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Waste considers as a liability, but its potential as an asset can be achieved through proper valorization. This study analyzed one of the valorization process, 'co-pyrolysis,' using insights from the bibliometric analysis and experimental literature sources. The analysis primarily focuses on understanding the impact of process parameters, catalysts, and feedstock characteristics. The empirical findings highlight the significance of polymer-to-biomass ratios in feedstock, where a higher plastic content leads to increased oil production, while greater biomass ratios tend to enhance char generation. The effect of temperature and resident time on co-pyrolysis yield is also apparent. Specifically, high temperature and resident time result in better oil production and reduced char formation during co-pyrolysis. Optimal oil yield occurs with intermediate resident times of 50–100 min with higher temperatures ranging from 450 to 700 °C. While the prime conditions for optimal char yield ranges within a residence time of 30–60 min and temperatures 400–500 °C. Moreover, the introduction of catalysts into the reaction enhances both oil yield and quality within the co-pyrolysis process. However, challenges pertaining to feedstock availability and sorting remain significant hurdles. Hence, the outcome reveals that higher amount of plastic waste, with higher temperature and appropriate resident time can increase the amount of oil in the co-pyrolysis process. • Effect of process parameters and feedstock ratios in co-pyrolysis process. • Bibliometric analysis of the co-pyrolysis process. • Higher ratio of plastic waste in feedstock produces more pyrolytic oil. • Temperature has a significant effect on the co-pyrolysis process yield. [ABSTRACT FROM AUTHOR]

[Display omitted] • Integrated process for blue and green hydrogen production through co-gasification. • Co-gasification process IRR of 8% at a process efficiency level of 70%. • Exergoeconomics costs of steam turbine and gasifier 6,561.3 $/h and 6,541.9 $/h. • Green hydrogen production through alkaline electrolysis cell (AEC) • Surplus electricity has a potential AEC green hydrogen production of 213.5 kg/day. A novel co-gasification process for biomass and plastic waste has been proposed to produce the blue and green hydrogen. For process feasibility, an Aspen Plus simulation model has been developed, and a sustainability analysis is being conducted, focusing on economic viability, exergy, advanced exergy considerations, and exergoeconomics evaluations. The current process has demonstrated economic sustainability, as evidenced by an internal rate of return (IRR) of 8 % at a process efficiency level of 70 %. The process with a waste capacity of 20 tons per hour has the potential to produce approximately 1079 kW-hours of electric power. The surplus electricity, exceeding the process requirements is utilized for green hydrogen production through an alkaline electrolysis cell (AEC). This surplus electricity has the potential to produce around 213.5 kg/day of hydrogen. The exergy analysis of this model highlights that the gasifier component exhibits the lowest exergy efficiency, resulting in the highest exergy loss, around 40 %. Furthermore, advanced exergy analysis identifies both the steam turbine and gasifier as primary sources of exergy destruction, with associated exergoeconomics costs of around $6,561.3 and $6,541.9 per hour, respectively. Consequently, improving the gasifier and steam turbine performance can enhance the overall sustainability of the process. [ABSTRACT FROM AUTHOR]

An innovative valorization process for biomass waste treatment has been developed in this study. The basic simulation process developed considering experimental studies, and it has been optimized by application of a pattern search algorithm to obtain the optimum output of energy efficiency, economic performance, and process safety index (PSI). Mainly, three different scenarios have been analyzed based on the sustainability index (SI). These SI has been determined through energy, economy, safety, and electric power potential. According to the results of the SI, the optimized processes are more sustainable (SI = 0.517 to 0.563) in all scenarios as compared to the basic process (SI = 0.503). Similarly, the economic analysis in terms of internal rate of return (%) of the basic process varies from 37 to 2% when the process efficiency dropped from 100 to 80%, and it varies from 44 to 6% for the optimized process without any subsidy. The optimized process has a potential of 2788–4044 kW of electric power generation from thermal energy of the process while it is only 2302 kW for basic scenario. Therefore, the optimized process has better energy, economic, electric power, and safety performances, thus it is more sustainable as compared with the basic process. [Display omitted] • Integration of pyrolysis and gasification for biomass valorization. • Pattern search algorithm application for valorization process optimization. • A novel sustainability index has been proposed. • Electricity potential from optimized process thermal energy is 2788–4044 kW. • Energy efficiency of the processes varies from 46% to 66%. [ABSTRACT FROM AUTHOR]