Pilot-Scale pyrolysis of HDPE waste: A technical and economic feasibility study for sustainable waste management in Colombia

Abstract Plastic waste presents a critical environmental challenge but offers significant potential as a carbon-rich feedstock for valuable products. Pyrolysis, especially of high-density polyethylene (HDPE), has emerged as a promising technology to convert plastic waste into pyrolytic oil, gases, and recoverable monomers, supporting sustainable waste management and energy security across various economies. This study examines the technical and economic feasibility of HDPE pyrolysis at a pilot scale, with a focus on Colombia’s emerging waste management infrastructure. Laboratory experiments optimized key process parameters, including temperature, heating rate, and residence time, while Aspen Plus simulations provided essential insights into mass balance and energy efficiency. Results showed that pyrolysis at 550 °C yielded the highest liquid fraction (71.04%), with fuel properties comparable to kerosene and diesel. The economic analysis suggests a minimum selling price of $0.80/kg for pyrolytic oil to achieve a 15% internal rate of return (IRR), highlighting the need for further cost optimization and competitive market strategies. While additional research, process improvements, and supportive policies are essential for large-scale adoption, this study underscores the potential of pyrolysis to contribute to sustainable economic growth and advance circular economy goals within Colombia and similar markets. Graphical abstract