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High Density Polyethylene Pyrolysis: Review and Progress

Chapter · July 2014

DOI: 10.1007/978-3-319-05708-8_47

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Chapter 47
High Density Polyethylene Pyrolysis:
Review and Progress

Farah Obeid and Isam Janajreh

Abstract Plastics; yet indispensable they are a growing environmental problem

which necessitates limiting its damage. Plastics are inexpensive, durable and
versatile which favored their use in manufacturing and meeting various consumer
needs. However, plastics are non-biodegradable material therefore becoming a
threat on both the environment and the society. Energy recovery (pyrolysis) is an
innovative plastic waste management technique that recently gained high interest
in research. In Waste to Energy lab in Masdar Institute of Science and Technology,
a batch reactor was used to study the production of fuel-like products from high
density polyethylene (HDPE) in the temperature range 375–425 C. The analysis
using gas chromatography-mass spectrometry (GC-MS) of the liquid fraction was
carried out to determine its composition and product distribution.

Keywords Plastic wastes  HDPE  Pyrolysis

47.1 Introduction

The consumption of plastics in the Western Europe, USA and Japan in 1995 was
25, 33.9 and 11.3 million tones, respectively. The major consumption of plastic in
Western Europe is attributed to packaging sector of 40 % [1]. In 2005, 10 years
later, the plastic consumption in Western Europe increased to 47.5 million tons
[2]. As the estimated daily global municipal solid waste (MSW) generation is more
than 2 9 109 metric ton, plastic holds a substantial fraction reaching up to 19 %.
United States, Germany and Switzerland (with high gross national income) gen-
erate MSW at a rate of 700 kg/ca annually; Japan generates 400 kg/ca annually.

F. Obeid  I. Janajreh (&)

Masdar Institute of Science and Technology, Abu Dhabi, United Arab Emirates
e-mail: ijanajreh@masdar.ac.ae

M. O. Hamdan et al. (eds.), ICREGA’14 - Renewable Energy: Generation 585

and Applications, Springer Proceedings in Energy, DOI: 10.1007/978-3-319-05708-8_47,
 Springer International Publishing Switzerland 2014
586 F. Obeid and I. Janajreh

In the gulf region, UAE is the highest consumer of plastic/capita with daily
average of 8.6 kg/ca (2009 figure) [3]. According to Waste Management Center-
Abu Dhabi (WMC) 6 million tons of waste was generated in the year 2007–2008
in Abu Dhabi emirate solely, this figure is estimated to reach 30 MTs by 2030 [4];
in 2009, plastic waste contributed to an estimate of 19 % of the municipal solid
waste generated in Abu Dhabi [3]. As dominant solid waste treatment scenario
practiced in many societies including Abu dhabi, is mainly Landfilling (in 2009
more than 1 MT of MSW was landfilled in Abu Dhabi), alternatives need to exist.
A lot of research has been done in Masdar Institute on material recovery [5],
pyrolysis and gasification [6] testing different types of polymeric wastes, muni-
cipal solid waste, and nonconventional fuel such as oil shale. However, more
serious attention should be given to pyrolysis as an alternative waste treatment
stream.
Schrimer et al. [7] conducted thermal decomposition of polyethylene in thermal
gravimetric analysis (TGA) and in a cycled-sphere reactor. 4.5 g of PE pellets were
heated in the TGA to reaction temperature of 600 C under nitrogen. Non-catalytic
degradation using TGA showed that complete degradation of polyethylene was
achieved at 490 C. Some experiments were carried in the cycled sphere reactor
where 150 g of PE (granule) were fed into the reactor. The process was batch mode
and the reaction temperature was maintained at 440 C, reaction time was 60 min
for thermal process. Products obtained from PE pyrolysis were mainly waxes
(65.76 %) in the range of C15–Cn, the yields of oil (C5–C15) and gas (C1–C4) were
low compared with the yield of wax giving 21.88 and 11.6 % respectively. More-
over the analysis of the oil yielded showed a wide spectrum of products.
Grieken et al. [8] employed batch reactor for thermal degradation in an inert
atmosphere of both high and low density polyethylene. 50 g of PE were fed into
the reactor and different experiments were conducted varying temperature 380,
400 and 420 C. Products resulted from LDPE thermal cracking were mainly
solids, and the yield of liquid and gas products was negligible for the various
temperatures tested. It was noticed that HDPE thermal cracking occurs at higher
temperature than LDPE leading as well to mainly wax. The analysis of the waxy
products obtained from thermal degradation of LDPE showed their potential to be
used in petrochemical application.
Ng et al. [9] thermally degraded polyethylene (HDPE and LDPE) in the tem-
perature range of 450–500 C in a closed tubing bomb reactor, other few exper-
iments were carried out in an open tubing reactor at 480 C. Reactions in both
systems took place under a flow of nitrogen. HDPE thermal degradation in a
closed system produced hard wax, distillates of 19.3 % and low yield of gas at
450 C. The increase in temperature caused an increase in the yield of gas and
naphtha over the expense of coke. At 500 C distillates are of 56.4 %, gas 23 %
and residue of 8.6 %. Gas obtained contains mostly alkanes of 85 % in the range
of C1–C4, and olefins which a decrease with the increase in temperature. Naphtha
in the range of C4–C10 showed a decrease with the increase in temperature; a-
olefin decreased from 27 to 3.3 % with a corresponding increase in mono-aro-
matics from 1.1 to 25 % at 450 and 500 C respectively. HDPE thermal
47 High Density Polyethylene Pyrolysis 587

