Extraction of carbon powder from pyrolysis of low-density polyethylene plastics and its application in composite laminates

The escalating environmental concerns associated with plastic waste, particularly Low-Density Polyethylene (LDPE), have spurred research into sustainable recycling strategies. Pyrolysis has been developed as a viable technique for transforming LDPE into appreciated by-products, including carbon powder, which holds potential for advanced material applications. This study investigates the extraction of carbon powder from LDPE via pyrolysis and its subsequent utilization in composite laminates.•Araldite LY 556 and Aradur HY 951 epoxy resins are used to create the laminates, and carbon and kevlar fiber reinforcement are added in different weight fractions of 0 to 30 % in the intervals of 10 % of carbon char generated from LDPE.•Tensile strength (ASTM D638), flexural strength (ASTM D790), X-ray diffraction (XRD), Fourier Transform Infrared Spectroscopy (FT-IR) and scanning electron microscopy (SEM) are used to do a thorough assessment of mechanical and structural features.•Incorporation of LDPE-derived carbon char significantly enhanced mechanical properties of epoxy-based laminates. At 30 wt % char, tensile strength increased by 75 % in carbon and 129 % in Kevlar composites, while flexural strength improved by 94 % and 196 %, respectively. SEM, XRD, and FTIR analyses confirmed improved interfacial adhesion, structural integrity, and filler stability, demonstrating char's effectiveness as a sustainable reinforcement.