Abstract <p>The waste almond shells (AS) were co-pyrolyzed with polyurethane (PU) in varied compositions to optimize the bio-oil and syngas production. The parametric synergistic co-relations and their influence in energy contents was investigated by Pearson co-relation heatmap. The addition of PU in AS showed a significant effect on the composition, quality, quantity and properties of the produced pyrolysis products. It was found that the addition of AS upgraded the bio-oil quality and reduced the wax formation. The composition of 30% AS and 70% PU achieved the maximum energy contents of 58763.12&#xa0;MJ along with bio-oil yield of 56.62 wt %. In addition, the similar composition also provided the maximum H₂ and CH₄ proportions. It was also concluded that the addition of polyurethane in almond shell significantly decreased the concentration of esters, acid, hydroxyl and furans and increased the high value organic compounds like alkanes, alkenes, mono and polycyclic aromatic hydrocarbons in bio-oil. The energy and economic analysis of developed technology was also carried out by considering 5tons/day of bio-waste and proposed waste to energy facility had potential of 7,345 KWh/Day which proved its higher practical significance. The developed technology will ensure a cleaner environment by following zero waste management approach and ensure energy security for the rural communities.</p> Statement of novelty <p>Current study investigated the co-pyrolysis of almond shells (AS) and polyurethane (PU) and compositional influences on upgradation of bio-oil and syngas quality. The parametric synergistic co-relation and their influence in energy contents was investigated by Pearson co-relation heatmaps first time as the best of authors knowledge. Addition of PU increased the contents of hydrocarbons while decreased nitrogen contents in syngas which is very novel aspect. The detailed economic and energy analysis of the proposed technology was also carried out. The proposed technology is very much novel and attractive for small and medium enterprises which has abundant resources of almond shells. The breakeven point of the developed project is 9 years and waste to energy production facility had potential of daily 7,345 KWh of electrical energy production and annual benefits of $44,434 was expected after the breakeven period. All these analysis and feasibility of commercial scale waste to energy power plant was made first time and not found in literature for almond shells and polyurethane foam.</p> Graphical Abstract <p></p>