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mixtures
F.J. Mastral *, E. Esperanza, C. Berrueco, M. Juste,
J. Ceamanos
Department of Chemical and Environmental Engineering, Centro Politécnico Superior, University of
Zaragoza, C/Marı́a de Luna, 3, 50018 Zaragoza, Spain
Received 25 October 2001; received in revised form 17 January 2002; accepted 7 June 2002
Abstract
0165-2370/03/$ - see front matter # 2002 Elsevier B.V. All rights reserved.
doi:10.1016/S0165-2370(02)00068-2
2 F.J. Mastral et al. / J. Anal. Appl. Pyrolysis 70 (2003) 1 /17
1. Introduction
The high consumption of polymeric materials means that they are a significant
share of solid waste (either municipal or industrial). The disposal of this waste has
become a technological, business, political and social issue that has attracted the
attention of researchers, businessmen, politicians, environmental activists, and the
general public.
Given their high calorific value, plastics can be recycled for energy recovery. When
mixed and incinerated with municipal solid wastes, plastics contribute to the safe
combustion of the mixture and generate valuable energy. In other thermal
degradation processes, they can replace other fuels in different proportions, saving
primary fossil fuels. Fuels derived from specific, separated plastics and combined
with a lignocellulosic fraction can be an important substitute for coal in cement
manufacture or for electricity generation in a power plant. In pyrolysis processes, the
energy necessary is supplied by partial combustion of the feed material or the gases
produced. In the latter case, it would be very interesting to compare the yields and
the product distributions obtained both in strict pyrolysis conditions, using nitrogen
as fluidizing agent, and in partial combustion conditions, using air and nitrogen as
fluidizing agent.
One of the materials present in significant quantities in municipal solid waste is
polyethylene. The pyrolysis of polyethylene has been the subject of numerous
studies, such as thermal decomposition kinetics [1 /4] or temperature influence on
product yields [5 /8]. These experimental studies have been carried out in fluidized
bed, with an inert gas as fluidizing agent. Other studies using steam or pyrolysis gas
as fluidizing agent have been carried out by Kaminsky et al. [9]. The reaction
mechanisms that generate the different pyrolysis products have been considered by
Bockhorn et al. [2], Ranzi et al. [3], Williams and Williams [8], Poutsma et al. [10],
McCaffrey et al. [11], and Savage et al. [12].
In this work, the results of product yields from the degradation of HDPE obtained
under pyrolysis and gasification conditions are shown. The temperature interval
used ranges from 640 to 850 8C. The main goal is the study of the influence of the
atmosphere in which the thermal decomposition takes place and the temperature on
the product distribution and heating value of the generated gas.
2. Experimental
The experimental system used in this work is shown in Fig. 1. The study was
carried out using a stainless steel, fluidized bed reactor 4.8 cm in diameter and 23 cm
in height. The material bed was 0.25 /0.27 mm silica sand with a static bed depth of
80 mm. The reactor was externally heated using an electrical ring furnace. The bed
temperature was measured by a K type thermocouple inside the bed. The HDPE
pyrolysis and gasification runs were carried out at bed temperatures of 640, 700, 730,
F.J. Mastral et al. / J. Anal. Appl. Pyrolysis 70 (2003) 1 /17 3
The operation flows used provided a fluidizing gas velocity five to eight times the
Umf. The average Umf of the sand used in the bed was experimentally found to be 2.2
cm s 1. The residence time of the gas in the reactor had values between 0.81 and 1.45
s, calculated in each experiment at the bed temperature, taking into account the total
gas flow produced and considering the internal volume of the reactor (the sand bed
and freeboard), the cyclone and the connections between the reactor and the cyclone
and between the cyclone and the water condenser.
The product stream was passed through the cyclone to remove any particulate
matter. The resulting stream of vapors was passed through a cool water heat
exchanger at 20 8C, where some heavy hydrocarbons were condensed (oil or waxes).
