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What is needed for large-scale upcycling of plastic waste to valuable chemicals like polyethylene?

Oct-2024

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Mark Schmalfeld, BASF Refinery Catalysts, mark.schmalfeld@basf.com

Large-scale upcycling of plastic waste into valuable chemicals can be considered in two basic steps. The first step is to enable the recycling of plastic waste, which requires a combination of factors that span across various stages of the recycling process. The second step is to focus on the factors critical to the technology and process for large-scale upcycling of plastic waste.

Step 1: Creating a steady supply of usable recycled plastic for the market
First, some key elements needed to facilitate plastic waste recycling, which contains the first steps in creating a steady supply of usable waste plastic and maintaining a market for products made from recycling, include:

- Policy and regulation: Implementing supportive policies and regulations can provide the necessary framework for plastic waste recycling. These can include setting recycling targets, implementing extended producer responsibility programmes, imposing landfill bans on recyclable plastics, or providing financial incentives to encourage recycling initiatives. Initiatives to improve the ability to sort and recycle materials are also critical policy initiatives.

- Education and awareness: Public education and awareness campaigns are crucial to promote the importance of recycling and encourage individuals to participate in recycling programmes. Informing people about the environmental impact of plastic waste and providing guidance on proper sorting and disposal of recyclable plastics can significantly increase recycling rates. Proper sorting of plastic waste is one of the biggest challenges to creating a consistent feedstock to produce new chemical feedstocks from the recycled materials.

- Efficient collection systems: The establishment of efficient and accessible collection systems is essential for effective plastic waste recycling. This includes implementing curbside recycling programmes, setting up drop-off centres, or partnering with waste management companies to ensure convenient collection points for recyclable plastics.

- Segregation and sorting: Proper segregation and sorting of plastic waste are critical for efficient recycling. Advanced sorting technologies, such as optical sorting machines, can help separate different types of plastic based on their chemical composition or physical properties, facilitating the recycling process and ensuring high-quality recycled materials.

- Infrastructure and facilities: The availability of recycling infrastructure and facilities is crucial for plastic waste recycling. This includes the establishment of recycling plants equipped with appropriate machinery, processing equipment, and quality control measures to efficiently process and transform plastic waste into reusable materials.

- Market demand for recycled materials: Creating a strong market demand for recycled plastics is essential to drive recycling efforts. Encouraging industries to use recycled plastics in their products through incentives, regulations, or labelling requirements can stimulate demand and create a sustainable market for recycled materials.

- Collaboration and partnerships: Collaboration among stakeholders is crucial for successful plastic waste recycling. Cooperation between government entities, waste management companies, recycling organisations, manufacturers, and consumers can facilitate the development of comprehensive recycling systems and promote a circular economy approach.
By addressing these factors collectively, it is possible to create an environment that enables effective and widespread recycling of plastic waste, contributing to the reduction of plastic pollution and the promotion of the potential to achieve more large-scale upscale recycling of plastic waste to valuable chemicals.

Step 2: Implementing the technical and commercial innovations utilising recycled raw materials to create valuable chemicals
After the first steps to enable plastic recycling, then the achievement of the second step, large-scale upcycling of plastic waste to valuable chemicals like polyethylene requires a combination of technical expertise, innovative processes, and a robust supply chain. Some key components that are necessary to achieve this second step of successful large-scale upcycling of plastic waste include:

- Feedstock preparation and processing: The first step in upcycling plastic waste is to prepare and process the feedstock. This involves sorting, cleaning, and shredding the waste into a consistent size and quality. If sorting is successful as plastic waste is collected, then the level of process and quality control is improved. Advanced technologies such as pyrolysis, gasification, or catalytic depolymerisation can be used to break down the plastic waste into valuable chemicals.

- Innovative technologies and processes: Innovative technologies and processes are essential for large-scale upcycling of plastic waste. These can include advanced catalysts, process optimisation, or novel reactor designs that enable high efficiency and selectivity. Innovations in process control and automation can also enhance consistency and reduce variability in product quality.

- Supply chain management: A reliable and robust supply chain is necessary for large-scale upcycling of plastic waste. This includes identifying sources of plastic waste, establishing collection and transportation infrastructure, and ensuring consistent feedstock quality and availability. Collaboration with waste management companies, municipalities, and other stakeholders in the supply chain is key to ensuring a steady supply of plastic waste.

- Market demand: The success of large-scale upcycling of plastic waste also depends on market demand for the products produced from the process. Identifying and developing markets for the products, such as polyethylene, is necessary to ensure the economic viability of the process. The public in a given region needs to support the market initiative.
Overall, large-scale upcycling of plastic waste to valuable chemicals like polyethylene can be considered in two major steps. The first step creates the recycling policy, recycling culture, and infrastructure to drive recycling of plastics. Then the second step requires a combination of technical innovation, supply chain expertise, and market fit to achieve a sustainable improvement that can deliver on the promise of large-scale upcycling of plastic wastes to valuable chemicals like polyethylene.

Oct-2024