Plastic waste signifies a global predicament, aggravated by deficient management practices. Unearthing methods to repurpose energy from this waste is pivotal. This study delves into the pyrolytic degradation of low-density plastics to convert plastic waste into valuable products on a modest scale. A small-scale, low-CO₂ emitting distiller was employed in the process. A zeolite was harnessed as a catalyst to augment the temperature and hasten the pyrolysis process. A comprehensive life cycle analysis was executed to assess the environmental impact of the process. In this scenario, zeolite-facilitated pyrolysis was more proficient compared to traditional thermal pyrolysis, generating a yield of 22.5% with the catalyst, contrasting with 18% without. A kinetic model was formulated, observing reaction mechanisms and temperature escalation and culminating in the extraction of aromatic oils. These oils were further distilled to produce liquid hydrocarbons, beginning the distillation at 60 °C with the catalyst. Characterization of the secured hydrocarbons was conducted using infrared, Raman spectroscopy, and gas chromatography, discovering compounds akin to gasoline, such as benzene, toluene, and xylenes. Additionally, the procedure exhibited a minimal environmental detriment, as validated by the life cycle analysis. This study concludes by highlighting the potential of small-scale, low-CO₂ emitting pyrolytic degradation of low-density plastics for energy recovery from plastic waste, demonstrating the practical and environmental benefits of this avant-garde method.

A pilot-scale reactor prototype was designed to produce hydrocarbons through the catalytic pyrolysis process of low-density polyethylene, thereby extending its life cycle and contributing to energy efficiency and sustainability. The reactor consists of a stainless-steel tank encased in a ceramic jacket with refractory cement and clay bricks. The tank, made of 304 stainless steel, ensures mechanical strength and efficient heat transfer to the reactor core. A spiral condenser was incorporated into a water tank to cool the vapors and recover the liquid oil. The insulating materials, ceramic, refractory cement and clay brick, demonstrated a high combined thermal resistance of 0.159 m²·K/W. Simulations and energy flow calculations demonstrated that heat is efficiently directed to the reactor core, reaching 350 °C with only 3000–3800 W, while the outside of the jacket remained close to 32 °C. These results confirm that the proposed design improves thermal efficiency and optimizes energy use for catalytic pyrolysis. The novelty of this design lies in its energy-efficient configuration, which can be replicated in rural regions worldwide due to the accessibility of its construction materials. This reactor was developed based on a smaller-scale model that previously yielded excellent results.