Demonstration of an innovative synthetic turf recycling system on an industrial scale

Aanleiding

There are currently no effective recycling solutions available for artificial turf pitches within the Netherlands.

These turfs are constructed of a backing (bottom layer) to which the plastic grass fibres are attached. When placed in a football field, a mixture of sand and rubber granulate is typically added. Even though LAP3 states that at minimum the sand and plastics must be recycled, no or only partial low-grade recycling is taking place within the Netherlands.

A recycling solution is therefore necessary, especially considering the growing market demand for artificial turf treatment (expected to reach quantities of around 325 pitches in 2026, compared to 275 pitches in 2019) and the national targets for reaching a fully circular economy by 2050.

Re-Match has developed a recycling solution for the complex artificial turf waste stream. It concerns a mechanical separation and sorting process in which the components sand, rubber, and plastic are recycled with virgin-like qualities. These components can be used for the production of new artificial turf pitches, thereby enabling a fully cradle-to-cradle solution for the artificial turf value chain.

Doelstelling

The goal of this project is to successfully demonstrate and validate the innovative Re-Match process, capable of recycling 250 AT pitches (62,500 tons) a year into pure materials to be used for the production of new AT pitches.

The aim of the DEI+ scheme is to support projects that enable a cost-effective reduction of CO2 emissions. The Re-Match solution increases circularity within the artificial turf value chain and effectively reduces an impressive 71.7 kiloton CO2 a year.

These turfs are currently temporarily stored on a large scale within the Netherlands, waiting for a real full recycling solution. Using the innovative Re-Match process, these artificial turfs can finally be treated in a responsible and circular manner.

Korte omschrijving

The Re-Match process is considered a TRL 7 innovation.

Three work packages (WPs) are defined to implement the innovation at the Tiel site of Re-Match:

1. WP1: preparation, construction, and commissioning
2. WP2: start-up
3. WP3: technical project management

In the first work package, Re-Match makes sure to finish detail engineering, procurement, construction, and commissioning. After the start-up phase, the demonstration plant will be tested and ready for commercial demonstration.

The technical project management WP is to make sure that all milestones are achieved within budget and planning and that project risks are effectively monitored, controlled, and mitigated.

Resultaat

The project result is a fully functional demonstration plant with an artificial turf processing capacity of 250 pitches.

This recycling facility has the following advantages:

• The effective recycling of 55,000 tons of plastics, sand, and rubber into high-grade secondary raw materials for further processing into new products.
• A CO2 reduction of 359 kiloton within a five-year period after commercial production, compared to a conventional incineration route of artificial turf. The environmental benefit will take place on site at Re-Match in Tiel.
• A validated business case and insights into a clear vision for further rollout of the technology.