Advanced recycling and fossil fuels in the age of net zero

The main objectives of developing sustainable plastics in relation to the fossil fuel industry is to reduce dependency on fossil fuels, minimise environmental impact and promote a circular economy.

Here are some key points elaborating on this objective:

• Reducing Fossil Fuel Dependency: Traditional plastics are derived from petroleum, a fossil fuel. By developing sustainable plastics, such as bioplastics made from renewable resources (e.g., corn, sugarcane, or other biomass), the goal is to lessen reliance on traditional, finite resources.
• Lowering Carbon Footprint: Sustainable plastics can help decrease greenhouse gas emissions associated with the production and disposal of conventional plastics. By using renewable feedstocks, the overall carbon footprint can be reduced, contributing to climate change mitigation.
• Promoting Circular Economy: Sustainable plastics often focus on recyclability, biodegradability, or compostability, which can help create a closed-loop system. This reduces waste and encourages the reuse of materials, diverging from the linear model of production and disposal prevalent in the fossil fuel industry.
• Reducing Environmental Pollution: The production and disposal of conventional plastics contribute significantly to environmental pollution, including ocean plastics. Sustainable alternatives aim to minimise waste and pollution, benefiting ecosystems and human health.
• Encouraging Innovation: The shift towards sustainable plastics fosters innovation in materials science and engineering. This can lead to the development of new technologies and processes that reduce the environmental impact of plastic production and use.
• Supporting Sustainable Development Goals (SDGs): The development of sustainable plastics aligns with various UN Sustainable Development Goals, particularly those related to responsible consumption and production (Goal 12) and climate action (Goal 13).

Overall, the transition to sustainable plastics represents a critical step towards reducing the environmental impacts associated with fossil fuel-derived materials while promoting a more sustainable and resilient economy.

Plastic production from the oil and gas industry and their role in the economy

The production of plastics from the oil and gas industry involves several key steps, starting from the extraction of raw materials to the final manufacturing of various plastic products. Here is an overview of that production process, the types of plastics produced, and their vital applications in society and the economy.

The process of plastic production

• Raw Material Extraction: The process begins with the extraction of crude oil and natural gas. These fossil fuels are the primary feedstocks for most conventional plastics.
• Refining: Crude oil is refined in a petroleum refinery, where it is separated into various components, including naphtha, which is a key precursor for plastic production.
• Cracking: The naphtha undergoes a process called cracking, where it is heated and broken down into smaller hydrocarbon molecules, primarily ethylene and propylene. This step can be performed using methods such as steam cracking or catalytic cracking.
• Polymerisation: The monomers (e.g., ethylene and propylene) produced from cracking are then polymerised through various chemical processes to form polymers. This can be done through addition polymerisation (for polyethylene and polypropylene) or condensation polymerisation (for polyesters).
• Compounding: The newly formed polymers are often mixed with additives (such as stabilisers, colorants, and plasticisers) to enhance their properties. This process is known as compounding.
• Moulding and Shaping: The compounded plastic is then processed into final products through methods such as injection moulding, blow moulding, extrusion, or thermoforming.
• Cooling and Finishing: After shaping, the plastic is cooled and may undergo additional processes like trimming, finishing, or surface treatment before being packaged and distributed.

Types of plastics and their applications:

• Polyethylene (PE): Types: Low-Density Polyethylene (LDPE), High-Density Polyethylene (HDPE). Applications: Grocery bags, plastic bottles, containers, toys, and packaging materials.
• Polypropylene (PP): Applications: Food containers, automotive parts, textiles, and various household items.
• Polyvinyl Chloride (PVC): Applications: Pipes, flooring, window frames, and medical devices (e.g., IV bags).
• Polystyrene (PS): Types: Solid polystyrene and expanded polystyrene (EPS). Applications: Disposable cutlery, foam packaging, insulation materials.
• Polyethylene Terephthalate (PET): Applications: Beverage bottles, food containers, and synthetic fibers (e.g., polyester).
• Polycarbonate (PC): Applications: Safety glasses, electronic components, and automotive parts.
• Acrylic (PMMA): Applications: Signage, displays, and optical lenses.
• Nylon (Polyamide): Applications: Textiles, automotive parts, and industrial components.

