Pyrolysis is one of the various types of chemical degradation processes that occur at higher temperatures (above the boiling point of water or other solvents). It differs from other processes like combustion and hydrolysis in that it usually does not involve the addition of other reagents such as oxygen (O2, in combustion) or water (in hydrolysis). Pyrolysis produces solids (char), condensable liquids, (light and heavy oils and tar), and non-condensable gasses.
Other pyrolysis types come from a different classification that focuses on the pyrolysis operating conditions and heating system used, which have an impact on the yield of the pyrolysis products.
In many settings, some amounts of oxygen, water, or other substances may be present, so that combustion, hydrolysis, or other chemical processes may occur besides pyrolysis proper. Sometimes those chemicals are added intentionally, as in the burning of firewood, in the traditional manufacture of charcoal, and in the steam cracking of crude oil.
When organic matter is heated at increasing temperatures in open containers, the following processes generally occur, in successive or overlapping stages:
Carbon and carbon-rich materials have desirable properties but are nonvolatile, even at high temperatures. Consequently, pyrolysis is used to produce many kinds of carbon; these can be used for fuel, as reagents in steelmaking (coke), and as structural materials.
The coke-making or "coking" process consists of heating the material in "coking ovens" to very high temperatures (up to 900 °C or 1,700 °F) so that the molecules are broken down into lighter volatile substances, which leave the vessel, and a porous but hard residue that is mostly carbon and inorganic ash. The amount of volatiles varies with the source material, but is typically 25–30% of it by weight. High temperature pyrolysis is used on an industrial scale to convert coal into coke. This is useful in metallurgy, where the higher temperatures are necessary for many processes, such as steelmaking. Volatile by-products of this process are also often useful, including benzene and pyridine. Coke can also be produced from the solid residue left from petroleum refining.
In the biomass components, the pyrolysis of hemicellulose happens between 210 and 310 °C. The pyrolysis of cellulose starts from 300 to 315 °C and ends at 360–380 °C, with a peak at 342–354 °C. Lignin starts to decompose at about 200 °C and continues until 1000 °C.
The low quality of oils produced through pyrolysis can be improved by physical and chemical processes, which might drive up production costs, but may make sense economically as circumstances change.
In 2015, a company called Monolith Materials built a pilot plant in Redwood City, CA to study scaling Methane Pyrolysis using renewable power in the process. A successful pilot project then led to a larger commercial-scale demonstration plant in Hallam, Nebraska in 2016. As of 2020, this plant is operational and can produce around 14 metric tons of hydrogen per day. In 2021, the US Department of Energy backed Monolith Materials' plans for major expansion with a $1B loan guarantee. The funding will help produce a plant capable of generating 164 metric tons of hydrogen per day by 2024. Pilots with gas utilities and biogas plants are underway with companies like Modern Hydrogen. Volume production is also being evaluated in the BASF "methane pyrolysis at scale" pilot plant, the chemical engineering team at University of California - Santa Barbara and in such research laboratories as Karlsruhe Liquid-metal Laboratory (KALLA). Power for process heat consumed is only one-seventh of the power consumed in the water electrolysis method for producing hydrogen.
The Australian company Hazer Group was founded in 2010 to commercialise technology originally developed at the University of Western Australia. The company was listed on the ASX in December 2015. It is completing a commercial demonstration project to produce renewable hydrogen and graphite from wastewater and iron ore as a process catalyst use technology created by the University of Western Australia (UWA). The Commercial Demonstration Plant project is an Australian first, and expected to produce around 100 tonnes of fuel-grade hydrogen and 380 tonnes of graphite each year starting in 2023. It was scheduled to commence in 2022. "10 December 2021: Hazer Group (ASX: HZR) regret to advise that there has been a delay to the completion of the fabrication of the reactor for the Hazer Commercial Demonstration Project (CDP). This is expected to delay the planned commissioning of the Hazer CDP, with commissioning now expected to occur after our current target date of 1Q 2022." The Hazer Group has collaboration agreements with Engie for a facility in France in May 2023, A Memorandum of Understanding with Chubu Electric & Chiyoda in Japan April 2023 and an agreement with Suncor Energy and FortisBC to develop 2,500 tonnes per Annum Burrard-Hazer Hydrogen Production Plant in Canada April 2022
The American company C-Zero's technology converts natural gas into hydrogen and solid carbon. The hydrogen provides clean, low-cost energy on demand, while the carbon can be permanently sequestered. C-Zero announced in June 2022 that it closed a $34 million financing round led by SK Gas, a subsidiary of South Korea's second-largest conglomerate, the SK Group. SK Gas was joined by two other new investors, Engie New Ventures and Trafigura, one of the world's largest physical commodities trading companies, in addition to participation from existing investors including Breakthrough Energy Ventures, Eni Next, Mitsubishi Heavy Industries, and AP Ventures. Funding was for C-Zero's first pilot plant, which was expected to be online in Q1 2023. The plant may be capable of producing up to 400 kg of hydrogen per day from natural gas with no CO2 emissions.
Alkaline pyrolysis of sewage sludge at low temperature of 500 °C can enhance H2 production with in-situ carbon capture. The use of NaOH (sodium hydroxide) has the potential to produce H2-rich gas that can be used for fuels cells directly.
Waste from pyrolysis itself can also be used for useful products. For example, contaminant-rich retentate from liquid-fed pyrolysis of postconsumer multilayer packaging waste can be used as novel building composite materials, which have higher compression strengths (10-12 MPa) than construction bricks and brickworks (7 MPa), as well as 57% lower density, 0.77 g/cm3 .
