Stapf, Dieter

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KIT – The Research University in the Helmholtz Association www.kit.eduChemical Recycling of Mixed Plastics Waste by PyrolysisVIth International Symposium (Waste), Stuttgart, November 4, 2022Dieter StapfH‒BrDieter Stapf – Chemical Recycling of Mixed Plastics Waste by Pyrolysis Institute for Technical ChemistryNovember 4, 20222Plastics Production and Plastics Waste Generation[ Mt / year ] EU 28+2* Germany**Plastics production 61.8 19.9Plastics consumption 51.2 12.6Plastic waste 29.1 6.2- Landfill 7.2 < 0.1- Energy recovery 12.4 3.2- Recycling 9.4 (export 1.8) 2.9 (export: 0.6)*) Lindner,C. et al.: Circular Economy of Plastics 2018 EU-28+2, Conversio Market & Strategy GmbH, Mainaschaff (2019)**) Lindner,C., Schmitt, J.: Stoffstrombild Kunststoffe in Deutschland 2017, Conversio Market & Strategy GmbH, Mainaschaff (2018)Additional plastics recycling capacity demand until 2030: 11 Mt / yearDieter Stapf – Chemical Recycling of Mixed Plastics Waste by Pyrolysis Institute for Technical ChemistryNovember 4, 20223Recycling Processes for Mixed Plastics Waste and Key ProductsPhysical processes  Recovered polymerChemical processes New productMechanical sortingSolvent extractionSolvolysis MonomerThermochemical conversionPyrolysis Pygas / -oilGasification Syngasapplicable to:  standard thermoplastics Pure polymers  Polycondensates  Mixed wastes,composite materialsDieter Stapf – Chemical Recycling of Mixed Plastics Waste by Pyrolysis Institute for Technical ChemistryNovember 4, 20224Capital Investments (excerpt):Chemical Recycling of Plastics Wastewww.plasticenergy.comEnerkem, CANW2C project, Rotterdam, NLPlastic Energy, UKOperations @ Almeria & Sevilla, ESSabic, SAUCooperation with Plastic Energy, Geleen, NLLyondellBasellMoReTec-Pilot plant, Ferrara, ITBASFCooperation with Quantafuel, NORCooperation with Pyrum, GER Cooperation with Arcus Greencycling Technologies, GERDieter Stapf – Chemical Recycling of Mixed Plastics Waste by Pyrolysis Institute for Technical ChemistryNovember 4, 20225Collection and Sorting of Lightweight Packaging Waste (LWP)Images: www.awg-info.de/index.php?id=65, www.erema.com/de/erema_news/IDobj=200, ww.reclaygroup.com/de/images/Content/Presse/pressefotos/bilddatenbank/sortierung/161010_Sortieranlage_Reclay_by-ASP_DSF3429.jpgDieter Stapf – Chemical Recycling of Mixed Plastics Waste by Pyrolysis Institute for Technical ChemistryNovember 4, 20226Composition of LWP Waste Sorting ResiduesMechanical treatment of leight weight packaging (LWP) collectedSorting residues (SR) resulting from separation of high value plastics & metals for recycling as well as coarse mineral fraction  energy recoveryComposition of a sorting plant random sampleDieter Stapf – Chemical Recycling of Mixed Plastics Waste by Pyrolysis Institute for Technical ChemistryNovember 4, 20227Recycling of Mixed Plastics Waste: The Pyrolysis Value Chain ExampleMixed plasticwasteDieter Stapf – Chemical Recycling of Mixed Plastics Waste by Pyrolysis Institute for Technical ChemistryNovember 4, 20228Examples of Plastics Waste ProducedWEEE = Waste of Electrical and Electronic EquipmentLWP-SR = Sorting Residues from Light Weight Packaging Waste collectedETICS = Thermal Insulation Composite SystemBuilding demolition waste ETICS  Dieter Stapf – Chemical Recycling of Mixed Plastics Waste by Pyrolysis Institute for Technical ChemistryNovember 4, 20229Waste Feedstock AnalysisLWP-SR[m.-%]WEEE  [m.-%]ETICS [m.-%] CW[m.-%]ASR[m.-%]EPS XPSMoisture (1) 1.7 0.5 0.0 0.0 0,0 1.5Ashes (550 °C) (2) 10.6 27.6 8.2 6.7 9.2 13.3C (2) 58.5 53.1 82.5 79.4 74.7 67.0H (2) 7.5 6.1 7.1 7.1 8.8 8.5N (2) < 1.0 1.5 < 1.0 < 1.0 < 1.0 1.8S (2) 0.1 0.1 < 0.1 < 0.1 < 0.1 0.2Cl + Br (2) 2.0 2.8 0.3 0.1 3.3 1.2O (2) (3) 21.3 8.8 1.9 6.7 4.0 6.1Calorific value(2) / MJ/kg ca. 25ca. 23 ca. 35 ca. 34 ca. 34 ca. 31(1)  pretreated (2) dry (3) calculated Waste random samplesDieter Stapf – Chemical Recycling of Mixed Plastics Waste by Pyrolysis Institute for Technical ChemistryNovember 4, 202210H / C – RatioLWP-SR[m.-%]WEEE  [m.-%]ETICS [m.-%] CW[m.-%]ASR[m.