Chemical Recycling: A Promising Solution to Improve Plastic Waste

Plastic pollution is one of the most pressing environmental issues of our time. Every year, millions of tons of plastic waste are produced and discarded, much of which ends up in landfills, incinerators, or the natural environment. While traditional recycling methods—such as mechanical recycling—help reduce plastic waste to some extent, they are often limited by the type of plastic and contamination. This is where chemical recycling comes into play. Chemical recycling, often referred to as advanced or molecular recycling, is emerging as a promising solution to tackle the challenges of plastic waste and improve the circular economy of plastics. But what is chemical recycling, what is its current status, and what are the potential impacts, both positive and negative?

What Is Chemical Recycling?

Chemical recycling refers to a variety of processes that break down plastics into their basic building blocks, or monomers, which can then be reused to create new plastic products. Unlike mechanical recycling, which involves shredding and melting plastics to form new items, chemical recycling involves altering the chemical structure of the polymer, enabling a more complete recovery of the material. The main objective of chemical recycling is to convert plastics back into their raw materials, allowing them to be reintroduced into the production chain without degradation in quality.

There are several types of chemical recycling technologies, each targeting different types of plastics:

1. Pyrolysis: This process uses heat in the absence of oxygen to break down plastics into smaller molecules, which can then be converted into fuel or new plastic products.
2. Gasification: Similar to pyrolysis, gasification involves the breakdown of plastic waste at high temperatures, but it also requires the presence of oxygen. This process produces a synthesis gas (syngas), which can be used to create fuels or other chemicals.
3. Depolymerization: This method breaks plastics down into their original monomers. For example, PET (polyethylene terephthalate) can be depolymerized into its constituent monomers, which can then be re-polymerized to produce new PET plastic.
4. Solvolysis: A chemical process that uses solvents to break down plastics into their original monomers or other useful chemicals, allowing for higher purity and quality of recycled products.

Current Status of Chemical Recycling

Chemical recycling is still in the early stages of commercialization, with several pilot projects and research initiatives underway. Large corporations, such as BASF, Dow, and ExxonMobil, have invested heavily in chemical recycling technologies, often in collaboration with startups and academic institutions. These investments are partly driven by increasing public and regulatory pressure to reduce plastic waste and find sustainable alternatives.

However, the commercial viability of chemical recycling remains uncertain. There are several challenges to overcome before chemical recycling can become a large-scale solution:

• High costs: The technology required for chemical recycling is still expensive to implement and maintain. This includes the costs of setting up specialized facilities, as well as the energy required for the chemical processes.
• Scalability: While small-scale pilot projects have demonstrated the potential of chemical recycling, scaling these technologies up to handle global plastic waste levels is a significant challenge. Many chemical recycling methods have not yet been tested at a large scale.
• Feedstock quality: Unlike mechanical recycling, which can be hindered by contaminants and mixed plastics, chemical recycling methods can potentially deal with a wider range of plastic types and contamination. However, the quality of the plastic feedstock is still an issue, as contaminated plastic can affect the output of the process.

Potential Impact on Plastic Recycling

Chemical recycling holds great promise for the future of plastic recycling, offering several potential advantages over traditional methods:

1. Improved Recycling Rates

One of the most significant benefits of chemical recycling is its ability to recycle a wider variety of plastics that are not typically recyclable through mechanical means. Plastics such as multi-layer films, polystyrene, and certain mixed plastics often end up in landfills because they cannot be processed through conventional recycling methods. Chemical recycling can help reclaim these materials, increasing the overall recycling rate.

2. Closing the Loop in the Plastic Lifecycle

Chemical recycling has the potential to close the loop in plastic production by enabling a circular economy. In an ideal scenario, plastic waste would be continuously broken down and converted back into high-quality raw materials, reducing the need for virgin plastic production. This could drastically reduce the carbon footprint of plastic manufacturing and promote more sustainable plastic use.

3. Reduction of Plastic Waste in Landfills and Oceans

As chemical recycling technologies improve and scale up, they can help divert large amounts of plastic waste from landfills and the ocean. Since chemical recycling is better suited for processing contaminated or mixed plastic waste, it can provide a more comprehensive solution to plastic pollution.

4. Production of High-Quality Plastics

Another advantage of chemical recycling is that it can produce new plastics that are virtually identical to those made from virgin materials. This is a significant improvement over mechanical recycling, which often degrades the quality of the plastic, limiting its recyclability.

Conclusion

Chemical recycling has the potential to significantly improve the recycling of plastics and help reduce the environmental impact of plastic waste. While it is still in its infancy, the progress made so far suggests that chemical recycling could play an important role in the future of plastic recycling, particularly in dealing with plastics that are difficult or impossible to recycle mechanically. However, challenges remain in terms of scalability, energy consumption, and economic viability. For chemical recycling to reach its full potential, continued investment, technological advancements, and a supportive regulatory environment will be necessary. Ultimately, chemical recycling should be viewed as part of a larger strategy to address plastic pollution, which also includes reducing plastic production, improving waste management systems, and promoting consumer behavior changes.

Written by Joe Grzyb, Director of Sustainability.

Joe Grzyb (pronounced “Gribb”) has over 25 years of experience in leading, managing, and growing high-tech companies primarily in the temperature-controlled packaging industry. Joe was a Co-Founder of NatureKool® and he now joins EFP as our first-ever Director of Sustainability. Before joining EFP, Joe held positions such as Founder of Aspen Technologies, CEO of Phase Change Energy Solutions, and leadership roles at AmeriTech Exports, ITT Defense and the US Air Force.