Continuous process design of the microwave chemical recycling of waste plastics using microwave-absorbing heating elements

Conventional pyrolysis methods to chemically recycle plastic waste require significant energy input owing to inefficient energy transfer from the heat sources to plastics and the generation of excess CO₂. Accordingly, there is an urgent need to develop alternative methods for the chemical recycling of waste plastics to limit global warming. In this study, the use of microwaves (MWs) as an efficient energy source for pyrolysis and chemical recycling. However, because plastic is transparent to MW energy, a method that utilizes carbon materials as MW-absorbing heating elements (MWAHEs) was developed. This method directly converted high-density polyethylene (HDPE) into light chemicals in up to 94% yield with 45% ethylene selectivity. A two-stage pyrolysis system incorporating MWAHE-assisted MW pyrolysis was also developed to produce light chemicals in 95% yield with 49% ethylene selectivity. From a chemical engineering perspective, this two-step pyrolysis system is an efficient and feasible method for producing valuable light olefins. This study also demonstrates that MWAHE assisted MW pyrolysis is effective for the chemical recycling of plastic waste. This study offers potential solutions for the environmental problems posed by plastic waste by developing efficient and scalable methods for its chemical recycling.