Octane Number Research Articles

Application of a property prediction model based on the structure oriented lumping method in the fluid catalytic cracking process

Based on the Structure Oriented Lumping (SOL) method and the Artificial Neural Network (ANN) algorithm, a SOL-ANN property prediction model was constructed to predict the properties of molecules and products in the fluid catalytic cracking (FCC) process. The properties of each structural vector in the molecular composition matrices of gasoline and diesel were calculated. The influences of reaction temperature on the properties of gasoline and diesel were investigated from the perspective of molecular composition. When the reaction temperature increased from 490 °C to 510 °C, the content of aromatics and olefins in gasoline and the content of aromatics in diesel increased, resulting in the research octane number (RON) of gasoline increasing by 2.96 units and the cetane number (CN) of diesel decreasing by 1.37 units. Using the molecular composition information of products to calculate the properties of molecules and products could guide the product quality evaluation and process optimization.

Facile production of ethyl furfuryl ether via reductive etherification of furfural over Rh nanoparticles supported red mud as a catalyst

Reducing reliance on fossil fuels and mitigating industrial waste are two strategies for clean environmental management. An active research topic within this framework is to convert abundant bio-derived compounds, like furfural (FF), into a petroleum blend by employing industrial waste, like red mud (RM), as catalyst support. Here, we demonstrate that furfural can be chemoselectively converted in a single step into ethyl furfuryl ethers (EFE), which significantly enhance the blended petroleum's octane number. This is achieved in the presence of a recyclable Rh-impregnated RM catalyst. In this context, a range of valuable metals (M = Rh, Ir, and Ru) are impregnated into the RM (M@RM) and extensively characterized by SEM, EDS, XRD, FT-IR, TEM, and XPS. The 1% Rh@RM composite,calcined at 400 °C (1% Rh@RM-400), produced 75 % EFE selectivity with the >99 % conversion of furfural. The prepared catalyst retains its stability for the multiple cycles of the furfural hydrogenation reactions.

Selective sorting of hexane isomers by anion-functionalized metal-organic frameworks with optimal energy regulation

Extensive efforts have been made to improve the separation selectivity of hydrocarbon isomers with nearly distinguishable boiling points; however, how to balance the high regeneration energy consumption remains a daunting challenge. Here we describe the efficient separation of hexane isomers by constructing and exploiting the rotational freedom of organic linkers and inorganic SnF62− anions within adaptive frameworks, and reveal the nature of flexible host-guest interactions to maximize the gas-framework interactions while achieving potential energy storage. This approach enables the discrimination of hexane isomers according to the degree of branching along with high capacity and record mono-/di-branched selectivity (6.97), di-branched isomers selectivity (22.16), and upgrades the gasoline to a maximum RON (Research Octane Number) of 105. Benefitting from the energy regulation of the flexible pore space, the material can be easily regenerated only through a simple vacuum treatment for 15 minutes at 25 °C with no temperature fluctuation, saving almost 45% energy compared to the commercialized zeolite 5 A. This approach could potentially revolutionize the whole scenario of alkane isomer separation processes.

Polyethylene waste co-processing in fluid catalytic cracking plants

Plastics pollution is an overwhelming environmental problem that must be solved as soon as possible. Refining processes such as the Fluidized Catalytic Cracking (FCC) process with a global capacity of 14 million barrels per day, may help to solve it in the short term, as many scientists have already pointed out. Just by co-processing 5 wt % polyethylene waste in those units, 37 million tons per year of polyethylene could be eliminated from landfills and transformed into valuable fuels. However, refiners must be completely sure that processing polyethylene in their FCC plants will not cause any deleterious effects. That is the purpose of this paper.Low density polyethylene waste was transformed into valuable hydrocarbons by co-processing in proportions of 5 and 10 wt % with heavy gasoil in an FCC pilot plant which operates as industrial FCC plants do. Polyethylene was completely converted mainly into naphtha and liquified petroleum gas; at 510 °C polyethylene was converted into naphtha (46 %), LPG (20 %), light cyclic oil (9 %), heavy cyclic oil (15 %), coke (6 %) and dry gas (4 %); at 530 °C, the order and proportions changed significantly, naphtha (43 %), LPG (35 %), heavy cyclic oil (0 %), light cyclic oil (2 %), coke (8 %) and dry gas (12 %); LPG olefinicity and naphtha research octane number increased slightly. No catalyst circulation problems nor clogging or plugging were observed. However, at the highest experimental reaction temperature (530 °C), dry gas yield increased to more than 4 wt %, this could be a problem for most of industrial plants since it may overload the wet gas compressor.

