Energy Demand for Pyrolysis of Mixed Thermoplastics and Waste Plastics in Chemical Recycling: Model Prediction and Pilot-Scale Validation

Pyrolysis of plastic waste is a key technology for closing the anthropogenic carbon cycle. The energy demand (ED) of this endothermic process is a crucial factor to evaluate its benefits compared to established recycling pathways. The pyrolysis ED can be determined experimentally. However, this is elaborate and limited in transferability. Existing models cover virgin plastics or hydrocarbon thermoplastic mixtures on a laboratory scale. Here, a model for calculating the ED of thermoplastic mixtures based on the superposition of virgin polymer data is developed. The material data, such as heat capacity, phase transition enthalpy, and reaction enthalpy, are determined using differential scanning calorimetry. Pilot-scale experiments are performed in a 1 kg/h screw reactor. These experimental data are compared to model calculations. The feedstock-specific ED for pyrolysis is plastic-type independent. It amounts to approximately 4–6% of the feedstocks’ net calorific value. The validation shows excellent accordance for virgin plastics and hydrocarbon plastics mixtures. The modeled ED of mixtures including heteroatoms is systematically underestimated, which indicates changes in the degradation mechanism. The model allows for resolving several phenomena contributing to the pyrolysis ED. The simple calculation of the ED with in-depth information on occurring phenomena enables more reliable process design, optimization, and evaluation.