-%]EPS XPSH / C - ratio 1.5 1.4 1.0 1.0 1.4 1.5Dieter Stapf – Chemical Recycling of Mixed Plastics Waste by Pyrolysis Institute for Technical ChemistryNovember 4, 202211Pyrolysis technology in pilot scaleScrew reactor with integrated hot gas/vapour filtrationFlow rate < 10 kg/hTemperature < 550°CPressure: 1 atmSolids residence time < 60 minDieter Stapf – Chemical Recycling of Mixed Plastics Waste by Pyrolysis Institute for Technical ChemistryNovember 4, 202212Pyrolysis Mass BalanceZeller, M., et al.: Chemical recycling of mixed plastic wastes by pyrolysis. Chem. Ing. Tech. 2021, 93 (11), 1-9. https://doi.org/10.1002/cite.202100102Dieter Stapf – Chemical Recycling of Mixed Plastics Waste by Pyrolysis Institute for Technical ChemistryNovember 4, 202213Pyrolysis Carbon RecoveryFeedstock Fraction of C-feed found back in oilycondensate[wt-%]LWP-SR 51.1CW 60.0ETICS (XPS) 74.6ETICS (EPS) 72.9ASR 57.5WEEE 60.5Dieter Stapf – Chemical Recycling of Mixed Plastics Waste by Pyrolysis Institute for Technical ChemistryNovember 4, 202214Pyrolysis Energy BalanceFeedstock Energy demand for heating, melting, thermal degradation, evaporation[% of feedstock higher heatingvalue]LWP-SR 5.1CW 5.2XPS 4.9ASR 5.4WEEE 3.7Dieter Stapf – Chemical Recycling of Mixed Plastics Waste by Pyrolysis Institute for Technical ChemistryNovember 4, 202215Upgrading of Pyrolysis Products to Secondary Petrochemical FeedstockUpgrading of pyrolysis products Removal of heteroatoms (N, O, Cl, Br, S, …) Fractionating (monomers, petrol refinery boiling cuts) Hydroprocessing (adapt hydrocarbon substance group contents)Monomers & intermediatesGasifier feedFCC-feedSteamcracker feedCondensateeGasesC3H6HClDieter Stapf – Chemical Recycling of Mixed Plastics Waste by Pyrolysis Institute for Technical ChemistryNovember 4, 202216Pyrolysis Oil Characterization* and Hydrotreatment10 20 30 400246810             Sum           amount / wt%carbon number / -Neuner, P. et al.: Chemical Conversion of Fischer–Tropsch Waxes and Plastic Waste Pyrolysis Condensate to Lubricating Oil and Potential Steam Cracker Feedstocks. Reactions 2022, 3, 352–373. https://doi.org/10.3390/reactions3030026EductHyd. 1Hyd. 2HP 350°CHP 370°CHP 390°C020406080100product yield / wt% Distillation Loss  Gas  Naphtha Middle Distillate  Heavy Residue*) PE based waxDieter Stapf – Chemical Recycling of Mixed Plastics Waste by Pyrolysis Institute for Technical ChemistryNovember 4, 202217Pyrolysis Gas Characterization**) Polyolefinic waste based pyrolysis gases as petrochemical feedstockThermal, non-catalytic pyrolysis of collected waste agricultural films, screw-pyrolysis @ 450°C, 30 minContaminated polyolefinic waste (LDPE basis)Average gas composition of 2 waste samplesH2 CO CO2CH4C2H6C2H4C3H8C3H6C4H10C4H8 Rest051015202530Gaszusammensetzung / Gew.-%  AGRAR-K AGRAR-DDieter Stapf – Chemical Recycling of Mixed Plastics Waste by Pyrolysis Institute for Technical ChemistryResearch on Chemical Recycling of Mixed Plastics Waste by PyrolysisGrowing volume of complex (plastics) waste that can hardly or cannot be recycled to high value products through collection, sorting and regranulationHigh recycling rates can be achieved through a combination of mechanical and chemical recycling, onlyPyrolysis as a thermal separation and product conditioning step Carbon efficiency: yield and composition of liquid (and gaseous) pyrolysis products; product upgrading depending on feedstock utilizationEnergy efficiency: no external energy demand of integrated pyrolysis processChemical recycling technology readiness is developping towards flexibility and efficiency:   mixed plastic waste feedstocks, reactor scale-up, product upgrading, process evaluationNovember 4, 202218Dieter Stapf – Chemical Recycling of Mixed Plastics Waste by Pyrolysis Institute for Technical ChemistryNovember 4, 202219AcknowledgementProject funding through:Waste feedstock samples supply by: ARN B.V.Pre Zero GmbH & Co. KGElectrocycling GmbHI.A.R. RWTH Aachen*KIT/Conversio, 2019: „BKV-Studie“ Thermal Processes for Feedstock Recycling of Plastics Waste, http://www.bkv-gmbh.de/infothek/studien.html*BMBF-project 033R214D KUBA: Nachhaltige Kunststoffwertschöpfungskette: Pilotfall Kunststoffe in Bauwirtschaft und Gebäuden 

Chemical Recycling of Mixed Plastics Waste by Pyrolysis

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Chemical Recycling of Mixed Plastics Waste by Pyrolysis

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