Hydrogen from Waste Plastics: Integrated Pyrolysis–Reforming Simulation and Techno-Economic Insights for a Circular Economy

Plastic waste poses a major environmental issue because it persists in nature for long durations and recycling facilities are not readily available. The conversion of waste materials into hydrogen creates two beneficial effects that help decrease pollution levels and establish hydrogen as a clean energy source for sustainable low-carbon systems. In this study, an integrated process for plastic-to-hydrogen conversion was developed using Aspen HYSYS v14. The system uses pyrolysis, steam reforming, and the water–gas shift (WGS) reaction, through pseudo-components of polyethylene, polypropylene and polystyrene to model decomposition processes. Following optimization, the hydrogen fraction in the syngas rose from 0.664 to 0.733. At this stage, the process produced roughly 651 kg of hydrogen per hour in steady operation. In addition, char and pyrolysis oil were produced as co-products that can be valorized in circular economy applications The implementation of heat integration achieved an 8% reduction in utility demand that proves that internal energy recovery stands as a vital element for sustainable design. The techno-economic analysis showed that the project would achieve a 39% internal rate of return and payback period of 5.95 years, thus proving its financial stability. The research demonstrates how modern process modeling techniques enable the creation of clean technology systems that address plastic pollution problems while producing low-carbon hydrogen.