Vital applications in society and the economy:

• Packaging: Plastics are widely used in packaging due to their light weight, durability, and flexibility, which combined, help reduce food waste and transportation costs.
• Construction: Plastics are essential in the construction industry for pipes, insulation, and building materials, contributing to energy efficiency and structural integrity.
• Automotive: Lightweight plastic components improve fuel efficiency and reduce emissions in vehicles.
• Healthcare: Plastics are crucial in the medical field for products like syringes, IV bags, and surgical instruments, ensuring hygiene and safety.
• Consumer Goods: A vast array of household items, appliances, and personal care products rely on plastics for functionality and convenience.

In summary, the oil and gas industries play a critical role in plastic production, which in turn has extensive applications across various sectors, significantly impacting society and the economy. However, the environmental implications of plastic production and disposal continue to drive the search for sustainable alternatives.

Plastic production and its impact on the economy

As of my last knowledge update in October 2023, the global production and management of plastic waste are significant concerns. Here are some key statistics and insights regarding plastic production, recycling, landfill disposal, incineration, and their environmental and societal impacts:

• Annual plastic production and recycling:
• Plastic Production: In 2021, global plastic production reached approximately 367 million metric tons. This number has been steadily increasing over the years, reflecting the growing demand for plastic in various sectors.
• Recycling Rates: Globally, it is estimated that only about 9% of all plastic waste ever produced has been recycled. This figure varies significantly by region and type of plastic, with some countries achieving higher recycling rates due to effective waste management systems.
• Landfill & Incineration: Approximately 79% of plastic waste ends up in landfills, while about 12% is incinerated. The remaining small percentage is either recycled or mismanaged, leading to environmental pollution.

Impact of non-recycled plastic on the environment and society

Environmental impact:

• Pollution: Non-recycled plastics contribute to pollution in various forms, including land, water, and air. Plastics can break down into microplastics, which contaminate soil and waterways, adversely affecting ecosystems and wildlife.
• Marine Life: A significant portion of plastic waste ends up in oceans, leading to the death of marine animals through ingestion or entanglement. Microplastics have been found in marine organisms, raising concerns about the food chain and human health.
• Greenhouse Gas Emissions: The production and incineration of plastics contribute to greenhouse gas emissions, exacerbating climate change. Plastics derived from fossil fuels release carbon dioxide and other pollutants during both production and disposal.

Societal impact:

• Public Health: Plastics can leach harmful chemicals into the environment, which may enter the food chain. This poses potential health risks to humans, including endocrine disruption and other long-term health issues.
• Economic Costs: The economic burden of plastic pollution includes cleanup costs, loss of tourism revenue, and impacts on fisheries and other industries affected by pollution. Communities may also face increased waste management costs due to the high volume of plastic waste.
• Social Inequity: Vulnerable communities often bear the brunt of plastic pollution, facing health risks and environmental degradation. This exacerbates existing social inequalities and can lead to conflicts over resources.
• Biodiversity Loss: The accumulation of plastic waste in natural habitats can lead to habitat destruction and loss of biodiversity, affecting ecosystems and the services they provide to humanity.

The statistics surrounding plastic production and recycling highlight a significant global challenge. The vast majority of plastics produced are not recycled, with a large portion ending up in landfills or being incinerated, leading to serious environmental and societal impacts. Efforts to improve recycling rates, reduce plastic production, and develop sustainable alternatives are essential to mitigate these issues and promote a healthier planet and society.

Mechanical and chemical recycling (a combined solution)

Mechanical recycling and chemical recycling are two distinct approaches to recycling plastics, each with their own advantages, limitations, and suitable plastic types. Here is a detailed comparison of both methods and how they can be effectively combined to support a circular economy and contribute to net-zero goals.

