Resource-Efficient Upgrading of Plastic Pyrolysis Oil: Nickel-Loaded Kaolin for Enhancing Light Oil Yield at Lower Temperatures

This study proposes a sustainable approach for converting waste-plastic pyrolysis oil into higher-value products through continuous catalytic reforming. A 5Ni/K catalyst, prepared by impregnating 5 wt % nickel onto kaolin, was specifically designed to operate at lower temperatures than conventional systems. Comparative experiments with commercial catalysts (ZSM-5 and kaolin) and nickel-impregnated catalysts (5Ni/K and 5Ni/Z) were conducted at various temperatures to evaluate product yields and properties. Despite operating at 280 °C─a significant reduction from the 520 °C required by conventional catalysts─5Ni/K achieved comparable or superior oil yields and light oil fractions. The kaolin-only catalyst exhibited minimal light oil production, whereas 5Ni/K utilized nickel-induced deoxygenation and kaolin’s moderate acidity to enhance cracking. Overall, these findings demonstrate that 5Ni/K─which utilizes inexpensive kaolin─can effectively address the economic and energy-related challenges of traditional pyrolysis oil reforming, paving the way for a more cost-efficient and environmentally responsible plastic waste management strategy.