Pyrolysis has also been used for trying to mitigate tobacco waste. One method was done where tobacco waste was separated into two categories TLW (Tobacco Leaf Waste) and TSW (Tobacco Stick Waste). TLW was determined to be any waste from cigarettes and TSW was determined to be any waste from electronic cigarettes. Both TLW and TSW were dried at 80 °C for 24 hours and stored in a desiccator. Samples were grounded so that the contents were uniform. Tobacco Waste (TW) also contains inorganic (metal) contents, which was determined using an inductively coupled plasma-optical spectrometer. Thermo-gravimetric analysis was used to thermally degrade four samples (TLW, TSW, glycerol, and guar gum) and monitored under specific dynamic temperature conditions. About one gram of both TLW and TSW were used in the pyrolysis tests. During these analysis tests, CO2 and N2 were used as atmospheres inside of a tubular reactor that was built using quartz tubing. For both CO2 and N2 atmospheres the flow rate was 100 mL min−1. External heating was created via a tubular furnace. The pyrogenic products were classified into three phases. The first phase was biochar, a solid residue produced by the reactor at 650 °C. The second phase liquid hydrocarbons were collected by a cold solvent trap and sorted by using chromatography. The third and final phase was analyzed using an online micro GC unit and those pyrolysates were gases.
Two different types of experiments were conducted: one-stepwise pyrolysis and two-stepwise pyrolysis. One-stepwise pyrolysis consisted of a constant heating rate (10 °C min−1) from 30 to 720 °C. In the second step of the two-stepwise pyrolysis test the pyrolysates from the one-stepwise pyrolysis were pyrolyzed in the second heating zone which was controlled isothermally at 650 °C. The two-stepwise pyrolysis was used to focus primarily on how well CO2 affects carbon redistribution when adding heat through the second heating zone.
First noted was the thermolytic behaviors of TLW and TSW in both the CO2 and N2 environments. For both TLW and TSW the thermolytic behaviors were identical at less than or equal to 660 °C in the CO2 and N2 environments. The differences between the environments start to occur when temperatures increase above 660 °C and the residual mass percentages significantly decrease in the CO2 environment compared to that in the N2 environment. This observation is likely due to the Boudouard reaction, where we see spontaneous gasification happening when temperatures exceed 710 °C. Although these observations were seen at temperatures lower than 710 °C it is most likely due to the catalytic capabilities of inorganics in TLW. It was further investigated by doing ICP-OES measurements and found that a fifth of the residual mass percentage was Ca species. CaCO3 is used in cigarette papers and filter material, leading to the explanation that degradation of CaCO3 causes pure CO2 reacting with CaO in a dynamic equilibrium state. This being the reason for seeing mass decay between 660 °C and 710 °C. Differences in differential thermogram (DTG) peaks for TLW were compared to TSW. TLW had four distinctive peaks at 87, 195, 265, and 306 °C whereas TSW had two major drop offs at 200 and 306 °C with one spike in between. The four peaks indicated that TLW contains more diverse types of additives than TSW. The residual mass percentage between TLW and TSW was further compared, where the residual mass in TSW was less than that of TLW for both CO2 and N2 environments concluding that TSW has higher quantities of additives than TLW.
The one-stepwise pyrolysis experiment showed different results for the CO2 and N2 environments. During this process the evolution of 5 different notable gases were observed. Hydrogen, Methane, Ethane, Carbon Dioxide, and Ethylene all are produced when the thermolytic rate of TLW began to be retarded at greater than or equal to 500 °C. Thermolytic rate begins at the same temperatures for both the CO2 and N2 environment but there is higher concentration of the production of Hydrogen, Ethane, Ethylene, and Methane in the N2 environment than that in the CO2 environment. The concentration of CO in the CO2 environment is significantly greater as temperatures increase past 600 °C and this is due to CO2 being liberated from CaCO3 in TLW. This significant increase in CO concentration is why there is lower concentrations of other gases produced in the CO2 environment due to a dilution effect. Since pyrolysis is the re-distribution of carbons in carbon substrates into three pyrogenic products. The CO2 environment is going to be more effective because the CO2 reduction into CO allows for the oxidation of pyrolysates to form CO. In conclusion the CO2 environment allows a higher yield of gases than oil and biochar. When the same process is done for TSW the trends are almost identical therefore the same explanations can be applied to the pyrolysis of TSW.
Harmful chemicals were reduced in the CO2 environment due to CO formation causing tar to be reduced. One-stepwise pyrolysis was not that effective on activating CO2 on carbon rearrangement due to the high quantities of liquid pyrolysates (tar). Two-stepwise pyrolysis for the CO2 environment allowed for greater concentrations of gases due to the second heating zone. The second heating zone was at a consistent temperature of 650 °C isothermally. More reactions between CO2 and gaseous pyrolysates with longer residence time meant that CO2 could further convert pyrolysates into CO. The results showed that the two-stepwise pyrolysis was an effective way to decrease tar content and increase gas concentration by about 10 wt.% for both TLW (64.20 wt.%) and TSW (73.71%).
Pyrolysis is used in the production of chemical compounds, mainly, but not only, in the research laboratory.
When the temperature is increased from 500 to 900 °C, most PAHs increase. With increasing temperature, the percentage of light PAHs decreases and the percentage of heavy PAHs increases.
In TGA, the sample is loaded first before the increase of temperature, and the heating rate is low (less than 100 °C min−1). Macro-TGA can use gram-scale samples to investigate the effects of pyrolysis with mass and heat transfer.
In recent years, machine learning has attracted significant research interest in predicting yields, optimizing parameters, and monitoring pyrolytic processes.
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