Mechanical recycling

Process:

1. Collection and Sorting: Post-consumer plastic waste is collected and sorted by type, color, and grade.
2. Cleaning: Contaminants: Such as food residues, labels, and adhesives are removed to prepare the plastics for recycling.
3. Shredding: The cleaned plastics are shredded into smaller pieces or flakes.
4. Reprocessing: The shredded plastic is melted and formed into pellets, which can be used to manufacture new products.

Types of plastics:

Best suited:

Mechanical recycling is primarily effective for thermoplastics, particularly:

• Polyethylene (PE): Widely used in packaging materials, bags, and bottles.
• Polypropylene (PP): Common in containers, automotive parts, and textiles.
• Polyethylene Terephthalate (PET): Often recycled from beverage bottles and food containers.

Limitations

Mechanical recycling is less effective for:

• Thermosetting Plastics: These cannot be melted and reformed, making them unsuitable for mechanical recycling.
• Contaminated Plastics: If plastics are not properly cleaned or sorted, the quality of the recycled material can be compromised.

Chemical recycling

Process:

• Depolymerisation: This involves breaking down plastic polymers into their monomeric or oligomeric forms using chemical processes such as pyrolysis, gasification, or hydrolysis.
• Purification: The resulting monomers or small molecules are purified and can be repolymerized to create new plastics.

Types of plastics

Best suited:

Chemical recycling can handle a broader range of plastics, including:

• Polyvinyl Chloride (PVC): Difficult to recycle mechanically due to contaminants and additives.
  
• Polystyrene (PS): Often not recycled through mechanical methods due to its low density and contamination issues.
• Mixed Plastics: Chemical recycling can process blends of different plastics that are challenging for mechanical recycling.

Limitations:

Chemical recycling can be more energy-intensive and may require complex infrastructure. Additionally, the quality of the output can vary based on the technology used.

Combining mechanical and chemical recycling for a circular economy

To achieve a circular economy in relation to net-zero goals, effectively combining mechanical and chemical recycling can optimise plastic waste management.

Complementary roles:

• Mechanical Recycling: Can efficiently process clean, single-type plastics, providing high-quality recycled materials for applications where performance is critical.
• Chemical Recycling: Can address the more challenging plastics that mechanical recycling cannot, such as contaminated or mixed materials.
• Integrated Systems: Hybrid Facilities: Developing recycling facilities that integrate both mechanical and chemical processes can maximise the recovery of various plastics. This allows for a more comprehensive approach to waste management.
• Feedstock Flexibility: By combining both methods, facilities can accept a wider variety of plastic waste, improving overall recycling rates and reducing landfill reliance.

Circular supply chains:

• Closed-Loop Systems: Manufacturers can design products with recyclability in mind, using materials that can be easily processed through either mechanical or chemical recycling. This encourages the use of recycled content in new products.
• Collaboration Across Sectors: Establishing partnerships between manufacturers, waste management companies, and recycling facilities can facilitate better collection, sorting, and processing of plastics.

Innovation and technology:

Investing in research and development to improve both mechanical and chemical recycling technologies can enhance efficiency, reduce energy consumption, and lower greenhouse gas emissions.

Policy and consumer engagement:

Promoting policies that encourage recycling and the use of recycled materials, along with consumer education about proper disposal and recycling practices, can drive demand for recycled plastics and support a circular economy.

By effectively combining mechanical and chemical recycling, we can create a more robust and efficient plastic recycling system that contributes to a circular economy. This approach not only helps reduce plastic waste and its environmental impact but also supports net-zero goals by minimising the reliance on virgin materials and reducing greenhouse gas emissions associated with plastic production and disposal.

Chemical recycling and circular economy

Chemical recycling, particularly pyrolysis, is an evolving field aimed at converting plastic waste back into valuable resources, either as new plastics or as fuels. Recent developments in engineering and chemistry are focused on enhancing the efficiency of pyrolysis processes, reducing energy consumption, and minimising emissions.