The remaining lighter components were condensed using an ice /NaCl bath at /
10 8C. The exit flow was divided into two fractions: the largest one being passed
through silica gel in order to retain the wax and oil carried by the gas in the form of
aerosol. The smaller fraction was passed through two ice /NaCl condensers at /
10 8C. Part of the flow from the condensers was collected online in a nylon bag for
analysis during the experiment. The rest of the flow from the condensers was passed
through a silica gel tube in order to retain the remains of waxes or oils. This flow was
introduced into an online CO /CO2 detector and exited the system. The experiments
lasted from 20 to 25 min.
2.2. Analysis
The gas fraction was analyzed by gas chromatography using a HP 5890 series II,
with a semi capillary column HPPLOT/Al2O3, 50 m/0.53 mm /15 mm, and a
molecular sieve 0.9 m/3 mm packed with 45/60 mesh, using two detectors
connected in series: a thermal conductivity detector (TCD) and a flame ionization
detector (FID). The concentration of H2, N2, CO and CO2 were determined by the
TCD detector whilst the rest of hydrocarbon components from C1 to C6 were
detected by the FID.
Waxes and oils were collected, weighed and analyzed by GC/MS. For purposes of
analysis, the oil and waxes were first dissolved in tetrahydrophurane (THF). The gas
chromatography mass spectrometry consisted of an HT-5 aluminum clad column, 25
m/0.32 mm /0.1 mm (non polar) with a Tmax 450 8C. Helium was used as carrier
gas with a flow rate of 1 ml min 1. Samples of 1 ml were injected, with a split mode
(20:1).
The high temperature column enabled oven temperatures of 400 8C to be reached
ensuring that hydrocarbons up to C60 could be analyzed. The temperature program
was 40 8C for 2 min followed by a heating rate of 5 8C min 1 up to 180 8C, then an
increase up to 350 8C at a heating rate of 10 8C min 1, and finally 10 min at
350 8C. Since no components were detected at temperatures over 330 8C, the
maximum oven temperature used was 350 8C. The ion trap detector had a mass
range from 32 to 800 amu and was linked to a computer with a Wiley library.
F.J. Mastral et al. / J. Anal. Appl. Pyrolysis 70 (2003) 1 /17 5
The pyrolysis and gasification of HDPE were carried out in the experimental
system previously described using different reactor temperatures. Table 1 shows the
yields to the different fractions obtained in the two types of experiments, referring to
the mass of HDPE fed, and for reactor temperatures ranging from 640 to 850 8C.
Table 1 also shows the main experimental conditions used in the experiments
performed: residence time, air ratio and real temperature in the reactor. The carbon
and hydrogen mass balances of the products, quite close to 100%, are also shown in
Table 1. The total yields over 100% observed in the gasification experiments are due
to the fact that the oxygen fed appears as a part of the products obtained. In the case
of the pyrolysis experiments, slight variations from 100% are also observed. They can
be explained taking into account that, since the total gas flow exiting the system is
not measured, the balances are solved using the nitrogen balance and the
composition of the different fractions. These compositions are measured at different
moments during the experiment, so slight variations can be observed.
A high quantity of waxes and oils were found in the pyrolysis and gasification
experiments carried out at 640 and 700 8C (real temperature), this mixture
presenting a higher viscosity at 640 8C than at 700 8C. In the pyrolysis experiments,
the yield was 68.5% at 640 8C and 39.6% at 700 8C. In the gasification experiments,
the wax/oil yield was 51.6% at 645 8C and 35.4% at 700 8C. The variation of
fraction yields (gas, oil and wax) with temperature is shown in Fig. 2. As can be
observed, for low temperatures the yield to gas increases as the temperature increases
in both pyrolysis and gasification experiments. For temperatures in the range of
640 /730 8C, this marked increase of the yield to gas ranges from 33.5 to 91.7 wt.%
in pyrolysis and from 54.2 to 104.6 wt.% in gasification. For higher temperatures, in
the range of 730/850 8C, the yield to gas reaches an approximately constant value in
both processes. A small amount of char, not quantified, appeared in waxes and oils.
As can be seen when comparing pyrolysis and gasification experiments, the wax/oil
yields are very similar at the different temperatures studied except at 640 8C at
which a higher yield is obtained under pyrolysis conditions. For the rest of the
temperatures studied, yields to wax/oil are slightly higher in pyrolysis. Yields to gas
in gasification are higher than in pyrolysis in all temperature intervals studied.