degradation in an open system promoted the production of gas oil over the expense
of gas and naphtha. Naphtha and gas oil fraction composed of low aromatics
(1 %), less saturates (27 %) but more olefins (40 %) unlike those obtained from
closed system. Distillates produced from the degradation of HDPE in an open and
closed system do not meet the requirements of transportation fuels.
Sakata et al. [10] has studied thermal degradation of high density polyethylene
(HDPE) in a semi-batch glass reactor under the flow of nitrogen. 10 g of HDPE
were loaded to the reactor and the degradation temperature was maintained at
430 C in the furnace. Products evolved from the thermal degradation of HDPE
were 69 % liquid and 21 % residues with only 9 % gaseous products. Gaseous
products obtained from thermal degradation were mainly C3 (propane, propylene),
C2 (ethane, ethylene) and small amount of C4 (butane, butane). The components of
liquid products were distributed over a wide range of carbon number. The oil
obtained contained paraffins and olefins but aromatics were not detected.
Miskolczi et al. [11] studied thermal degradation of 200 g of HDPE in a Pyrex
batch reactor for different temperatures (400, 420 and 450 C) under nitrogen
atmosphere. The yield of gas (2.4 % at 400 C) and liquid (3.1 % at 400 C)
increased with the increase in temperature yielding 5.8 % gas and 74.5 % liquid at
450 C. On the other hand the yield of residue decreased drastically with the
increase in temperature; 93.5 % at 400 C decreased to 19.7 % at 450 C. Product
analysis of the gaseous fraction showed that C2 and C4 are the dominating com-
ponents. Concerning liquid fraction, aliphatic hydrocarbons in the range of C5–
C25; main type of fuels were gasoline, kerosene, diesel and heavy oil. Low sulfur
content is favored for the advantage of both the environment and human health;
therefore sulfur content was tested and was \20 ppm for different degradation
temperatures but it was noticed that the content decreased with the increase of
temperature (14 ppm at 450 C) which makes the liquid fraction favored for uti-
lization as fuel-like product.
Hernandez et al. [12] carried thermal cracking of HDPE in a fluidized bed
reactor under nitrogen flow and reaction temperature was varied in the range of
400–800 C. At 400 C the yield of gas was almost negligible but started to
increase with the increase of temperature yielding &60/100 g of HDPE; however
the gaseous fraction was obtained over a wide range of molecular weights. At
800 C, components were mainly C2 (16.5 g ethene/100 g HDPE), C3 (10.5 g
propene/100 g HDPE), C4 (5.1 g 1-butene/100 g HDPE) and 2.2 g benzene/100 g
HDPE. Same group [13] studied the thermal pyrolysis of HDPE and results were
confounded with their previous findings; products evolved from thermal cracking
of HDPE were (15 % gases and 41 % liquids) at 500 C and (58 % gases and
24 % liquids) at 700 C. Products in the liquid fraction were composed of wide
range of carbon atoms (C10–C40) diolefins, olefins and paraffin were present while
aromatic compounds were not identified.
Marcilla et al. [14] aimed to study the effect of the heating rates (flash and slow
pyrolysis) on the degradation process of HDPE and the type of products yielded.
Experiments were carried in a fluidized bed reactor and nitrogen was the fluidizing
agent. In flash experiments the reactor degradation temperature was in the range of
588 F. Obeid and I. Janajreh

