Plastic waste treatment and utilization: Unveiling the environmental impacts of efficient conversion and high value utilization in Greek industries

The growing accumulation of plastic waste presents major environmental and health challenges. This is largely due to the widespread use of plastics, driven by their versatility, low cost, and broad range of applications. Innovative plastic waste management strategies aligned with circular economy principles are urgently needed to reduce emissions and mitigate end-of-life treatment issues. Focusing on the case study of a Greek industry, the environmental impacts of advanced plastic waste treatment technologies, such as pyrolysis, as well as its potential for high-value utilization are being investigated. This work employs a comprehensive methodology combining experimental analysis and Life Cycle Assessment to assess the efficiency and sustainability of the conversion of different plastic wastes to liquid fuels via pyrolysis, evaluating also their physicochemical properties compared to conventional fuels. Results indicate that pyrolysis can effectively produce high-value liquid fuels from non-recyclable plastic waste, contributing to resource efficiency within a circular economy framework. Among the scenarios assessed, the configuration incorporating industrial waste heat demonstrates superior environmental performance, including significant reductions in greenhouse gas emissions, particulate matter formation, and resource depletion. However, the reuse of pyrolysis by-products such as char and gas for internal combustion was found environmentally suboptimal, highlighting the need for alternative valorization pathways. Despite its potential, challenges such as feedstock variability, pre-treatment costs, and regulatory uncertainties must be addressed for large-scale implementation. Overall, the study underscores the viability of pyrolysis as a key strategy for sustainable plastic waste management, particularly when embedded within existing industrial infrastructures and supported by favorable policy frameworks.