Closing the Loop between Plastic Waste Management and Energy Cogeneration: An Innovative Design for a Flexible Pyrolysis Small-Scale Unit

This study proposes a simplified unit that can be employed in an industrial facility for the utilization of its own abundant plastic waste, primarily from discarded packaging, to achieve full or partial energy autonomy. By converting this waste into synthetic pyrolysis oil equivalent to 91,500 L, the industry can power a combined heat and power generation unit. The proposed unit was designed with a focus on maintaining high temperatures efficiently while minimizing oxygen exposure to protect the integrity of hydrocarbons until they transform into new compounds. Pyrolysis stands as a foundational procedure, paving the way for subsequent thermochemical transformations such as combustion and gasification. This study delves into the factors affecting pyrolysis and presents analytically the mathematical formulations and relevant calculations in order to effectively design and apply a real-life system. On this basis, fuels from plastic waste can be produced, suitable for utilization in typical equipment meant to produce heat, estimated for six months’ operation and 800 MWh of electricity. This study enhances the transition towards a more circular and resource-efficient economy with technologies that unlock the latent energy contained within the discarded matter. Additionally, it demonstrates the feasibility of a moderate investment in a co-generation system for industries utilizing 568 tonnes of plastic waste per year. The design and accurate calculations of this study highlight the theoretical potential of this technology, promoting environmental sustainability and resource conservation.