Stapf, Dieter

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KIT – The Research University in the Helmholtz Association www.kit.eduTechnical Assessment of Combined Mechanical and Chemical RecyclingDieter StapfH‒BrDieter Stapf Institute for Technical ChemistryOctober 13, 20202Examples of Plastic Waste ProducedWEEE = Waste of Electrical and Electronic EquipmentLWP = Light Weight Packaging WasteCTIS = Compound Thermal Insulation SystemDieter Stapf Institute for Technical ChemistryOctober 13, 20203Recycling of Collected Plastic Waste -The Pyrolysis Value Chain ExampleLightweight packaging waste LWPDieter Stapf Institute for Technical ChemistryOctober 13, 20204Pyrolysis Process Energy Demand(for heating, melting, pyrolysis & evaporation)Netsch, N., et al., Chemisches Recycling kunststoffhaltiger Abfälle – Das Potenzial der Pyrolyse, Chemie-Ingenieur-Technik 92(9), 2020, p.1260LWP WEEE CTIS ASR CWIntermediate pyrolysis, 450°C,solids residence time: 30 minDieter Stapf Institute for Technical ChemistryOctober 13, 20205Naphtha 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 MaterialRegranulateSorting residues that are used energeticallyExtracted metals via sorting Heavy contents/ Residues that are landfilledRecycling of Lightweight Packaging WasteRecovery RoutesDieter Stapf Institute for Technical ChemistryOctober 13, 20206Pyrolysis Route: Material Flow AnalysisChemical RecyclingOutput basedPre-treatmentCombustionSteamCrackingPyrolysisLandfillResidueSolidsOrg. & Fine FractionGas + CondensateRefuse Derived FuelFe-Metals NF-MetalsFlue GasDistrict HeatCombustion Air8.1 t/h65.5 MW5.6 t/h60.2 MW2.6 t/h3.1 MW0.3 t/h12.5 t/h53.400,900.27373.50-1.101.090.22 t/h2.5 t/h1.25 t/h0.15 t/hIncineration95% 71.5%Glass, Ceramics, Small stoneLightweight Packaging WasteOlefins / Intermediate ProductsCost [€/t]PED [MJ/kg]GWP [kg CO2-eq/kg]ηC-Eff (Carbon Efficieny) [%]Costs: BKV-study: Thermal processes for feedstock recycling of plastics waste, study conducted by KIT and Conversio Market & Strategy GmbH on behalf of BKV GmbH and Plastics Europe AISBL, 2019. https://www.bkv-gmbh.de/en/info-zone/studies.html Yields: Andreas, B., et al., Pyrolytische Rohstoffrückgewinnung, Mannesmann VEBA Umwelttechnik GmbH, Eisen und Metall AG, Rütgerswerke AG, 1981 Dieter Stapf Institute for Technical ChemistryOctober 13, 20207Mass Flow Diagram of LWP Waste Pyrolysis RouteDieter Stapf Institute for Technical ChemistryOctober 13, 20208LWP Recycling Routes Compared to Primary Plastics Production of HDPE  Recycling scenario Cost[€/kgInput]CED[MJ/kgInput]GWP [kgCO2e/kgInput]Overall CarbonEfficiencyMechanical, 42% yield -0.15 -15.3 0.4 42Mechanical, 22% yield -0.08 -3.5 0.8 22Chemical recycling -0.23 -14.4 0.4 59Combined recycling, mech. 42% -0.29 -28.6 -0.1 74Combined recycling, mech. 22% -0.26 -21.6 0.1 66Volk,R., et al., Techno-economic Assessment and Comparison of Different Plastic Recycling Pathways - a German Case Study, submitted for journal publication, 2020Dieter Stapf 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 combined mechanical / chemical recycling in comparison to energetic recoveryEnergy: Mechanical and chemical recycling are similar; advantageous over crude oil based productsCO2 emissions: Mechanical and chemical recycling similar; advantegous over crude oil based product Recycling quotas can be achieved through a combination of mechanical and chemical recyclingOctober 13, 20209Dieter Stapf Institute for Technical ChemistryOctober 13, 202010BackupTeam KIT: Institute for Technical Chemistry: Hans Leibold, Niklas Netsch, Frank Richter, Dieter Stapf, Manuela Wexler, Savrina P. Yogish, Michael ZellerInstitute for Industrial Production: Frank Schultmann, Christoph Stallkamp, Justus Steins, Rebecca VolkStudy funded by:Dieter Stapf Institute for Technical ChemistryOctober 13, 202011Plastics 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 Institute for Technical ChemistryOctober 13, 202012Collection 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 Institute for Technical ChemistryOctober 13, 202013Pyrolysis Products DistributionLWP WEEE CTIS ASR CWSolidsOilAqueous c. GasAcc. lossNetsch, N., et al., Chemisches Recycling kunststoffhaltiger Abfälle – Das Potenzial der Pyrolyse, Chemie-Ingenieur-Technik 92(9), 2020, p.1260Intermediate pyrolysis, KIT: 450°C,solids residence time: 30 minDieter Stapf Institute for Technical ChemistryRecycling Processes for Mixed Plastic Waste and Key ProductsPhysical processes  Recovered polymerChemical processes New productMechanical sortingSolvent extractionSolvolysis MonomerThermochemical conversionPyrolysis Pygas / -oilGasification Syngas15.7.2020applied to:  standard thermoplastics Pure polymers  Polycondensates  Mixed wastes,composite materialsDieter Stapf Institute for Technical ChemistryOctober 13, 202015Input basedCost [€/t]PED [MJ/kg]GWP [kg CO2-eq/kg]ηC-Eff (Carbon Efficieny) [%]

Technical Assessment of Combined Mechanical and Chemical Recycling

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Technical Assessment of Combined Mechanical and Chemical Recycling

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