1 Chemical recycling: Turning plastic waste into chemical feedstock Dr. Christian Lach Project Lead ChemCycling TM BASF Research Press Conference on December 10, 2020 BASF Research Press Conference 2020 Today’s recycling landscape for plastic waste Fate of 30 million metric tons of plastic waste generated in EU28+2 in 2018 2 Landfill Energy recovery Mechanical recycling Chemical recycling Only one third of all plastic waste is kept in the materials cycle in EU28+2. 20% 20% 30% 30% 31.1% 0.1% 41.0% 24.5% 3% Globally: 250 million metric tons Unmanaged / Leaks < 0.1% Source: Conversio, “Circular Economy of Plastics 2018 EU28+2”, September 2019 // Conversio, “Global Plastics Flow 2018”, February 2020
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Chemical recycling: Turning plastic waste into chemical feedstockDr. Christian LachProject Lead ChemCyclingTM
BASF Research Press Conferenceon December 10, 2020
BASF Research Press Conference 2020
Today’s recycling landscape for plastic wasteFate of 30 million metric tons of plastic waste generated in EU28+2 in 2018
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Landfill
Energy recovery
Mechanical recycling
Chemical recycling
Only one third of all plastic waste is kept in the materials cycle in EU28+2.
20%
20%
30%
30%
31.1%
0.1%
41.0%
24.5%
3% Globally: 250 million metric tonsUnmanaged / Leaks
< 0.1%
Source: Conversio, “Circular Economy of Plastics 2018 EU28+2”, September 2019 // Conversio, “Global Plastics Flow 2018”, February 2020
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BASF Research Press Conference 2020
Chemical recycling can increase the overall amount of plastic waste recycled
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ChemCyclingTM is complementary to mechanical recycling.
Incineration
Landfill
Refinery
Naphtha
Steam cracker Chemical production
Manufacturedgoods
Plastic waste
Basicchemicals
Semi-finishedgoods
Plasticgoods Recovery
Disposal
Monomers,additives, etc.
Plastics production
BASF Research Press Conference 2020
Chemical recycling can increase the overall amount of plastic waste recycled
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ChemCyclingTM is complementary to mechanical recycling.
Refinery
Naphtha
Steam cracker Chemical production
Manufacturedgoods
Plastic waste
Basicchemicals
Semi-finishedgoods
Plasticgoods Recovery
Disposal
Monomers,additives, etc.
Plastics production
Mechanical recycling
Polymer to polymer Clean single-stream waste needed Products are not “virgin-grade”
Incineration
Landfill
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BASF Research Press Conference 2020
Chemical recycling can increase the overall amount of plastic waste recycled
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ChemCyclingTM is complementary to mechanical recycling.
Chemical recycling
Waste to chemicals Can handle mixed plastic waste Products are “virgin-grade”
Refinery
Naphtha
Steam cracker Chemical production
Manufacturedgoods
Plastic waste
Basicchemicals
Semi-finishedgoods
Plasticgoods Recovery
Disposal
Monomers,additives, etc.
Plastics production
Mechanical recycling
Polymer to polymer Clean single-stream waste needed Products are not “virgin-grade”
Incineration
Landfill
BASF Research Press Conference 2020
Towards a stable and scalable chemical recycling process
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Flexible feedstocks Mass Balance conceptVerbund concept
+ +BASF
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BASF Research Press Conference 2020
The purificationchallenge
ChemCyclingTM: technological challenges
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BASF addresses these challenges with partner companies.
The scale-upchallenge
How can pyrolysis technology be scaled-up best for commercial use?
How do we achieve the necessary specification of pyrolysis oil for use in the BASF Verbund?
BASF Research Press Conference 2020
The purificationchallenge
ChemCyclingTM: technological challenges
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The scale-upchallenge
How can pyrolysis technology be scaled-up best for commercial use?
How do we achieve the necessary specification of pyrolysis oil for use in the BASF Verbund?
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BASF Research Press Conference 2020
The purification challenge
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Waste plastic feedstock contains a variety of chemical structures and a significant amount of heteroatoms, e.g., chlorine, nitrogen, oxygen.Source: PlasticsEurope, Plastics – the Facts 2019
Plastics demand distribution (51.2 million metric tons) by resin types 2018 in EU28+2
Polyethylene (PE)
Polyamide (PA)Polyurethane (PUR)
Polyvinyl chloride (PVC)
Polystyrene (PS) + EPS
Polypropylene (PP)
Others
Polyethylene terephthalate (PET)
H H
H H
C C
n
H CI
H H
C C
n
HHC
n
CO
O O
ONN R2
R1
HHC
n
CH
H H
H CH3
C C
n
Hn
CR
O
N
H n
C
O
O
H
H H
C
O H
C
H
H
C
H
O
BASF Research Press Conference 2020
The purification challenge: chemistry matters
Purification is essential for pyrolysis oil. The use in existing assets demands narrow specifications.
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Why heteroatoms are undesirable in pyrolysis oil
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ClChlorine35.453
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OOxygen
15.999
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NNitrogen14.007
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SSulfur32.065
Corrosion “Blue liquids” may be formed, which create explosion risk for
steam cracker
Corrosion, catalyst poison
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BASF Research Press Conference 2020
Quantafuel and BASF collaborateto supply the BASF Verbund with pyrolysis oil
In Skive, Quantafuel is realizing its process for the first time at full-scale – with BASF’s support.
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Unique integrated process of pyrolysis of mixed plastic waste and purification into a secondary raw material
Catalytic purification happens at ambient pressure
Flexibility in scale enables optimization of the supply chain setup
16kt/a plant in Skive, Denmark (world’s largest plastic pyrolysis plant) with first-generation catalyst is operating
BASF Research Press Conference 2020
Deep Dive purification:catalytic cracking and hydrogenation of plastic waste
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Pyrolysis feed Purification catalysts
Purified pyrolysis oil
>99.9% carbon, hydrogen
Contaminant Stream
NH2ClCl
CH3
O
CH3H3C
O HCl
SH H
HH H
N
Catalyst performance is key to meet the demanding specifications of chemical industry.
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BASF Research Press Conference 2020
Tackling the purification challengein collaboration with hte GmbH in Heidelberg
Catalyst optimization targets yield, service life and energy consumption.
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hte tests catalysts under industrially relevant conditions in high-throughput reactor systems with up to 48 reactors in parallel
hte supports our partners in optimizing the catalyst by screening
chemical composition
morphology
hte enables a fully automated and digitalized testing workflow with efficient data management
BASF Research Press Conference 2020
The purificationchallenge
ChemCyclingTM: technological challenges
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The scale-upchallenge
How can pyrolysis technology be scaled-up best for commercial use?
How do we achieve the necessary specification of pyrolysis oil for use in the BASF Verbund?
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BASF Research Press Conference 2020
Tackling the scale-up challengewith our supercomputer Quriosity