Crosslinked polyethylene (PEX) to naphtha via catalytic pyrolysis

The project aims to strengthen competence and foster industrial collaboration in the chemical recycling of plastic waste into value-added naphtha-range hydrocarbons through cooperation between RISE, Uponor, and FCCSA. A key element of the project is the development, operation, and evaluation of a reliable and purpose-designed catalytic pyrolysis infrastructure. As part of this effort, RISE will establish a pilot-scale continuous rotary-kiln pyrolysis unit with a feed capacity of 1–5 kg h⁻¹. The pyrolyzer will be integrated with a fixed-bed catalytic reactor for ex-situ upgrading of the generated pyrolysis vapors, enabling systematic investigation and optimization of catalytic vapor upgrading under continuous operating conditions.

This project explores the role of catalyst properties in directing the catalytic pyrolysis of cross-linked polyethylene (PEX) toward valuable naphtha- and diesel-range hydrocarbons. By selecting catalysts with appropriate physicochemical and catalytic characteristics, the process aims to enhance hydrocarbon selectivity and improve the composition and quality of the liquid product. Such catalytic upgrading may facilitate the production of refinery- and petrochemical-compatible hydrocarbon streams while supporting the circular utilization of PEX waste. Naphtha-rich pyrolysis liquids are of particular interest as potential feedstocks for steam cracking.

This project leverages an integrated continuous rotary-kiln pyrolyzer and fixed-bed catalytic reactor configuration, enabling the direct, single-stage catalytic upgrading of pyrolysis vapors derived from mixed plastic waste streams.