A Pressure-Oscillation-Based RON Estimation Method for Spark Ignition Fuels beyond RON 100

Knock in spark ignition (SI) engines occurs when the air–fuel mixture in the combustion chamber ignites spontaneously ahead of the flame front, reducing combustion efficiency and possibly leading to engine damage if left unattended. The use of knock sensors to prevent it is common practice in modern engines. Another measure to mitigate knock is the use of higher-octane fuels. The American Society for Testing and Materials’ (ASTM) determination of the Research Octane Number (RON) and Motor Octane Number (MON) of spark ignition fuels has been based on measuring cylinder pressure rise at the onset of knock since its inception in the 1930s. This is achieved through a low-pass filtered pressure signal. Knock detection in contemporary engines, however, relies on measuring engine vibrations caused by high-frequency pressure oscillations during knock. The difference between conditions in which fuels are evaluated for their octane rating and the conditions that generate a knock intensity signal from the knock sensor suggests a potential difference between octane rating and the knock limit typically identified by a contemporary knock sensor. To address this disparity, a modified RON measurement method has been developed, incorporating pressure oscillation measurements. This test method addresses the historical lack of correlation between RON and high-frequency pressure oscillation intensity during knock. Using toluene standardization fuels (TSFs) as a reference, the obtained results demonstrate excellent high-frequency knock intensity-based RON estimations for gasoline. The method is able to differentiate between two fuels that share the same ASTM RON, associating them with a RON-like metric that is more aligned with their performance in a modern SI engine. This alternative method could potentially serve as a template for an upgrade to the existing ASTM RON method without significantly disrupting the current approach. Additionally, its capability to evaluate fuels beyond RON 100 opens the door to assessing a wider range of fuels for antiknock properties and the intensity of fuel oscillations during knocking combustion.

Optoacoustic interferometric characterization system (OPTICS) for the evaluation of fuel quality through speed of sound measurements

Ultrasonic techniques have been applied to assess crucial physical parameters in various types of fuels including the speed of sound (SoS), the bulk modulus and the acoustic attenuation coefficient. Such investigations may have important practical significance as the knowledge of fuel properties is directly related to the analysis of combustion characteristics, engine’s overall performance and exhaust emission in the environment. Nevertheless, typical pulse-echo acoustic methods, require the exact determination of both acoustic source – reflector distance and the time of flight of a finite temporal width ultrasonic pulse, setting thus an upper limit as regards the accuracy of the measurements. To encounter these challenges, we present a novel technology implemented through a low-cost and potentially portable optoacoustic interferometric characterization system (OPTICS) for the investigation of SoS variations in common fuels including automotive diesel, hydrous ethanol and gasoline. At 25 °C, diesel/kerosene blends demonstrated a SoS variation ranging from 1322.91 m/s (0.6 diesel volume fraction) to 1349.79 m/s (diesel fuel only), whereas hydrous ethanol samples varied between 1199.92 m/s (0.95 ethanol volume fraction) to 1149.39 m/s (pure ethanol only). Finally, assessments for 95 and 100 research octane number (RON) gasoline blends showed a SoS range from 1134.42 m/s (RON 95) to 1159.86 m/s (RON 100). The high precision and repeatability (relative uncertainty: ∼10-4) of the performed SoS measurements in controlled samples, has demonstrated the promising potential of OPTICS for the evaluation of fuel physical properties as well as the potential detection of contamination with adulterants.

Novel variants conceptional technology to produce eco-friendly sustainable high octane-gasoline biofuel based on renewable gasoline component

The creation of green engine fuels from renewable and sustainable gasoline additives is essential as a consequence of ecological concerns and the energy problem. Bio-alcohols are currently a promising sustainable fuel substitute for gasoline in automotive transportation. In this perspective, the ongoing investigation intends to evaluate the influence of sustainable and renewable petrol additives, like isopropanol, which has outstanding anti-detonation properties and great chemical and physical characteristics on reformable naphtha (HSRN) and light naphtha (LSRN), which possess low chemical and physical characteristics, and low octane rating. Additionally, the second goal is to create biofuel with an eco-octane number of high by blending other gasoline components than those previously indicated. Several gasoline fuels and experimental setups compliant with European standard norms were used to carry out the current work. The results reported that gasoline RON92, RON95, and RON98 were produced based on isopropanol as a renewable and sustainable resource. Moreover, the quantity and quality of light naphtha were maximized. Likewise, the laboratory findings reported that the antiknocking efficiency could be ranked sequentially as isopropanol > reformate > isomerate > fluidized catalytic cracked gasoline (FCC) > PRF-70 > LSRN > HSRN by octane rating. Furthermore, the Reid vapor pressure (RVP) for petrol RON92 was bigger than gasoline RON95 and RON98, unlike the density at 15 °C for gasoline RON 98 was bigger than gasoline RON92 and RON95. Finally, major problems like energy, water scarcity, and the environment affect people all around the world. Two of the earlier environmental and energy-related problems will be resolved by using these sustainable and renewable additions.

