PLASTIC2WAXLIFE: Demonstrating a scalable modular pyrolysis process to give new life to waste plastics while enabling local production of sustainable wax (aka NEWLIFE2PLASTIC)

Introduction

Today’s world is overwhelmed by the urgent need to address a growing flux of unsustainably produced and disposed materials. In 2018 alone, 12.5 million tonnes of waste plastics were burned and 7.3 million tonnes landfilled in Europe, further raising concern regarding microplastics dispersion.

Project Overview

PLASTIC2WAXLIFE will demonstrate and bring to market an innovative chemical recycling process based on pyrolysis for the conversion of waste plastics into sustainable wax. This initiative aims to displace current unsustainable practices of plastics disposal while simultaneously unlocking a market opportunity for large-scale production of sustainable specialty wax, replacing polyolefin waxes.

Importance of Wax

Wax is a material globally used in many manufacturing sectors essential for Europe. Currently, it is obtained from foreign fossil resources, and the demand is expected to exceed supply by 20%.

Scaling Up the Process

PLASTIC2WAXLIFE will scale up a proprietary pyrolysis process already validated at LAB (Belfast, UK) and PILOT (Portlaoise, Ireland) scale, from 4,000 to 12,000 tonnes/year DEMO capacity. The project will further deploy the same process at a 40,000 tonnes/year INDUSTRIAL scale.

Collaboration

This scaling will occur in close collaboration with:

• Waste feedstock providers (Bord na Mona / AES, SABRINA/SIS, Whirlpool)
• End-users (H&R Group (DE), DOW Chemicals (NL))

This collaboration aims to ensure a fully secured sustainable value chain from feedstock to client.

Expected Outcomes

By doing so, the project is expected to deliver an industrial plant capable of:

1. Preventing up to 24,000 tonnes/year of waste plastics incineration
2. Reducing 23,000 tonnes of CO2eq/year of GHG emissions
3. Achieving up to 354 GWh/year of energy savings every year

Overall, such a value chain will satisfy corporate social responsibilities from a shareholder and customer perspective, as well as align with the SDGs, the EU Green Deal, and the LIFE Programme goals.