November 11, 2024 • 5 min read
Scaling up plastic recycling to achieve a circular economy
Considering the future of plastic recycling technology, and how to scale up facilities
Over 90 percent of the 400 million tons of plastic produced globally each year is designed and distributed for a single use. Less than 20 percent of these plastics are recycled in any way.
Most of this environmentally disruptive material is incinerated or sent to landfills, where the complex chemicals can take decades or even centuries to degrade.
Most regions lack suitable, cost-effective plastic recycling facilities to provide alternative solutions to reduce environmental impacts. This reality must change to plan for future needs.
“Plastic recycling and reuse are simply not progressing quickly enough to meet increasing company and consumer demands,” says Dr. Geert Reyniers, Vice President, Sustainable Chemicals.
“This mounting pressure is driving plastics producers to set ambitious 2030 and 2050 sustainability targets and implement plans that turn these aspirations into reality.”
Executives and management teams must adopt a fresh mindset and review outdated processes to achieve these new targets.
“Traditional decision making, execution, and asset operation approaches no longer suffice given these aggressive timelines,” explains Reyniers.
“The industry must rethink the entire value chain and foster cooperative relationships that drive innovation and reduce risk to scale up sufficiently. And all the while, manage financial, and operational risks.”
It’s a delicate balance to strike. However, there are ways to help ensure we succeed.
Powering recycling successes with potent partnerships
Several stakeholders are involved in plastics production, including producers, technology providers, converters, waste management companies, brand owners, and consumers.
The ecosystem also includes policymakers; governments; regulators; infrastructure operators; and engineering, procurement, and consultant (EPC) contractors. Achieving meaningful outcomes requires every stakeholder to invest and collaborate.
“Scaling up plastic recycling at an industrial pace requires collaboration across the entire chain,” says Reyniers. We are supporting customers on this journey today, stepping in as an integrator between parties and driving alignment to foster innovation and maximize success.
“Consumers also contribute to the net effort by sorting plastics separately from other waste streams.”
It’s a communal process that Reyniers is well acquainted with. “We’re a strong collaborator in this market, through our plastics expertise and global engineering resources,” he says. “We can also reimagine existing assets or design and build state-of-the-art facilities. Modularization and standardization are key, fostering scalable and rapidly deployable solutions across sites.”
Reyniers emphasizes that transporting waste materials over long distances is rarely practical, highlighting the need for strategically located plants. “By standardizing and modularizing these facilities, companies can achieve economies of scale that optimize capital investments, enhance operational consistency, and drive further efficiencies.”
“Of course, these efforts must align with local regulations and compliance frameworks to ensure long-term success.”
Because external factors can also change unexpectedly, recycling facilities must adapt quickly to seize opportunities or address unforeseen challenges. In particular, the regulatory environment around plastics can shift rapidly.
“We create operations roadmaps to ensure long term viability and protect investments in projects. Additionally, we serve as integrators, bringing together the right contributors to support a strong business case,” says Reyniers.
Using recycling technology that’s fit for purpose
Identifying the right tool for the job can be more complicated than it might initially seem.
“Today, more than 200 different technologies are being developed to address specific aspects of the recycling process,” explains Reyniers. “This diversity creates both opportunities and challenges for companies looking to scale their recycling efforts.”
To complicate matters, the quantity and quality of plastic waste can differ based on regional waste management practices and variable consumer behavior. However, innovation will likely lead to greater efficiency and choice over time.
“As advanced sorting techniques for mixed plastics progress, infrastructure owners will have more options,” says Reyniers. “These advancements enable more targeted, cost-effective treatment processes, enhancing the output of recycled polymers.”
Mechanical recycling – repurposing the material without changing its chemical structure – remains an attractive option whenever feasible, but it’s not the ultimate solution. It’s limited by the types of plastics it can handle and the number of cycles before degradation occurs, leaving a significant amount of waste. Other technologies offer more potential.
“The depolymerization of plastics into valuable monomers, referred to as ‘chemical recycling,’ holds great promise in converting today’s linear plastics economy into a true circular economy,” says Reyniers.
“Chemical recycling offers the highest potential to achieve circularity in the fastest way.”
Companies prepared to invest in adaptable technologies that evolve alongside market demands and regulatory changes will gain a competitive edge.
“We design plastic waste management plans based on whichever tech they choose,” says Reyniers. “Our commitment to technology neutrality allows us to offer unbiased advice, helping our customers select the best solution for your specific application.
“Additionally, we go beyond the plant’s front-end systems and process, helping customers manage the output of recycling facilities to meet the precise requirements of off takers. This ensures that recycled materials align with market demands and create value across the supply chain.”
The plastics supply chain of the future
We’re only just beginning to tap into plastic recycling’s potential.
“The future supply chain for plastics will evolve as consumer sorting behaviors and pretreatment techniques improve, allowing for more defined feedstocks for both mechanical and chemical recycling,” says Reyniers.
“Another emerging trend is the growing demand for material traceability from brand owners, who want proof of ethical handling throughout the supply chain.”
These changes should affect how plastic recycling facilities are planned and operated, creating infrastructure that meets current needs while remaining flexible for future demands.
“For example, some sites may prioritize large, centralized operations, while others might focus on smaller, agile facilities that adapt to local conditions,” explains Reyniers. “Newer technologies for tracking, collecting, and sorting materials, such as blockchain, also offer promising ways to address logistical challenges.
“However, the involvement of key stakeholders like local regulators, authorities, and logistics providers is crucial, as their support can determine the success of these solutions.”
Balancing sustainability with employee and consumer safety
As Reyniers outlines, risk management is also a key issue.
“As recycling efforts grow, so will health, safety, and environmental (HSE) requirements,” he says. “This applies not only to facilities but also to health concerns surrounding plastic reuse, particularly in food-grade applications.”
Some concerns are warranted. Plastic degradation and potential contamination are significant challenges, especially when recycled materials are reintroduced into production. Technological developments are already making an impact in this regard.
“Mechanical recycling is absolutely a viable option that mitigates some risks associated with plastic reuse,” Reyniers notes. “However, chemical recycling is even more effective, as it allows recyclers to return to high monomer-grade quality, significantly reducing HSE risks.”
Many plastic producers are now investing in solvent-based technologies to create food-grade polypropylene, addressing some safety concerns that consumers, researchers, or regulators have raised. Each producer and stakeholder must conduct appropriate due diligence to determine whether mechanical or advanced recycling is optimal for them.
“Our strength lies in helping customers navigate these complexities,” says Reyniers. “We provide master planning and foster strategic partnerships, mapping the entire recycling process, identifying potential risks, and developing strategies to mitigate them.
“Working together, we can overcome these challenges and scale up more efficient solutions.”
