products distribution obtained from the
were primarily insoluble in these solvents, while PVC and glass reactor. The model PVC has produced 16.9% liquid oil
PS were completely soluble in hexane, toluene and THF. product in comparison to waste PVC with 12.1%. The model
The petroleum residue contained about 6% insolubles PVC also produced 54.1% hydrogen chloride gas while waste

Table 1
Products distribution from unreacted plastics
Material % Weight % Soluble % Recovery
Hexane soluble Toluene soluble THF soluble IOM
LDPE 0.59 4.97 2.08 92.36 7.64 99.98
HDPE 0.22 1.12 1.74 96.92 3.08 99.99
PET 0.66 1.12 0.85 97.37 2.63 99.99
PS 0.57 99.43 0.00 0.00 100 99.99
PP 0.79 2.34 1.65 95.22 4.78 99.99
PVC 0.15 6.20 93.65 0.00 100 99.99
Petroleum residue 94.20 5.80 0.00 0.00 100 99.99
M.F. Ali, M.N. Siddiqui / J. Anal. Appl. Pyrolysis 74 (2005) 282289 287

Table 2
Products distribution from the pyrolysis of plastics
Product distribution % % Conversion % Recovery
Gas Hexane soluble Toluene soluble THF soluble IOM
HDPE 2.6 11.0 6.5 3.5 76.4 23.6 99.3
LDPE 1.9 15.4 6.5 5.7 70.5 29.5 98.1
PS 5.0 71.2 13.8 0.0 10.0 90.0 99.3
PP 2.1 30.6 14.7 19.2 33.4 66.6 98.4
PVC 51.3 3.6 9.7 4.5 30.9 69.1 97.9
Petroleum residue 10.3 61.5 15.2 7.9 5.1 94.9 99.0
% Conversion: conversion of plastics/petroleum residue into gases and pyrolysis oils.

Table 3
Products distribution from single-stage pyrolysis of mixture
Products PVC (10 g) PVC waste (10 g) PVC + iron oxide catalyst (10 g + 0.5 g) Petroleum residue (10 g) PVC + Petroleum residue (4 g + 6 g)
Liquid 16.9 12.1 11.1 77.1 43.8
HCl 54.1 51.5 50.6 00.0 20.6
Gas 0.7 1.8 1.6 4.9 4.4
IOM 28.1 34.2 36.6 17.5 30.2
Total 99.8 99.6 99.9 99.5 99.0
Reaction conditions: 1 h at 150 8C + 1 h at 430 8C both under the stream of N2 gas.

PVC produced 51.5%. Over all these results are within the of HCl gas [10]. The chlorination of asphaltenes appears to be
expected range of hydrogen chloride contents of the PVC. The taking place very rapidly as indicated by the lower amounts of
conversions of the model and waste PVC into gaseous and hydrogen chloride gas formed during the reaction. This also
liquid products were found to be 71.9 and 63.8%, respectively. shows a very high tendency of asphaltenes towards reactions
One batch of petroleum residue was also charged and found to with chlorine. The presence of petroleum residue, however,
decompose into 77.1% liquid oils and 4.9% gaseous products. increased the overall conversion in the binary coprocessing
The model PVC was also pyrolyzed with 5% iron-oxide reactions compared to the single component reaction. In view
composite carbon catalyst at 350 8C for 2 h and results were of this, the need of carrying out degradation reactions in two-
not significantly different from non-catalytic reactions. It stages, first dechlorination of PVC then followed by catalytic
indicates that this catalyst is not effective for the conversion of cracking of the dechlorinated residue to liquid products, was
PVC alone into liquid fuel products. In another experiment, considered.
when PVC and petroleum residue (40:60 wt%) were
pyrolyzed under similar conditions, the results obtained were 3.4. Two-stage reactions using micro reactor
very interesting. The liquid oil product contents jumped to
43.8% and hydrogen chloride gas contents reduced to 20.6% In two-stage process, model PVC, VGO and a number of
but there were also very significant percent of IOM left. The different catalysts were used in a stainless steel autoclave
loss of HCl contents could be attributed to the reactions taking micro tubular reactor at 350 8C under the stream of N2 gas
place between asphaltenes of petroleum residue and chloride for 1 h and at 430 8C under 950 psi (6.5 MPa) H2 pressure
radical evolved from the cracking of PVC before the formation for the duration of 2 h. Significantly different products