500–800 C, in slow pyrolysis experiments the reactor was heated to 700 C in the
rate of 5 C/min. It was obvious from both experiments (flash and slow pyrolysis)
that higher percentages of liquid (heavy oil), wax and solid residues are obtained
from thermal degradation of HDPE. However in flash pyrolysis the increase in
temperature caused a drastic increase in gas yield; 15.2 % were released at 500 C
increased to 66.3 % at 800 C.
Ng et al. [15] thermally cracked the blended HDPE with VGO (vacuum gas oil)
under nitrogen in the fixed bed reactor, sand was also loaded to the reactor and
reaction temperature occurred at 510 C. Two concentration of HDPE (5 and
10 %) resulted in different conversions; thermal cracking of 5 % HDPE resulted in
77 % conversion of HDPE, producing 11.5 % dry gas, 16 % LPG, 33.5 % gaso-
line and 15.3 % coke; whereas lower conversion (52.4 %) of HDPE was achieved
when its concentration increased to 10 % and the yield of product was lower
giving 7, 8.7, 22 and 14.7 % of dry gas, LPG, gasoline and coke respectively. In
the gaseous fraction, olefins were mainly ethylene, propylene and 1-butene.
Methane was produced in significant amount. Sand insured a better heat transfer
which resulted in a better conversion.
Aguado et al. [16] observed that only 27 % of LDPE was converted when
thermally cracked in an inert atmosphere in a stirred batch reactor at 420 C. 20 %
of gases (C1–C5) mainly olefins and 6.6 % heavy oil (C13–C35) mainly n-paraffins;
while the yield of liquid (C6–C12) was negligible.
William et al. [17] degraded LDPE thermally in the fluidized bed reactor in the
temperature range of 500–700 C. Nitrogen was the fluidizing gas and the bed
material was silica sand. It was observed that gas yield increased from 10.8 to
71 % as they temperature increased from 500 to 700 C with a corresponding
decrease in oil/wax fraction from 89 to 28.5 % with the oil having the highest
proportion. It can be concluded that wax decomposed to oil as the temperature
continued to increase then to gas. Main gases evolved were ethene, propene and
butene of yield 26.8, 18.6 and 7.6 % at 700 C respectively. Among the alkane
gases methane was evolved significantly with yield of 11.8 % at 700 C. Liquid
products (oil and wax) were distributed over a wide range of carbon number C8–
C57. As the pyrolysis temperature increased, aliphatics above C30 decreased with a
significant increase in the single and poly-aromatic hydrocarbons (PAH) which
comprised more than 25 % in the oil produced. This raises the environmental
concern due to the presence of PAH and requires a further treatment of the oil.
Renzini et al. [18] thermally cracked LDPE in a fixed bed reactor at 500 C for
different reaction times (20 and 60 min). Non-catalytic degradation yielded 81 %
solids mainly waxes with very negligible amounts (relative to solids) of liquids and
gases of 6.4 and 12 % respectively at reaction time of 20 min. On the other hand,
the increase of reaction time to 60 min positively influenced the distribution of
products yielding 24.4 and 18.7 % of gas and liquid respectively.
The pyrolysis of low density polyethylene in a batch autoclave reactor at
425 C and 1 h residence time was tested by Insura et al. [19]. Products yielded
(90 % oil, 10 % gas and no coke detected). Gas composition was mainly alkanes
of 69 % (ethane and propane dominant gases) and 32 % alkene. Long chain
47 High Density Polyethylene Pyrolysis 589

