Application of an integrated pyrolysis and chemical leaching process for pulper waste conversion into coal, hydrogen and chemical flocculating agent.

[Display omitted] • By slow pyrolysis, pulper waste is converted into a stable, carbon-rich material. • Chemical leaching upgrades the carbon-rich solid to a fossil coal substitute. • The process enables to recover more than 90 % of Ca and Al from pulper waste. • By precipitation, a reusable Al-based flocculating agent is obtained. • Clean hydrogen is produced by the reaction between metallic Al and HCl. This work aims to investigate the potentials of integrating slow pyrolysis and chemical leaching to recycle pulper waste (PW), the waste generated by paper mills, and consists of plastics, metallic films, and biobased polymers. The concentration of chlorine and metals is a barrier against PW valorisation by combustion or high temperature thermochemical processes. In this study, PW was tested by slow pyrolysis at 400 °C and 500 °C. Chemical leaching tests were performed by processing both chars in a 1.4 M HCl solution, at 80 °C for 2 h, to remove inorganic compounds and upgrade the char to a coal-like material. Then, precipitation by NaOH was conducted on the leachate. Slow pyrolysis led to a char mass yield around 30 %. Due to the high inorganic matter concentration (almost 36 %, mainly including chlorine, calcium, and aluminium), the char retained only 25 % of the feedstock's chemical energy, while the remaining 75 % was recovered in the pyrogas. Leaching of the 500 °C pyrolysis char led to extract 93 % of aluminium, and almost 100 % of calcium and chlorine, resulting in an upgraded char containing 15.5 % ash, comparable to a fossil coal. By char leaching, the oxidation reaction of aluminium could produce 8 kg hydrogen per dry ton PW. The effectiveness of the precipitated compounds as flocculating agents was demonstrated, enabling a closed-loop recycling in the same paper mill. In conclusion, the proposed process demonstrated to be an effective solution to convert PW into high quality products. [ABSTRACT FROM AUTHOR]