Evaluating Techno-Economic and Environmental Feasibility of Plastic Waste Pyrolysis under Malaysia Market: A Process Simulation Approach

Rapid plastic consumption has led to significant plastic waste accumulation. In Malaysia, where recycling rates remain low, alternative waste-to-resource pathways are needed to complement conventional practices. Among these technologies, plastic waste pyrolysis offers a promising route to convert mixed plastic waste into value-added products. However, comprehensive studies integrating process modelling and simulation, techno-economic evaluation, and environmental assessment under Malaysian market conditions remain limited. This work develops an integrated process modelling and simulation framework to evaluate the feasibility of pyrolyzing mixed plastic waste. The framework combines market analysis, site selection, steady-state process simulation, techno-economic analysis, and environmental assessment to establish a comprehensive desktop evaluation methodology. Aspen Plus V14 was used to develop the process flowsheet and generate mass and energy balances. The proposed process was designed to treat 6850 kg/h of plastic waste, producing 68.5% pyrolysis plastic oil, 3.6% char, and 27.8% fuel gas. Site selection analysis identified Klang, Selangor, as the most suitable location due to its robust recycling network, Port Klang logistics, and utility access. Economic evaluation indicates a positive Net Present Value and acceptable payout period under subsidized feedstock scenarios, with strong sensitivity to feedstock price. Environmental assessment based on Scope 1 and 2 greenhouse gas shows that direct emissions from on-site fuel combustion are the primary contributor to CO2-equivalent (CO2e) emissions. Utilization of internally generated fuel gas for process heating reduces total operating expenditure by 4.6%, shortens the payout period by 18.7%, and lowers overall CO2e emissions by 10.7%, with minimal impact on capital cost.