n-alkanes (46 %) were the main component in the oil obtained from the thermal
degradation of LDPE and 12.5 and 12 % of n-alkene and aromatics (toluene,
benzene and xylene) were obtained. These results were compatible with those
obtained from thermal cracking of LDPE at 500 C investigated by Bagri et al.
[20] in a fixed bed reactor; where high yield of oil (&95 %) and low gas (5 %)
was also achieved. Oil composition was mainly aliphatic in the range of C9–C50
whereas a very low amount of polycyclic aromatics (naphthalene and their methyl
derivatives) was detected. Gases were composed of alkane (mainly ethane and
propane) and alkene (mainly propene and butane).
Thermal degradation of LDPE was investigated by Aguado et al. [21] employed
a screw kiln reactor; experiments were conducted in the temperature range of
450–550 C and using nitrogen to insure inert atmosphere. A total conversion of
LDPE was observed giving high selectivity toward heavy hydrocarbons; 35.5 %
heavy oil (C13–C23) and 26 % wax (C24–C55) and low yield of gasoline (C5–C12)
and gas (C1–C4) of 29 and 9 % respectively. Therefore, thermal degradation of
LDPE led to a wide distribution of carbon number and heavy hydrocarbons were
the major outcomes.

47.2 Experimental Method

47.2.1 Materials

Virgin HDPE was obtained as pellets from Ducab Inc., Abu Dhabi, United Arab
Emirates, the particle size is 2–4 mm diameter and 2–4 mm length each and is
originally traded under P. W. Hall, UK (PPM 914), being used in the wire and cable
industry for outer sheathing in medium voltage (MV) and high voltage (HV) cables.

47.2.2 Batch Autoclave Pyrolyser

Thermal degradation of virgin HDPE was conducted in autoclave reactor obtained

from Buchiglas, Uster, shown in Fig. 47.1. The vessel is made of stainless steel with
CrNiMoTi alloy stirrer with 2 L volume. The reactor is heated electrically (3000 W/
230 V). The rector temperature is controlled by the jacketing purified water cooling
jacket and heating elements built in the wall of the vessel. The stirrer is integrated in
the reactor to maximize the distribution of heat flow to the polymer. The temperature
inside the reactor is controlled by ICC-self optimizing controller, where the pressure
is measured using pressure gauge. 50 g of virgin HDPE pellets were placed in the
reactor; then closed and pre-purged with nitrogen for 5 min to ensure that the reactor
is free from oxygen and that the experiment is taking place in an inert atmosphere.
The reactor is then pressurized with nitrogen at 10 bar and heated to 375–425 C and
590 F. Obeid and I. Janajreh

Fig. 47.1 Batch autoclave reactor

residence time of half an hour. Three fractions were collected at the end of each
experiment; gases were collected using tedlar bags directly through the depressur-
izing valve, oil and residues were collected from the reactor bottom. All collected
products are weighed after each experiment.

47.2.3 Simultaneous Thermal Analyzer STA (Q600 SDT TA

Instruments)

10–15 mg of HDPE were used for the Simultaneous Thermal Analyzer (STA)
which is a device combining Thermogravimetric Analysis (TGA), and Differential
Scanning Calorimetry (DSC) for the thermal analysis Fig. 47.2. The former
measures the change of the mass of the sample as a function of temperature and the
DSC determines the melting and decomposition temperature of the polymer.

47.2.3.1 Gas Chromatography: Mass Spectrometry

In the end of each experiment, liquid and residue fractions were collected, weighed
and dissolved in dichloromethane (DCM) GC grade. These compounds were
identified and quantified by a Thermo GC–MS provided with an HP-5MS column
(30 m 9 0.25 mm 9 0.1 lm). The column program is: injector temperature,
280 C; initial column temperature, 40 C; initial time, 5 min; heating rate, 12 C/
min; final temperature, 305 C; final time, 25 min; run time, 53.33 min; carrier
gas, Helium, 1 ml/min; average velocity, 38 cm/s; solvent delay, 6 min. The ion
trap detector had a mass range from 50 to 650 amu and is linked to a computer
equipped with the NIST library.
47 High Density Polyethylene Pyrolysis 591

