Compound-Resolved Gas–Water Assessment of RDF Pyrolysis with Wet Scrubbing: Operating Windows for Internal Combustion Engine Combined Heat and Power and Closed-Loop Water Management

Pyrolysis of refuse-derived fuel (RDF) is a promising waste-to-energy route, but its use in higher-value applications remains limited by tar carryover, benzene, toluene, ethylbenzene, and xylenes (BTEX), heteroatom-containing compounds, and pollutant accumulation in recirculated scrubber water. This study evaluated operating windows for RDF pyrolysis coupled with direct wet scrubbing and closed-loop water reuse, with the aim of identifying regimes suitable for different end-use tiers. A Taguchi L27 design of experiments (DOE), i.e., an orthogonal array comprising 27 experimental runs, was applied to evaluate the effects of pyrolysis temperature, residence time, scrubber liquid-to-gas ratio, and scrubber-water temperature, while sequential reuse of the same scrubber-water inventory was evaluated at 5, 10, and 15 cycles. Cleaned-gas pollutants were quantified by compound-resolved gas chromatography–mass spectrometry (GC–MS) after solid-phase adsorption (SPA) sampling, while phenolics and polycyclic aromatic hydrocarbons (PAHs) in scrubber water were determined by extraction followed by GC–MS. Feasibility within each end-use tier was defined as simultaneous satisfaction of tier-specific cleaned-gas thresholds (Ctar, CBTEX, IN, and IS) and the corresponding water-loop hazard limit (Itox), using literature-informed engineering screening criteria. The results showed that stronger scrubbing reduced gas-phase tar and BTEX burdens, whereas extended water reuse caused systematic accumulation of phenolics and PAHs and increased the composite water-loop hazard index. Boiler-grade operation remained feasible across a broad operating range, with 23 of the 27 tested conditions remaining robust, whereas internal combustion engine combined heat and power (ICE-CHP) feasibility was restricted to a narrow robust regime, and no robust microturbine-grade condition was identified. These findings show that operating windows for RDF pyrolysis must be defined jointly by gas cleanliness and water-loop management constraints.