A Microporous Multi‐Cage Metal–Organic Framework for an Effective One‐Step Separation of Branched Alkanes Feeds

AbstractThe improvement of the Total Isomerization Process (TIP) for the production of high‐quality gasoline with the ultimate goal of reaching a Research Octane Number (RON) higher than 92 requires the use of specific sorbents to separate pentane and hexane isomers into classes of linear, mono‐ and di‐branched isomers. Herein we report the design of a new multi‐cage microporous Fe(III)‐MOF (referred to as MIP‐214, MIP stands for materials of the Institute of Porous Materials of Paris) with a flu‐e topology, incorporating an asymmetric heterofunctional ditopic ligand, 4‐pyrazolecarboxylic acid, that exhibits an appropriate microporous structure for a thermodynamic‐controlled separation of hydrocarbon isomers. This MOF produced via a direct, scalable, and mild synthesis route was proven to encompass a unique separation of C5/C6 isomers by classes of low RON over high RON alkanes with a sorption hierarchy: (n‐hexane≫n‐pentane≈2‐methylpentane>3‐methylpentane)low RON≫(2,3‐dimethylbutane≈i‐pentane≈2,2‐dimethylbutane)high RON following the adsorption enthalpy sequence. We reveal for the first time that a single sorbent can efficiently separate such a complex mixture of high RON di‐branched hexane and mono‐branched pentane isomers from their low RON counterparts, which is a major achievement reported so far.

A Microporous Multi-Cage Metal-Organic Framework for an Effective One-Step Separation of Branched Alkanes Feeds.

The improvement of the Total Isomerization Process (TIP) for the production of high-quality gasoline with the ultimate goal of reaching a Research Octane Number (RON) higher than 92 requires the use of specific sorbents to separate pentane and hexane isomers into classes of linear, mono- and di-branched isomers. Herein we report the design of a new multi-cage microporous Fe(III)-MOF (referred to as MIP-214, MIP stands for materials of the Institute of Porous Materials of Paris) with a flu-e topology, incorporating an asymmetric heterofunctional ditopic ligand, 4-pyrazolecarboxylic acid, that exhibits an appropriate microporous structure for a thermodynamic-controlled separation of hydrocarbon isomers. This MOF produced via a direct, scalable, and mild synthesis route was proven to encompass a unique separation of C5/C6 isomers by classes of low RON over high RON alkanes with a sorption hierarchy: (n-hexane≫n-pentane≈2-methylpentane>3-methylpentane)low RON≫(2,3-dimethylbutane≈i-pentane≈2,2-dimethylbutane)high RON following the adsorption enthalpy sequence. We reveal for the first time that a single sorbent can efficiently separate such a complex mixture of high RON di-branched hexane and mono-branched pentane isomers from their low RON counterparts, which is a major achievement reported so far.

Impact of RON on a heavily downsized boosted SI engine using 2nd generation biofuel – A comprehensive experimental analysis

Sustainable energy solutions are paramount in the urgent global drive against climate change, especially in transportation. This research focuses on second-generation biogasolines and their potential in the context of decarbonisation. Two biogasolines, 99 RON E20 and 95 RON E20, were rigorously tested in a downsized single-cylinder engine. Their performance, combustion, and emissions were compared against the conventional fossil fuel, 95 RON E10, under varying engine loads. Additionally, a comprehensive injection parameter sweep was conducted for both biofuels at low and high loads, shedding light on their unique operational characteristics and operational regimes. This research significantly enhances our knowledge about the potential of these new biofuels and their implications for a more sustainable energy future. The findings of the experiments demonstrate no substantial difference between the tested biofuels and fossil fuels. Biofuel with a higher octane number provides more knock resistance than fossil fuel, resulting in increased thermal efficiency due to spark advance ability. However, more significant hydrocarbon emissions were detected for biofuels than fossil fuels due to more extensive aromatic content. Both biofuels have stable combustion in low and high-load operations under varying injection pressures and injection start times. 99 Bio E20 has a wider operational range than 95 Bio E20. However, due to very high HC emissions, especially at high-load operations, an early injection start with more significant injection pressure is not recommended for biofuel. From a broader perspective, both biofuels exhibit the promising potential to serve as drop-in replacements in spark ignition engines.

