Two-stage thermal pyrolysis of plastic solid waste: Set-up and operative conditions investigation for gaseous fuel production.

• Catalyst-free approach for a technologically advantageous pyrolysis. • Two-stage plant to optimize gas yield (∼65 % w/w) and calorific value (∼41 MJ/kg). • Pyrolytic gas has potential for replacing fossil fuel in combustion engine. • Integration with combustion engine is promising for electricity and thermal power. In response to the escalating global challenge of mounting plastic waste and the imperative to adopt more sustainable practices for resource utilization, our study focuses on the utilization of plastic solid waste (PSW) through a two-stage thermal pyrolysis process. This aims to demonstrate its potential as a high-performance alternative to existing two-stage catalytic pyrolysis methods. The experimentation involved processing real scrap PSW material in a lab-scale batch set-up, emphasizing optimizing residence time in the cracking reactor to maximize gas yield and its lower heating value (LHV). The study underscores the advantages of the employed two-stage thermal pyrolysis apparatus through a comparative analysis with established set-up dedicated to maximizing gas yield. Once the operative conditions were explored, resulting pyrolysis products underwent detailed characterization to assess their suitability as a sustainable fuel source. The study also presents a practical application of the produced gaseous fuel, envisioning its combustion in an internal combustion engine (ICE), known for its flexibility regarding fuel properties. This application is demonstrated through a simulation conducted in Unisim Design©. The successful processing of real PSW material in the two-stage lab-scale experimental set-up showcased optimal gas yield achievements (>65 % w/w) with an LHV (∼41 MJ/kg), comparable to that of natural gas. This emphasizes the potential of these sustainable alternatives to replace fossil fuels, especially in the context of ICE applications. The integration of the pyrolysis plant with an ICE demonstrated promising prospects for generating electricity in the transportation sector and facilitating thermal power for heat integration in pyrolysis reactors. [ABSTRACT FROM AUTHOR]