Thermal Cracking for Recycling Plastics and Contaminated Pyrolysis Oils: A Theoretical Process Design based on Mixed Household Packaging Waste.

Abstract

This study shows that thermal cracking can effectively convert mixed household plastic waste into useful products, with about 70% liquid yield. The process works especially well with polyolefin-rich plastics, but contaminants like PET and PVC reduce oil quality and require additional upgrading. Energy analysis reveals that the process is energy-intensive, although some energy can be recovered using the produced gases. Economically, pyrolysis oil can be produced at a cost close to naphtha, making it potentially competitive. However, profitability depends heavily on low-cost feedstock, process scale, and efficient upgrading. Overall, thermal cracking is a promising option for handling mixed plastic waste, but its success depends on managing contamination, energy use, and processing costs.