Stapf, Dieter

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KIT – The Research University in the Helmholtz Association www.kit.eduMechanical & chemical recycling of packaging plastics2nd International Akademie Fresenius Conference, 12 Sept. 2022Dieter StapfH‒ClDieter Stapf – Mechanical & chemical recycling of packaging plastics Institute for Technical ChemistrySeptember 12, 20222Plastics Production and Plastics Waste Generation[ million t / a ] 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)Dieter Stapf – Mechanical & chemical recycling of packaging plastics Institute for Technical ChemistrySeptember 12, 20223Industry investments into plastics pyrolysis (excerpt):www.plasticenergy.comRecycling Technologies, UKRT7000 project, Perthshire, ScotlandPlastic Energy, UKOperations @ Almeria & Sevilla, ESSabicCooperation with Plastic Energy, Geleen, NLLyondellBasellMoReTec-Pilot plant, Ferrara, ITBASFCooperation with Quantafuel, NORCooperation with Pyrum, GER Cooperation with Arcus Greencycling Technologies, GERDieter Stapf – Mechanical & chemical recycling of packaging plastics Institute for Technical ChemistrySeptember 12, 20224Recycling Processes for Mixed Plastic Waste and Key ProductsPhysical processes  Recovered polymerChemical processes New productMechanical sortingSolvent extractionSolvolysis MonomerThermochemical conversionPyrolysis Pygas / -oilGasification Syngasapplied to:  standard thermoplastics Pure polymers  Polycondensates  Mixed wastes,composite materialsDieter Stapf – Mechanical & chemical recycling of packaging plastics Institute for Technical ChemistrySeptember 12, 20225Collection and Sorting of Lightweight Packaging WasteImages: 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 – Mechanical & chemical recycling of packaging plastics Institute for Technical ChemistrySeptember 12, 202216Recycling of Collected Plastic Waste -The Pyrolysis Value Chain ExampleMixed plasticwasteDieter Stapf – Mechanical & chemical recycling of packaging plastics Institute for Technical ChemistrySeptember 12, 20227Composition of LWP-SR as Pyrolysis FeedstockMechanical 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 – Mechanical & chemical recycling of packaging plastics Institute for Technical ChemistryPyrolysis of Light weight packing (LWP) sorting residues8Process efficiency:Carbon recovery in condensate: 51.1%Energy demand*: 5.1% of feedstock higher heating value *) for heating, melting, thermal degradation & evaporationhZeller, 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.202100102lting, thermal degradation, evaporationSeptember 12, 2022Dieter Stapf – Mechanical & chemical recycling of packaging plastics Institute for Technical ChemistrySeptember 12, 20229Mass Flow Diagram of LWP Waste Pyrolysis Routeplastic wasteDieter Stapf – Mechanical & chemical recycling of packaging plastics Institute for Technical ChemistrySeptember 12, 202210Naphtha Chemical Plant (Steamcracker + Polymer Synthesis)Pretreatment Sensor-Sorting Chem. Recycling Chemical PlantSensor based SortingPretreatmentPrimary Plastic Production:Mechanical Recycling:Combined Recycling:Chemical Plant Chem. RecyclingPretreatmentChemical Recycling:Lightweight Packaging WasteLightweight Packaging WasteLightweight Packaging WasteVirgin MaterialRegranulateVirgin MaterialVirgin MaterialRegranulateResidues that are used energeticallyExtracted metals via sorting Heavy contents / Mineral residues that are landfilledCase Study: Recycling of Light Weight Packaging WasteComparison of Recovery RoutesDieter Stapf – Mechanical & chemical recycling of packaging plastics Institute for Technical ChemistrySeptember 12, 202211LWP Waste Recycling Routes Compared to Primary Plastics Production of HDPE  Recycling scenarioCost[€/kgInput]CED[MJ/kgInput]GWP [kgCO2e/kgInput]Overall CarbonRecycledMechanical, 42% yield -0.16 -18.1 0.2 42%Mechanical, 22% yield -0.08 -6.9 0.6 22%Chemical recycling -0.24 -15.9 0.3 59%Combined recycling, mech. 42% -0.29 -30.1 -0.2 74%Combined recycling, mech. 22% -0.25 -23.1 0.0 66%Volk,R., et al.: Techno-economic Assessment and Comparison of Different Plastic Recycling Pathways - a German Case Study, Journal of Industrial Ecology, 2021, 1-20; https://doi.org/10.1111/jiec.13145Dieter Stapf – Mechanical & chemical recycling of packaging plastics Institute for Technical ChemistryTechnology infrastructure of a circular economy of plastics23. Juni 202212Plastic wasteVirgin quality polymerBase chemicalsPolymer recyclatePolymerisationPetrochemical processesThermo-chemical processesSorting & regranulationMechanical pretreatmentPure condensation polymersStandard thermoplastics ofhigh qualityLow quality polmersEstablished processesNew processesMixed plastics oflow qualityLow quality byproducts MonomersMonomersSolvolysisSustainablefeedstocksDieter Stapf – Mechanical & chemical recycling of packaging plastics Institute for Technical ChemistryConclusionsTechnical assessment of combined mechanical and chemical recyclingComparison of the production of plastics from fossil raw materials with the combined mechanical / chemical recycling of post-consumer waste, taking into account energy recoveryCosts: Economic attractiveness of both, mechanical and chemical recycling Energy: Mechanical and chemical recycling perform similar; advantageous over crude oil based productsCO2 emissions: Mechanical and chemical recycling perform similar; at high recycling rates advantegous over crude oil based products, today already  High recycling rates can be achieved through a combination of mechanical and chemical recycling, onlyChemical recycling technology readiness is insufficient: Reactor scale-up, product upgrading, process evaluationSeptember 12, 202213Dieter Stapf – Mechanical & chemical recycling of packaging plastics Institute for Technical ChemistrySeptember 12, 202214AcknowledgementProject 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 

Mechanical and Chemical Recycling of Packaging Plastics

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Mechanical and Chemical Recycling of Packaging Plastics

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