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Harnessing Pyrolysis for Industrial Energy Autonomy and Sustainable Waste Management

Author

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  • Dimitrios-Aristotelis Koumpakis

    (Sustainability Engineering Laboratory, Department of Mechanical Engineering, Aristotle University of Thessaloniki, P.O Box 483, 54124 Thessaloniki, Greece)

  • Alexandra V. Michailidou

    (Sustainability Engineering Laboratory, Department of Mechanical Engineering, Aristotle University of Thessaloniki, P.O Box 483, 54124 Thessaloniki, Greece)

  • Christos Vlachokostas

    (Sustainability Engineering Laboratory, Department of Mechanical Engineering, Aristotle University of Thessaloniki, P.O Box 483, 54124 Thessaloniki, Greece)

Abstract

This study describes the step-by-step development of a simplified system which can be implemented in industrial facilities with the help of their own surplus of plastic waste, mainly packaging waste, to reach a level of energy autonomy or semi-autonomy. This waste is converted to about 57,500 L of synthetic pyrolysis oil, which can then be used to power industries, being fed into a Combined Heat and Power system. To achieve this goal, the design has hydrocarbon stability at elevated temperature and restricted oxygen exposure, so that they can be converted to new products. Pyrolysis is a key process which causes thermo-chemical changes—ignition and vaporization. The research outlines the complete process of creating a basic small-scale pyrolysis system which industrial facilities can use to generate energy from their plastic waste. The proposed unit processes 360 tons of plastic waste yearly to produce 160 tons of synthetic pyrolysis oil which enables the generation of 500 MWh of electricity and 60 MWh of heat. The total investment cost is estimated at EUR 41,000, with potential annual revenue of up to EUR 45,000 via net metering. The conceptual design proves both environmental and economic viability by providing a workable method for decentralized waste-to-energy solutions for Small and Medium-sized Enterprises.

Suggested Citation

  • Dimitrios-Aristotelis Koumpakis & Alexandra V. Michailidou & Christos Vlachokostas, 2025. "Harnessing Pyrolysis for Industrial Energy Autonomy and Sustainable Waste Management," Energies, MDPI, vol. 18(12), pages 1-23, June.
    • Handle: RePEc:gam:jeners:v:18:y:2025:i:12:p:3041-:d:1674522
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    References listed on IDEAS

    as
    1. Christos Vlachokostas, 2020. "Closing the Loop Between Energy Production and Waste Management: A Conceptual Approach Towards Sustainable Development," Sustainability, MDPI, vol. 12(15), pages 1-15, July.
    2. Maria P. C. Volpi & Jean C. G. Silva & Andreas Hornung & Miloud Ouadi, 2024. "Review of the Current State of Pyrolysis and Biochar Utilization in Europe: A Scientific Perspective," Clean Technol., MDPI, vol. 6(1), pages 1-24, February.
    3. Christos Mertzanakis & Christos Vlachokostas & Charalampos Toufexis & Alexandra V. Michailidou, 2024. "Closing the Loop between Waste-to-Energy Technologies: A Holistic Assessment Based on Multiple Criteria," Energies, MDPI, vol. 17(12), pages 1-21, June.
    4. Pablo Benalcazar & Marcin Malec & Przemysław Kaszyński & Jacek Kamiński & Piotr W. Saługa, 2024. "Electricity Cost Savings in Energy-Intensive Companies: Optimization Framework and Case Study," Energies, MDPI, vol. 17(6), pages 1-16, March.
    5. Canice C. Uzosike & Lachlan H. Yee & Ricardo Vasquez Padilla, 2023. "Small-Scale Mechanical Recycling of Solid Thermoplastic Wastes: A Review of PET, PEs, and PP," Energies, MDPI, vol. 16(3), pages 1-23, January.
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