Demonstration of a closed loop recycling process for HDPE, preparing EU replications, and transferring to PP recycling

PROJECT DESCRIPTION

BACKGROUND

Global production of plastic amounted to 322 million tonnes in 2015, with European demand of 49 million tonnes. At the end of the use phase, 40% of plastic is incinerated, 30% goes to landfill and just 30% is recycled. Over the last 10 years, the incineration rate has been increasing and the percentage going to landfill has declined, although there are big disparities between EU Member States. Over 40% of plastic is used in packaging, its most common use. However, only 40% of that packaging is recycled, mainly containers and bottles made from polypropylene (PP) and high-density polyethylene (HDPE). Improvements in sorting technology could help increase the recycling rate.

OBJECTIVES

LIFE PEPPCYCLE would establish two large-scale lines for sorting and recycling HDPE and PP from mixed waste streams. The recovered material would be processed into high-quality recyclates, which can be used for the consumer goods market. The HDPE line would be built first and lessons from its operation would be used to optimize the subsequent polypropylene line. The odour, colour purity and other properties of the recyclates would be compared to virgin plastic. The project intended to demonstrate that 100% substitution for virgin materials is possible, whilst making significant savings in energy and carbon dioxide emissions. It would carry out a lifecycle assessment of the environmental impact of three products (one HDPE, one PP and a consumer product made of compounds). The project would be implemented in Germany but preparations for market uptake and replication in other EU countries were planned. This would involve drafting a business plan and exploring potential markets.

This project would have supported the implementation of the EU plastics strategy and the Circular Economy Action Plan, and to achieving climate policy goals by 2030.

Expected results:

Production of high-quality recyclates and compounds to replace virgin material in consumer goods applications and packaging materials;

Demonstration of the HDPE process at a recycling rate of 70% of the input capacity with a maximum output capacity of 36 000 tonnes per year by the end of the project;

Validation of estimated process energy-saving potential of 32% and CO2 saving potential of 20% for a HDPE product made of 100% recyclates compared to virgin material;

Reduction of GHG emissions from the process by 12 899 t CO2eq compared to virgin HDPE production;

Reduction of fossil feedstock energy use by 1 700 TJ/year compared to virgin HDPE production;

Reduction of fuel energy use by 396 TJ/year compared to virgin HDPE production;

Reductionof air pollutants and overall environmental footprint across the value chain based on the cradle to gate LCA approach;

Landfill, incineration and downgrading of at least 50 000 tonnes of plastic waste avoided (corresponding to the input needed for 36 000 tonnes output);

Achievement of highest product quality of recyclate: translucent/bright colour, low/no odour;

Technology transfer to polypropylene at a capacity of 8 900 tonnes per year in 2020;

To demonstrate the production of compounds at a capacity of 8 900 tonnes per year in 2022;

The development of upscaling, replication and transferability scenarios for the waste and recycling industry;

The implementation of broad dissemination actions, involving a wide stakeholder community;

First market replications immediately after the project; and

High-performance, user specific material that can open up new markets and added value due to compounding integration.

RESULTS

The project was terminated on 12/12/19