Thermogravimetric
analysis (TGA) was used to investigate thermal
and catalytic pyrolysis of waste plastics such as prescription bottles
(polypropylene/PP), high density polyethylene, landfill liners (polyethylene/PE),
packing materials (polystyrene/PS), and foams (polyurethane/PU) into
crude plastic oils. In the first phase of this investigation, a statistical
design experiments approach identified reaction temperature and time
as the most important factors influencing product oil yield. Kinetic
parameters including activation energy determined for both catalytic
and noncatalytic processes showed a reduction in activation energy
for the catalytic reactions. In the second phase, the interactions
of reaction temperature and time with a number of catalysts were investigated
to determine the effect on the yield of crude plastic oil. It was
found that Y-zeolites increased conversion at reduced temperature
for PP and PE while spent fluid catalytic cracking and sulfated zirconia
catalysts supported pyrolytic decomposition of PS and PU foams. Response
surface methodology (RSM) was utilized to optimize TGA conditions
for pyrolytic decomposition of PP. The results were then validated
through batch scale experiments, and the resulting crude oils were
characterized and distilled into motor gasoline, diesel #1, diesel
#2, and vacuum gas oil fractions. Catalysts enhanced cracking at lower
temperatures and narrowed the molecular weight (hydrocarbon) distribution
in the crude oils. Chemical characterization of the crude oils indicated
an increased gasoline-range fraction in oils obtained in the presence
of catalyst while the distillate fractions were more evenly distributed
among gasoline-range and diesel-range hydrocarbons in the absence
of catalyst. The distillates obtained were characterized for fuel
properties, elemental composition, boiling point, and molecular weight
distribution. The fuel properties of the diesel-range distillate (diesel
fraction) were comparable to those of ultralow sulfur diesel (ULSD).