Thermochemical Conversion of Automotive Paint Sludge: A Review

Automotive paint sludge (APS) is a hazardous industrial waste generated during automotive coating operations and is characterized by high moisture content, variable organic and inorganic composition, volatile organic compounds, pigments and heavy metals. Conventional disposal methods, including landfilling and direct incineration, present increasing environmental and regulatory challenges, thereby motivating interest in thermochemical conversion technologies for APS valorization and energy recovery. This review evaluates the current state of research on APS thermochemical conversion through incineration, pyrolysis and gasification pathways. The review compares the major operational characteristics of thermochemical pathways, including reactor conditions, temperature ranges, product yields, energy recovery potential, pollutant formation and downstream cleanup requirements. Also, techno-economic considerations such as drying energy demand and scale-up limitations are discussed. According to the current literature, incineration is the most industrially mature route for APS destruction, whereas pyrolysis offers more flexibility for fuel and material recovery. Gasification shows potential for syngas and hydrogen production but remains insufficiently studied for APS applications. Despite growing interest in APS valorization, a lot of research gaps remain regarding standardized feedstock classification, pilot-scale validation, process integration, environmental risk assessment and techno-economic optimization. Conclusively, future approaches towards managing APS would need to incorporate process optimization for specific APS types, incorporation of co-processing techniques, as well as an overall assessment for both environmental and economic feasibility.