Fig. 47.2 SDT Q600

Fig. 47.3 Liquid fraction collected from the reactor

47.3 Results and Discussion

Several runs on virgin HDPE were carried out using Batch autoclave reactor.
Experiments took place under nitrogen pressure at 10 bars at temperature of
400 C and the reactor was maintained at this temperature for half an hour. Three
fraction were collected from each experiment; liquid and residues were collected
from the reactor Fig. 47.3 and separated by filtration and gas fraction was collected
using tedlar chemically resistive Polyvinyl Fluoride (PVF) gas sampling bags
Fig. 47.4. The yield of HDPE pyrolysis experiments favored the production of
592 F. Obeid and I. Janajreh

Fig. 47.4 Gas Fraction collected using tedlar bag

Fig. 47.5 Liquid fraction chromatogram

liquid fraction giving *60 %, a good yield of gas was also obtained of 37 % and
relatively low yield of residue of 3 %. The GC-MS chromatograph and analysis
are shown in Fig. 47.5 and Table 47.1 respectively. Table 47.1 shows that the
liquid fraction is composed of alkanes with carbon chain number ranging from C10
to C28, alkenes in the range of C10–C35 and alkynes (C11–C20).
Diesel carbon number distribution of various fractions is distributed as Naph-
tha \C10, Gasoline C11–C15, Diesel C16–C20 and heavy oil fraction [C20 [22].
47 High Density Polyethylene Pyrolysis 593

Table 47.1 GC-MS Liquid fraction composition from the pyrolysis of HDPE at 400 C
Alkanes Formula
Decane C10H22
Undecane C11H24
Dodecane C12H26
Tridecane C13H28
Tetradecane C14H30
Pentadecane C15H32
Hexadecane C16H34
Octadecane C18H38
Nonadecane C19H40
Heneicosane C21H44
Docosane C22H46
Tetracosane C24H50
Heptacosane C27H56
Octacosane C28H58
Alkenes
1-Decene C10H20
1-Undecene C11H22
1-Dodecene C12H24
1-Tridecene C13H26
1-Pentadecene C15H30
1-Hexadecene C16H32
3-Heptadecene C17H34
1-Nonadcene C19H38
1-Docosene C22H44
9-Hexacosene C26H52
17,Pentatriacontene C35H70
Alkynes
1,10-Undecadiene C11H20
1,11-Dodecadiene C12H22
1,13,Tetradecadiene C14H26
1,19-Eicosadiene C20H38

Compounds detected using GC-MS in pyro-oil as C10-decane, C11-undecane, C18-

octadecane and others is an indication that it is a fuel-like product.
Thermogravimetric analysis (TGA) was used for HDPE characterization
Fig. 47.6. The virgin HDPE samples of about 10–15 mg were placed in the sample
holder and pyrolyzed in nitrogen atmosphere in each experiment. The nitrogen
flow rate was kept constant at 75 ml/min, at heating rate 10 C/min to a final
temperature of 550 C. It was observed that the melting temperature of virgin
HDPE is at 135 C. The onset degradation temperature is 300 C after which the
conversion of HDPE is initiated, the termination of the total conversion of HDPE
is at 500 C; however literature [23] states that degradation temperature of HDPE
takes place around 500 C. During the pyrolysis experiments of HDPE the total
594 F. Obeid and I. Janajreh

Fig. 47.6 Thermal properties of HDPE

conversion was achieved at 400 C; the decrease of 100 C is correlated to the fact
that the reactor was pressurized by nitrogen. Therefore, pressure can also affect the
initiation and termination of polymer degradation. As total conversion can
be achieved at lower temperature, thus energy is saved affecting the economic
feasibility of pyrolysis process.

47.4 Conclusion

Thermochemical conversion is an innovative alternative to landfilling and incin-

eration of plastic waste eliminating several social and environmental problems and
providing an environmentally friendly source of energy. In this research, HDPE
was thermally degraded in a pyrolysis batch reactor yielding high liquid (60 %)
and gas (37 %) fractions. In addition, the compositional analysis using GC-MS of
the liquid fraction showed that it is fuel-like product. Different temperatures and
pressures will be tested in order to study their effect on the polymer degradation,
the yield and the composition of the products.

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