Table 4
Products distribution from two-stage pyrolysis of mixture
Exp. no. Reactants HXNs TOLs THFs IOM *HCl GAS
1 PVC + iron oxide catalyst 6.8 4.3 0.0 36.6 50.6 1.6
2 VGO + ZSM-5 70.5 4.2 0.0 9.5 0.0 15.8
3 VGO + PVC + ZSM-5 61.3 6.5 1.3 10.8 8.3 (54) 11.8
4 VGO + PVC + NiMo 61.5 6.2 1.8 9.8 7.9 (51.3) 12.8
5 VGO + PVC + FCC 65.9 7.1 1.8 10.2 8.1 (52.6) 6.9
6 VGO + PVC + HC-1 65.2 7.9 1.7 10.7 7.8 (50.7) 6.7
7 VGO + PVC + iron oxide catalyst 55.0 8.5 2.6 16.0 7.7 (50) 10.2
8 VGO + PVC + HC-2 59.0 7.1 2.1 13.0 7.8 (50.7) 11.0
9 VGO + PVC + HC-3 60.1 6.7 1.9 14.1 7.6 (49.4) 9.6
Note: Exp. 1: PVC 10 g, catalyst 0.5 g; Exp. 2: VGO 12.5 g, catalyst 1.25 g; Exp. 39: VGO 12.5 g, PVC 2.5 g, catalyst 1.25 g. Figures in parenthesis under
*HCl are %HCl content of PVC. Yield calculation basis: wt%. GAS = 100  (HXs + TOLs + THFs + IOM + HCl). HCl = NaOH titration. Reaction
conditions: 1 h at 350 8C under N2 gas + 2 h at 430 8C under 6.5 MPa H2 gas.
288 M.F. Ali, M.N. Siddiqui / J. Anal. Appl. Pyrolysis 74 (2005) 282289

Fig. 5. Selective product distributions obtained from the pyrolytic process of the mixed reactants.

distributions were obtained as shown in Table 4. Catalytic when iron oxide; HC-2 and HC-3 catalysts were used. This
decomposition of VGO alone afforded 70.5% hexane trend indicates that these catalysts are cracking the PVC/
soluble, 4.2% toluene soluble and 9.5% IOM. Fig. 5 VGO mixture most efficiently and effectively. The proper
compares the effect of different catalyst on the distributions determination of HCl amount is also very important in this
of gas, IOM and HCl obtained from PVC/VGO mixture. study because chlorine plays an important role in converting
FCC and hydrocracking catalysts (HC-1) produced mini- PVC to useful ends. Again the lower recovery of HCl in two
mum amount of gases while NiMo catalyst gave the highest. hydrocracking and iron oxide catalysts mixtures may partly
The IOM produced in each of the reaction system after the due to the lower cracking of mixed plastics that led to the
completion of reaction was in substantial amount. The increase of IOM amount.
amount of IOM obtained from the reaction mixture was Fig. 6 compares the distribution of liquid products
around 10% in almost all of the reaction products except mainly, HXs, TOLs, and THFs; obtained from PVC/VGO

Fig. 6. Selective product distribution obtained from the pyrolysis of mixed reactants.
M.F. Ali, M.N. Siddiqui / J. Anal. Appl. Pyrolysis 74 (2005) 282289 289

mixture using different catalysts. As expected, THFs were mixed in the reactor before the start of the reaction that
found to be lowest in amount followed by TOLs and HXs strongly affected the conversion and product slate in the
were found to be in highest amount and this is most PVC/VGO reactions. It is envisaged that this problem of
important liquid product. Among the various catalysts used, mixing may become more serious when mixed plastics
FCC and HC-1 catalysts were most effective in producing wastes will be used. It shows that the catalytic coprocessing
hexane soluble fraction. Iron oxide catalyst was least of PVC with VGO is a feasible process by which PVC and
effective. The hexane soluble from this initial conversion VGO materials can be converted into transportation fuels at
can further be upgraded to gasoline and other high value bench scale. A pilot plant study could be conducted to
diesel fuels or chemical feedstock for refinery. These trends evaluate the feasibility of carrying out this project on
indicate that the selection of catalyst plays a vital role in industrial scale.
carrying out coprocessing studies of PVC with VGO. Some
catalysts showed greater reactivity than other catalyst as
indicated by the higher percent conversion to liquid fuel Acknowledgements
products. The effect of different catalysts on the conversions
and product distribution showed a significant improvement The authors wish to thank King Fahd University of
when the temperature and time were changed. Petroleum & Minerals for financial support to carry out this
research work under SABIC Project Grant SAB-2002/08.
The help provided by Mr. M. Mazhar Hasan in the
4. Conclusions experimental work is also gratefully acknowledged.
The optimum conditions considered for our work were: at
350 8C under the stream of N2 gas for 1 h and at 430 8C
under 950 psi (6.5 MPa) H2 pressure for the duration of 2 h. References
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