Fluidized-bed gasification of aluminum-containing plastic waste originating from multilayer packaging materials

Abstract At present, polymer barrier-coated packaging board waste is processed with other paperboard waste, where the cellulose fiber fraction is separated through a re-pulping process and recycled, while the residual plastic-rich fraction containing aluminum is combusted for energy production. This paper reports on experimental research on gasification of aluminum-containing plastic reject for the generation of synthesis gas, which can subsequently be converted to methanol and then olefins, used as feedstock in polymer manufacturing. Gasification experiments were performed using a bench-scale bubbling fluidized bed gasifier equipped with a hot filter and catalytic reformer. The temperature for gasification was 650–670 °C to avoid aluminum melting in the gasifier. Sand was used as the initial bed material. Aluminum was separated in the filter unit, and the tar and hydrocarbon-containing gas that passed through the filter was sent to the catalytic reformer. The gasifier operated efficiently and achieved over 99% carbon conversion during testing. Raw gas was successfully filtered at approximately 500 °C, and the hydrocarbon-rich raw gas was subsequently converted to synthesis gas in the catalytic reformer. Analysis of the extracted filter dust revealed significant aluminum content, suggesting potential opportunities for aluminum recovery.