Tuning the interfacial interactions between alumina support and pseudo single atom platinum-tin catalytic sites for heavy naphtha reforming

Heavy naphtha reforming, a crucial downstream process in oil refineries for improving the octane number of the gasoline feedstock, requires expensive Pt metal catalysts and it accounts for 60% of the catalyst cost. These conventional Pt nanoparticle sizes range between 1 – 2 nm and thus, only ≈ 80% of the Pt atoms of the particle are available for the catalytic reactions. In this work, we hypothesized that it might be possible to achieve 100% atom utilization if the Pt atoms are distributed as single or pseudo-single atom clusters, where all the atoms are exposed to the reactant molecules and by tuning their Interfacial Interactions. We aimed to significantly reduce the Pt contents by dispersing the active Pt sites as pseudo-single atoms on industrially relevant γ-Al2O3 support. Interfacial Interactions and stability of Pt sites were then tuned by using tin (Sn) as a promoter. These catalysts were then evaluated for heavy naphtha reforming in a fixed-bed reactor. The catalyst with Sn/Pt mole ratio of 1.68 showed excellent performance with aromatics of 83 wt% and research octane number (RON) of ≈ 103. These results indicated our catalyst preparation methodologies and interfacial interaction tuning successfully disperse Pt on the spherical alumina support leading to better atom economy. With 30–50% less Pt content when compared to the industrially used catalyst, made the heavy naphtha reforming process economical and sustainable.

BIOETHANOL PRODUCTION FROM AGRICULTURAL WASTE: A REVIEW

The importance of this research lies in keeping pace with the global trend to diversify energy sources and reduce climate change and air pollution by shedding light on how to benefit from agricultural waste by using it as a raw material for the production of bioethanol, which is one of the most important types of renewable fuels. This review highlighted the; ways of converting agricultural and fruit waste into bioethanol and its environmental and economic benefits-including adding it to gasoline used as car fuel in different proportions, as it works to raise the octane number of gasoline and improve its quality, thus reducing its production costs and reducing gas emissions from vehicle exhaust. In addition, the global production of bio-ethanol was reviewed and is expected to reach it by the end of 2023. It also highlighted the results of several studies that dealt with the properties and uses of ethanol and the best agricultural wastes used for this purpose. It is suggested to focus on the agricultural waste in Iraq, such as rice husks, in terms of cost and conditions for improvement to increase bio-ethanol production using fermentation processes.

Управление непрерывными технологическими процессами в нефтепереработке на примере каталитического риформинга при неопределенности

Using the example of catalytic reforming, a scientific description of the task of managing continuous techno-logical processes in oil refining under uncertainty has been performed and an appropriate management approach has been developed. It is proposed to take into account the influence of disturbances in the systems of automatic control of parameters (temperature, level, flow and pressure) in the unit for stabilizing the catalysate in the catalytic reforming unit. These parameters are important characteristics of the catalysate stabilization unit, whose indicators characterize the quality of functioning of the entire catalytic reforming complex. The problem of control for continuous technological processes in oil refining is solved using the example of catalytic reforming under uncertainty by solving the following tasks: development of a procedure and selection of methods for optimizing these processes; development of optimization algorithms for these processes; application of an optimization algorithm for these processes in order to calculate optimal control values; ensuring the stability of automatic control systems (stabilization) of the parameters of these processes. The management of these processes consists in finding optimal controls that contribute to achieving a minimum of a single criterion of op-timality, taking into account disturbances and constraints. The development of a control system for catalytic reforming provides a more efficient control option for catalytic reforming with the most important positive effects: a decrease in the average annual organizational costs for the technological process by 86.74 million rubles. with no increase in the octane number for gasoline produced, an increase in the average octane number for gasoline produced by 1.1 with no decrease in the amount of organizational costs for the technological process.