Fig. 3 shows the variation of the yields to the different fractions (gases except CO
and CO2, CO /CO2, olefins, oxygenated compounds and aromatics). Different
observations can be noted: CO and CO2 are obviously not observed in the pyrolysis
experiments and the yield to olefins decreases rapidly as the temperature increases,
this fraction being more abundant in the pyrolysis experiments. As can be observed,
the yield to aromatic compounds increases as the temperature increases and similar
values are obtained regardless of which gas is used in the experiments. The
oxygenated fraction, relatively important in gasification experiments carried out at
low temperatures, decreases down to zero over 730 8C.
6
F.J. Mastral et al. / J. Anal. Appl. Pyrolysis 70 (2003) 1 /17
Table 1
Product yields (wt.% of feed) and component mass balances for pyrolysis and gasification of HDPE
Table 2 shows the yields to the different gas species obtained in the pyrolysis and
gasification processes. As previously mentioned, the main difference observed
between the gasification and pyrolysis experiments is the production of some gas
species such as carbon dioxide, carbon monoxide and water in gasification, due to
the HDPE partial combustion and reduction reactions. The yield to hydrogen is
Fig. 4. Variation of CO and CO2 production and CO/CO2 ratio with gasification temperature.
10 F.J. Mastral et al. / J. Anal. Appl. Pyrolysis 70 (2003) 1 /17
Fig. 5. Variation of H2 and CH4 production with pyrolysis and gasification temperature.
Fig. 6. Variation of C2H4 production and C2H4/C2H6 ratio with pyrolysis and gasification temperature.
F.J. Mastral et al. / J. Anal. Appl. Pyrolysis 70 (2003) 1 /17 11
fraction is smaller than that observed in pyrolysis. For temperatures higher than
730 8C the liquid composition is similar in both pyrolysis and gasification
experiments.
In Fig. 10 aromatic compounds are detailed. Benzene and naphthalene production
increases as the temperature increases. At a given temperature, the results show
similar values in pyrolysis and gasification, being slightly higher in the case of
gasification. In all conditions benzene is the most abundant aromatic compound.
The product distributions observed can be explained qualitatively taking into
account the mechanisms of thermal degradation suggested by different authors
[2,3,10 /13,15 /18] and shown in Fig. 11. In general, the polymer cracking reactions
to yield smaller olefinic chains and gases (as experimentally observed in Fig. 3). At
higher temperatures secondary reactions yield aromatic and polyaromatic com-
pounds (also observed in Figs. 3, 8/10). In gas-phase, where the substrate
concentration is low, and at high temperatures, the Rice/Kossiakoff mechanism
[17] predicts the formation of mainly alkenes, C2H4, CH4 and H2, with only very
small amounts of alkanes and dialkenes being formed. Similar trends are shown in
the experimental data obtained (Figs. 5 and 6). As temperature is increased, more
scissions in the polymer chain occur leading to a high number of short primary
F.J. Mastral et al. / J. Anal. Appl. Pyrolysis 70 (2003) 1 /17 13
Fig. 9. Comparison of product distribution under pyrolysis and gasification conditions. Influence of
temperature.
radicals, which undergo successive b-scission reactions and eliminate small molecules
(this coincides with the results obtained, with the gas yield increasing as the
temperature increases, and the high production of ethylene). Moreover, the higher
radical concentration favors intermolecular hydrogen transfer (the higher concen-
14 F.J. Mastral et al. / J. Anal. Appl. Pyrolysis 70 (2003) 1 /17
Fig. 10. Comparison of aromatic product distribution under pyrolysis and gasification conditions.
Influence of temperature.
4. Conclusions
Acknowledgements
The authors express their gratitude to CICYT (project QUI 98-0669) for providing
financial support for this work.
References
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[17] F.O. Kossiakoff, Rice, J. Am. Chem. Soc. 65 (1943) 590.
[18] R.P. Lattimer, J. Anal. Appl. Pyrol. 31 (1995) 203.