PLASTIC TO FUEL CONVERSION

311 Mt/y plastics produced

Almost 40% of the total plastics demand are for the packaging sector

European plastics demand* by segment 2013 Source: PlasticsEurope (PEMRG) / Consultic / ECEBD * EU-27+NO/CH

By 2050 more plastic in the ocean than fish

“In a business-as-usual scenario, the ocean is expected to contain one ton of plastic for every three ton of fish by 2025, and by 2050, more plastics than fish [by weight].” says Ellen Mc Arthur

450 years

The time needed by nature to decompose a plastic bag

Our vision

Plastics are an integral and important part of the global economy. They should never become waste.

Our vision is to create an effective revalorization of plastics, drastically reducing the leakage of plastics into natural systems by converting the waste plastic into clean fuel.

keypoint-plastic-to-fuel.png

Typical applications

  • Recycling companies: valorization of non-recyclable plastics, profitable alternative to incineration or landfilling
  • Municipalities: Collect waste plastic to produce oil for public transportation
  • Industries: Waste plastic conversion for fuel replacement
  • Isolated areas: Decentralized energy production from waste plastic

Target waste plastics

Polyolefins (PE, PP, PS)

  • Recycling companies: valorization of non-recyclable plastics, profitable alternative to incineration or landfilling
  • Municipalities: Collect waste plastic to produce oil for public transportation
  • Industries: Waste plastic conversion for fuel replacement
  • Isolated areas: Decentralized energy production from waste plastic

Process description

Click picture(s) to zoom
diagram-plastic-to-fuel.png

Non-reusable waste plastics (mainly polyolefins) are collected from sorting platforms, cleaned and shredded.

  1. The material is fed into a first reactor, heated in absence of oxygen around 275°C, and melted.
  2. The liquefied plastic is transferred into a second reactor where the temperature is smoothly increased up to 375°C. During this operation the plastic molecules are gently cracked into smaller hydrocarbon molecules which evaporate into gas.
  3. The gas is collected in a rectification-distillation column where about 85% of the gas is condensed into two fuel fractions. The fuel fractions are clean hydrocarbon liquids similar to kerosene and diesel oil.
  4. The non-condensable gas is burnt on site to produce the heat necessary for the operation.
  5. Gas phase inertisation through a nitrogen washing unit.

This multi-stage process is unique and fully protected by patents.

Key figures for plant design

  • Typical size: 10 000 to 15 000 tons per year of sorted waste plastics.
    This is the targeted waste plastic generated by an area of 250 000 inhabitants
  • Footprint of the plant: Plastic conversion - 2000 m2
    Sorting area - 3000 m2
    Total site (including storage areas) - approx. 10000 m2
  • System efficiency: Out of 1 ton of plastic, 900 lt. fuel are produced.
    Typical CAPEX - 14 to 22 M€
    Typical OPEX - 0,20 to 0,25 €/lt.

Environmental benefits

  • Preventing waste plastic from accumulating in our environment (land and sea)
  • Better energy valorization than incineration
  • No hazardous emissions

Deliveries

  • Waste qualification and specification of sorting process
  • Project development (feasibility study, risk analysis)
  • Financing
  • Site development and permitting
  • Project management
  • Engineering
  • Procurement
  • Construction, installation and commissioning
  • Operation and Maintenance
  • Fuel distribution.

References

Pilot plant

(Basel)

Semi-industrial plant

(Sihlbrugg, Switzerland)

Typical industrial plant