A STUDY OF THE RELATIONSHIP BETWEEN THE OCTANE NUMBER AND THE CHEMICAL COMPOSITION OF REGULAR, MIDGRADE, AND PREMIUM GASOLINE

The present study was conducted at Zakho City in Northern Iraq to evaluate three different types of gasoline: Regular, Midgrade, and Premium. These types of gasoline are categorized based on their octane rating, which was measured to verify their classification. The results showed that the initial classification was accurate, with respective values of 87.5, 89.8, and 91.1. The study evaluated the three grades of gasoline available at Zakho Gas Stations in Northern Iraq, including Regular, Midgrade, and Premium. The study also compared the chemical composition of the three gasoline grades in terms of aromatics, olefin, sulfur content, and oxygen content. All the three gasoline grades met the American Society for Testing and Materials (ASTM) standard for chemical composition, and all had acceptable specific gravities. However, Midgrade gasoline is not recommended for use during the summer due to its high Reid vapor pressure (RVP) value, low Initial boiling point (IBP), and final boiling point( FBP). In general, the study showed that the Regular and Premium gasoline types sold in North of Iraq meet international quality standards. However, Midgrade gasoline is not recommended for use during the summer due to its high RVP value, low IBP, and FBP, which can lead to increased volatility and environmental pollution, Moreover, using this type of gasoline may cause problems with the car engine.

Transfer of near infrared calibration for gasoline octane number based on screening consistent wavelengths combined with direct standardization algorithm

In order to share multivariate calibration models of gasoline research octane number between different near infrared spectrometers, a novel calibration transfer method, namely combination of screening consistent wavelengths and direct standardization (SWCSS-DS) was proposed. Firstly, screening wavelengths with consistent and stable signals (SWCSS) between instruments was used to select the wavelengths with best stability, and then direct standardization (DS) further corrected the systematic errors that still exist after the SWCSS was implemented. The spectra of 120 standard gasoline samples collected on two near infrared spectrometers of the same type were investigated in detail to verify the validity of the new algorithm. Compared results of other transfer methods such as SWCSS, Slope/Bias (S/B), direct standardisation (DS), and piecewise direct standardization (PDS), the root mean squared error for prediction (RMSEP) of SWCSS-DS algorithm for target samples was decreased from 5.75 to 0.295, and the Akaike information criterion value decreased from 1516 to 640, which were better than those of the SWCSS, S/B, DS and PDS algorithms. Therefore, the joint algorithm of SWCSS-DS has not only improved the universality of the master model, but also reduced the dimension of the spectral matrix and calibration equation, that would provide a more efficient model transfer strategy for the practical applications.

Optimization and screening of process parameters for the robust co-pyrolytic study of waste motor oil and rice stubble toward sustainable waste-to-fuel generation

The current study explores the co-pyrolysis of waste motor oil (WMO) and rice stubble in a designed lab-scale pyrolyzer to produce alternative energy fuels. The parameter screening was followed by optimization utilizing the Box-Behnken design (BBD). Reactor temperature (TR), mixing ratio (M), and holding time (t) affected the co-pyro-oil yield substantially. A maximum co-pyro-oil yield of 90.3% was achieved at a TR = 485 °C, t = 12.5 min, and M = 5% rice stubble to waste motor oil, which was further characterized and compared with the commercial diesel fuel properties. The highest research octane number of 76.15 was obtained for the co-pyro-oil (Co-PO), followed by the pyro-oil generated from only waste motor oil (POWMO). Consequently, the paraffin content increased to 64.34 wt% from 27.66 wt % for PO RS. The carbon number varied from C7–C17 for PO WMO and Co–Po, aligning with the diesel fuel requirements. Furthermore, a substantial enrichment in the physio-chemical properties of the produced Co-PO with reduced moisture content and enhancement in higher heating value (HHV) was also noticed. Hence, the generated Co-PO could be utilized as transport-grade fuel.

Solketal Synthesis from Glycerol and Acetone Using Amberlyst-36 Catalyst

Recently, biodiesel production has increased condiserably due to the use of B30 in Indonesia. As a side product of biodiesel production, glycerol is also produced in large amount. Glycerol conversion to fuel additive is one of promising path for glycerol utilization. Solketal is one of fuel additives that can be derived from glycerol and it may enhance octane number on gasoline. Solketal can be synthesized from glycerol and aceton by using Amberlyst-36 as catalyst. The aim of this paper was to study the effect of catalyst loading to glycerol conversion as well as to develop a kinetic model to correlate catalyst loading to kinetic parameter. A series of experiments were conducted in a batch reactor heated in water bath, equipped with cooler, and stirrer speed at 650 rpm for 180 minutes, mole ratio glycerol to acetone is 1:4, at temperature 500 C, varying catalyst loading at 1, 3, 5, 7 wt. %. The result showed that the highest glycerol conversion was achieved as high as 88.19% at 500 C temperature using 7 wt. % of catalyst.

