Recycling of unsorted heterogeneous plastic waste - IDENTIFIED BY INCITE

The technique uses high-temperature pyrolysis for plastic waste recycling to foster syngas producition, which could be integrated downstream the furnace of the steam cracker.

The process will start with pre-processing of unsorted plastic waste streams which do not find any market and is landfilled or incinerated (including mixed plastics RDF, and textile (e,g, woven, non-woven, polyester). PREZERO will provide the waste from its sorting and management facilities, it receives unsorted plastic waste within Spain. Also, a waste stream sent by SCGC (ASEAN country) will be tested. These streams will be tested and pre-processed by applying an appropriate and compatible pre-treatment to achieve the parameters required for pyrolysis treatment process.

Economical parameters such as plastic waste price and availability will be considered in the selection of the plastic waste flows. It will be taken intoaccount for the variability of waste depending on time and location. This step is needed to ensure optimisation of the materials for best mix needed to produce polyolefins.

The pre-processed waste will be tested at ETIA where a small-scale pyrolysis unit already located. In parallel to phase 1, Repsol will build aTRL 7 pilot plant (including the pyrolysis unit, condensation unit, gas purification system and liquid upgrading system) at its Tech Lab in Spain. The plant will serve as the basis for testing, validation and optimisation of the entire recycling process to be scaled up at the demonstration scale (TRL 8-9).

In phase 3 of the project, the demo plant will be designed and built following conventional engineering workflow, but also innovative engineering solutions will be developed and applied as required. Near the end of the construction, the commissioning of the plant will bridge the gap between the construction and the start of plant operation. The commissioning is a critical stage to hand over a safe, efficient and operation-ready facility. After the commissioning of the plant, a 6-month operation campaign is planned in an industrial and integrated process.

Basic information about the technique

Relevant alternative technique

Incineration and existing plastics recycling processes

Participant Companies

Project partners

REPSOL SA
ACTECO PRODUCTOS Y SERVICIOS SL
ARTTIC INNOVATION GMBH
CENTRO DE INVESTIGACIONES ENERGETICAS MEDIOAMBIENTALES Y TECNOLOGICAS - CIEMAT
TECHNICAL UNIVERSITY OF DENMARK DTU
E.T.I.A. - EVALUATION TECHNOLOGIQUE INGENIEURIE ET APPLICATIONS SA
HOLCIM ESPANA SA
PREZERO ESPANA SA
SCG CHEMICALS COMPANY LIMITED
SMART INNOVATION NORWAY AS
TECNICAS REUNIDAS SA - TRSA
TEKNOLOGIAN TUTKIMUSKESKUS VTT OY
UNIVERSIDAD DE CASTILLA - LA MANCHA - UCLM

Under development / testing

Expected TRL 7

Date of development of the technique: Start date 1 June 2022

End date 31 May 2027
Environmental purpose of the innovative technique: Circular economy (e.g. recovery/reuse/recycling of residues, industrial symbiosis)
Relevant industrial sector: Waste treatment
IED activity: 5.2a Disposal or recovery of waste in waste incineration plants or in waste co-incineration plants (no exceeding 3 tonnes p/h)

Locations

Repsol Tech Lab

Mostoles 28925 Spain

Environmental benefits

As compared to: Incineration and existing plastics recycling processes

Legend

Expected data (on project completion)
Estimated data (not measured)
Monitored data in pilot scale installation
Monitored data in full scale installation

GHG Emission

CO2

Percentage reduction of GHG emissions

2027

80 % Max

0 % 100 %

Project

Plastics2Olefins

Plastics2Olefins project will design, build, and run a demonstration plant for recycling of unsorted plastic waste at Repsol’s industrial site (Spain), which will be digitalized and run on 100% renewable (electric) energy. The project estimates to reduce the lifecycle GHG emissions by 70-80% compared to incineration and existing plastics recycling processes, providing an important contribution to the EU reaching climate neutral by 2050 and set a pathway for commercialization of recycled plastic feedstock replacing fossil feedstocks.