The pyrolysis and gasification pathways of automotive shredder residue targeting the production of fuels and chemicals

Automotive shredder residue (ASR), also referred to as car fluff, is the 15-25% of end-of-life vehicle’s mass remaining after de-pollution, dismantling, shredding of the hulk and removal of metals from the shredded fraction. ASR typically consists of metals, plastics, rubber, textile, wood and glass, and is commonly landfilled. The use of ASR as a fuel in incineration processes is controversial since toxic pollutants can be generated as by-products if operational conditions and gas cleaning systems are not carefully controlled. Thermochemical treatment of ASR consists of advanced technology processes that convert ASR components liable to decomposition under the application of heat into liquids and/or gases and a solid residue containing metals. Within the thermochemical treatment options for ASR, pyrolysis and gasification are generally considered as the emerging technologies. The pyrolysis process uses medium temperatures (400-600°C) and an oxygen-free environment to decompose ASR chemically, thus producing minimum emissions and allowing metals to be recovered. Gasification is operated at higher temperatures (>700-800°C) and typically uses air as a gasification agent, which raises some issues in terms of emissions. Lab and pilot-scale plants fed with ASR have been built using both technologies, also considering a combination of them. The aim of this paper is the identification of the best conversion pathway for the production of transportation fuels, aviation fuels or chemicals (hydrogen, methanol, etc.) from ASR. The intermediate products from gasification and pyrolysis are used as feedstock in secondary processes for the production of the final products. The heterogeneous and complex composition of ASR raises several challenges upon its thermochemical treatment, so that the second step of the conversion process is typically not even addressed. Instead, this further step is fundamental to obtain some valuable products that can directly replace fossil derived fuels or chemicals. The updated picture presented in this work should help identify the main advantages and drawbacks of the pyrolysis and gasification processes when considered part of an overall ASR to fuels or chemicals plant.