Solketal Reaction Optimization by Glycerol Acetalization Using Amberlyst-36 Catalyst

Glycerol is an important chemical and widely used in many applications. Glycerol can be produced from a biodiesel industry as a by-product. In order to improve the economic value of glycerol as a by-product, it can be reacted with acetone to form solketal. Solketal can be used as a fuel additive to increase octane number. Reaction between glycerol and acetone can be catalyzed by Amberlyst-36. The objective of present study was to investigate the effect of mole ratio of glycerol:acetone and reaction temperature to the glycerol conversion. The process of acetalization was conducted in a batch reactor equipped with heater, temperature control, cooler and stirrer. The weight of catalyst was set on 5% based mass of glycerol and the stirrer speed was set on 650 rpm with reaction time of 3 hours. The mole ratio of glycerol to acetone was varied at 1:3, 1:4, 1:5 and 1:6, and the temperatures were varied on 40, 50 and 55 °C. The results showed that the highest conversion was 86.61 %, which was obtained at 120 minutes reaction, 50 °C and 1:6 mole ratio.

Piston geometry and stroke optimization for high efficiency propane spark ignition engines

Propane has unique properties and offers interesting characteristics for high-efficiency spark ignition engines. Its high volatility reduces or completely eliminates fuel-wall wetting and facilitates fuel air mixing. Furthermore, propane has a research octane number of 112 and a high octane sensitivity of 15. Finally, its laminar flame speed is on the same order as that of conventional gasoline, and it exhibits high dilution tolerance. Modern spark ignition internal combustion engines rely on fast combustion rates and high dilution to achieve high brake thermal efficiencies. To accomplish this, high stroke-to-bore ratios and high geometric compression ratios have been used in new engine designs. Therefore, propane’s relatively high laminar flame speeds, high knock resistance, and dilution tolerance make it an excellent candidate fuel for modern spark ignition engines. The objective of this work is to co-optimize the piston geometry and the engine stroke to maximize the efficiency of a spark-ignition engine fueled with propane. 3D computational fluid dynamics (CFD) simulations employing the extended coherent flamelet model were used to study the parametric effects of piston shape and stroke length. A piston geometry based on high performing pistons was parameterized using four controlling parameters. The piston geometry and engine stroke design space was explored using deterministic and quasi-random sampling techniques. A Gaussian process regression model was built using the simulation data to explain the results observed.

Optimization of Pyrolysis Process Parameters for Fuel Oil Production from the Thermal Recycling of Waste Polypropylene Grocery Bags Using the Box–Behnken Design

The impact of dumping plastic waste is realized in different ecosystems of the planet. Several methods have been adopted to dispose of these wastes for energy recovery. This study, for the first time, proposed the Box–Behnken design technique to optimize the pyrolysis process parameters for fuel oil production from waste polypropylene (PP) grocery bags using a semibatch-type pyrolytic reactor. The semibatch-type pyrolytic reactor was developed and employed to produce fuel oil from waste PP grocery bags. The effect of different process parameters on fuel oil production was comprehensively analyzed using the response surface methodology (RSM) with the conjunction of the Box–Behnken design (BBD). The BBD facilitates the prediction of the response variables with respect to changes in the input variables by developing a response model. The BBD was used to optimize the process parameters, such as the reaction temperature (400–550 °C), nitrogen flow rate (5–20 mL min−1), and substrate feed rate (0.25–1.5 kg h−1), and their effect on the responses were observed. The optimum response yields of the fuel oil (89.34 %), solid residue (2.74%), and gas yield (7.92%) were obtained with an optimized temperature (481 °C), a nitrogen flow rate (13 mL min−1), and a feed rate (0.61 kg h−1). The quadratic model obtained for the fuel oil response denotes the greater R2 value (0.99). The specific gravity and calorific value of the fuel oil were found to be 0.787 and 45.42 MJ kg−1, respectively. The fuel oil had higher research octane number (RON) (100.0 min) and motor octane number (MON) (85.1 min) values. These characteristics of the fuel oil were matched with conventional petroleum fuels. Further, Fourier transform infrared spectroscopy (FT-IR) and gas chromatography–mass spectroscopy (GC-MS) were used to analyze the fuel oil, and the results revealed that the fuel oil was enriched with different hydrocarbons, namely, alkane (paraffins) and alkene (olefins), in the carbon range of C4–C20. These results, and also the fractional distillation of the fuel oil, show the presence of petroleum-range hydrocarbons in the waste PP fuel oil.