Real world recycling innovation
Real talk: Managing plastic waste is a complex issue—but Shell Polymers is embracing sustainability and drawing inspiration from innovative organizations at the forefront of recycling technology.
From our handy smartphones to life-saving medical equipment and more, there’s no doubt that plastic products benefit our everyday lives. However, plastic waste management presents a complex societal problem.
Spoiler: There’s no one one-size-fits-all solution for plastic waste due to the variety of plastic grades, additives, and recycling programs. That’s where two types of recycling come into play!
The first type of recycling is called mechanical recycling. This thorough recycling process includes collecting, sorting, washing, drying, grinding, re-granulating, and compounding.
Second is advanced recycling also referred to as chemical recycling, which has similar introductory processes of mechanical recycling like collecting and sorting—but takes it a step further by using chemical reactions to break down complex materials into their basic components. Pyrolysis is a common advanced recycling method that converts plastic waste into liquid through a heating process. The resulting liquid (called pyrolysis oil) is further processed and manufactured into circular chemicals.
The resulting circular chemicals produced are then used to create everyday items, without requiring customers to make any changes to their manufacturing processes, as the chemicals have identical properties and performance levels as other alternatives. (That’s what we call a win/win.)
Associated UN Sustainable Development Goals
Takeaways:
- Understanding mechanical and advanced recycling can help with future business success.
- There are existing small-scale innovative recycling and upcycling methods that can further enable a more circular economy.
- Shell Polymers continuously draws inspiration from innovative industry organizations to future-proof the plastics industry.
Title:
Breaking Down Pyrolysis | Shell Polymers
Duration:
1:08 minutes
Description:
Consumers are demanding more recycled material in plastic products. By thoroughly understanding different advanced recycling methods like pyrolysis, plastic converters like you can meet that demand.
Transcript:
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Real talk: Consumers want more recycled material in the plastic products they buy.
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3D visual of a plastic bottle
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Advanced recycling is helping to manage plastic waste.
Let’s break down one type of advanced recycling: Pyrolysis.
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How it works:
Plastic waste is gathered and sorted.
Hard-to-recycle plastics can even be gathered for advanced recycling.
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Grocery bag and plastic food container placed into recycling bin
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Waste is heated through an oxygen-free process called pyrolysis, converting it into pyrolysis oil.
The resulting liquid is processed and manufactured into chemicals.
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3D pyrolysis oil flowing freely
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A third-party (such as ISCC) certifies the value chain, ensuring the use of circular resources.
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ISCC logo
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Circular-certified chemicals are then used to make new plastic products.
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Flowing pyrolysis oil transitions to 3D visual of plastic detergent bottles
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In short?
Pyrolysis can help plastic producers meet consumer demand for more recycled material in plastic products while also helping to reduce plastic waste.
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3D plastic pellet floating around.
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That’s what we like to call a win/win.
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Shell Polymers logo
Shell Polymers prioritizes innovation, so we’re always actively seeking future partnership opportunities while drawing inspiration from other organizations that are making strides in the recycling space.
Read on to learn more about recycling trailblazers and the projects we’re excited about.
Transforming plastic to graphene 1
Each type of plastic has its own distinct properties, making some methods of recycling more suitable than others. However, two companies are currently developing technologies that can recycle all types of plastic.
A Canadian company, Plastonix, has come up with a way to transform petroleum-based substances into chips or powder that can be repurposed into items such as construction
blocks, paving stones, tile beams and more. Even plastic materials previously believed to be non-recyclable can be processed through their zero-emission method.
Taking it one step further, Texas-based Elemental Recycling sells a plastic recycling machine that utilizes a one-step, zero-emission process to turn any plastic into high purity graphite and graphene for use in electronics, fighter jets and more. The best part? The process produces hydrogen, which can be used in other applications.
Using ethanol-based recycling 2
University of Colorado researchers created a process similar to pyrolysis that uses ethanol to break down plastic to its smallest molecules—which can then be used to make new plastic products specifically in the electronic, automobile and aerospace industries. What really sets this new process apart is that it doesn’t use high temperatures.
Though it isn’t yet ready for large scale manufacturing, we’re eager to see next steps for this technology as it could, if applied properly, turn the industry on its head while serving as a viable alternative to current recycling methods.
Recycling historically unrecyclable PVC 3
PVC is a widely used plastic in the United States and globally, ranking as the third highest by volume worldwide. Unfortunately, it also has a zero percent recycling rate in the United States—which is exactly what makes the University of Michigan’s work so exciting.
Researchers at U of M have officially discovered a way to chemically recycle polyvinyl chloride (PVC) by successfully breaking PVC down into reusable
components. Chemical recycling can emit hydrochloric acid, but the team's method minimizes this by releasing the acid at a slower and controlled rate.
The most interesting part? Researchers found a way to use the phthalates in plasticizers, a harmful component of PV, as the mediator for the entire chemical reaction.
Recycling polyester with bacteria 4
This University of Texas Austin project is likened to "PacMan for pollution," making the Longhorns popular in the sustainability realm and maybe even among gamers!
PET (most commonly associated with clear plastic drinking bottles) can now be degraded by a natural enzyme called PETase through a combination of AI, chemical engineering, and synthetic biology.
However, the team didn’t stop there. By modifying PETase, researchers created a new enzyme (FAST-PETase) which allows bacteria to recycle PET plastic at faster rates and lower temperatures. The UT Austin scientists are ramping up production for real-world uses, so we’ll definitely keep an eye out for more breakthrough work from this team.
Creating batteries from microplastics 5
Microplastics present many societal challenges…but researchers at Inha University in South Korea are here to change that.
The Inha University team is turning microplastics into batteries through electrocoagulation—a technology that removes total suspended solids, heavy metals, and other contaminants from water.
The team uses this electrocoagulation to successfully filter microplastics from water, which can be utilized as battery electrodes. Though they are still perfecting the process, it’s safe to say this new recycling solution really energizes us.
Converting plastic bags into fuel 6
An international research team led by the Department of Energy’s Pacific Northwest National Laboratory has found a way to turn plastic waste into fuel at mild temperatures and with few byproducts.
Instead of “cracking” recycled plastics, they employ a two-step reaction using alkylation catalysts to control the bonds being formed. Currently, the process works for low-density polyethylene (LDPE) and polypropylene plastic (PP).
