Pyrolysis Oil and Syngas – Plastics Recycling

Project Scope: Conti Testing Laboratories supported a client developing a new facility to convert waste plastics into syngas and pyrolysis oil by providing comprehensive analytical testing of raw plastics, syngas, and pyrolysis oil samples.

Overview

The client’s goal was to transform mixed waste plastics into valuable syngas and pyrolysis oil products for energy and chemical feedstocks. To enable successful facility commissioning and process optimization, the client required fast, accurate testing to understand how different plastic feedstocks affected product quality.

Client Need / Challenge

The primary challenge was developing a streamlined analytical process to test a wide variety of analytes across numerous plastic waste streams with a 1–3 day turnaround. Rapid AB testing was required to evaluate process control parameters, plastic input variations, and product quality while supporting environmental permitting needs.

Services Provided

Conti Testing Laboratories provided full analytical support, including:

• Major and Trace Element Analysis (metals in feedstock, syngas, and oils)
• Anion Analysis: Chloride, bromide, and fluoride quantification
• Density and Viscosity Testing
• Water Content Determination
• Mercury and Sulfur Analysis
• Gas Composition Analysis: Methane, ethane, ethylene, propane, and other hydrocarbons

Select Methods Used

• Metals Determination: ASTM D5185
  
• Density: ASTM D4052
• Nitrogen (N): ASTM D5762
• Sulfur (S): ASTM D2622
• Water Content: ASTM D4176
• Viscosity: ASTM D7042
• Mercury (Hg): EPA 7473
• Halogens (Total, Cl-, Br-, F-): ASTM D7359
• Gasses: ASTM D1946

All testing was completed within 1–3 day turnaround to align with the client’s aggressive development timeline.

Results and Impact

Conti’s rapid, high-quality analysis enabled the client to:

• Perform timely AB testing of process adjustments and plastic feedstock variations
• Refine process parameters for improved yield and quality of syngas and pyrolysis oil
• Facilitate environmental permitting by providing data on trace metals, sulfur, and halides
• Establish ongoing quality control protocols for consistent product quality during scale-up.

The collaboration allowed the client to accelerate development timelines while ensuring regulatory compliance and product viability in the growing circular plastics economy.