Here are some key advancements and strategies that can improve pyrolysis for a more effective closed-loop system:

Catalytic pyrolysis:

Use of catalysts: Catalysts can significantly lower the energy requirements of the pyrolysis process by facilitating the breakdown of polymers at lower temperatures. Research is focusing on developing efficient catalysts (such as zeolites or metal oxides) that enhance the conversion rates of various plastics into monomers or fuels.

Tailored catalysts: Engineering catalysts to selectively target specific types of plastics can improve yield and reduce by-products, leading to higher-quality outputs suitable for repolymerisation.

Process optimisation:

• Temperature and Pressure Control: Advances in sensor technology and process control systems allow for precise monitoring and adjustment of temperature and pressure during pyrolysis. Optimising these parameters can enhance the efficiency of the process and improve the quality of the end products.
• Continuous Flow Systems: Transitioning from batch processes to continuous flow pyrolysis systems can enhance throughput and energy efficiency. Continuous systems allow for real-time adjustments and can be more easily integrated with downstream processing.
• Hybrid Pyrolysis Technologies- Integration with Other Processes: Combining pyrolysis with other waste treatment technologies, such as gasification or hydrothermal liquefaction, can improve overall efficiency. For example, integrating pyrolysis with gasification can convert solid residues into syngas for energy generation.
• Co-Pyrolysis: Co-pyrolysing plastics with biomass or other organic materials can improve the quality of the fuel produced and reduce the amount of plastic waste requiring processing. This approach can also help balance the carbon footprint of the process.

Energy recovery and utilisation:

• Heat Integration: Implementing heat recovery systems within the pyrolysis process can significantly reduce energy consumption. Captured heat from exothermic reactions can be reused to preheat incoming feedstock or create steam for power generation.
• Utilisation of By-Products: Developing methods to utilise by-products from pyrolysis (such as carbon black or char) can create additional revenue streams and reduce waste. For example, carbon black can be used in rubber manufacturing or as a pigment.

Advanced feedstock preparation:

• Pre-Treatment Technologies: Innovations in pre-treatment methods (such as washing, shredding, and sorting) can improve the quality of the feedstock entering the pyrolysis process. Cleaner, more homogenous feedstock can lead to higher yields and reduced emissions.
• Feedstock Blending: Research into optimal blending ratios of different types of plastics can enhance the pyrolysis process, improving output consistency and quality.
• Life Cycle Assessment and Process Design- Life Cycle Analysis (LCA): Implementing LCA methodologies during the design phase of pyrolysis plants can help identify opportunities to reduce emissions and energy consumption throughout the process. Understanding the full environmental impact can drive improvements in technology and process design.
• Design for Recycling: Encouraging manufacturers to design products with recycling in mind (e.g., using compatible polymers) can facilitate easier processing and improve the efficiency of pyrolysis operations.

Emerging technologies

• Plasma Pyrolysis: This cutting-edge technology uses plasma arcs to achieve high temperatures for breaking down plastics. Plasma pyrolysis can potentially reduce energy consumption and emissions while allowing for the conversion of a wider range of materials.
• Microwave-Assisted Pyrolysis: Utilising microwave energy to heat plastics can provide more uniform heating and reduce energy requirements. This method is still under research but shows promise for improving pyrolysis efficiency.

The ongoing developments in engineering and chemistry related to pyrolysis are critical for creating a more efficient closed-loop system for recycling plastics.

By focusing on catalytic processes, optimising operational parameters, integrating hybrid technologies, and utilizing advanced feedstock preparation techniques, the pyrolysis process can achieve higher yields, lower energy consumption, and reduced emissions.

These advancements not only enhance the feasibility of converting plastic waste back into valuable resources but also align with the broader goals of sustainability and a circular economy, contributing to efforts toward net-zero emissions.

Fossil fuel & recycling, net zero

Achieving a circular economy and Net Zero emissions requires a collaborative approach among the fossil fuel, chemical and mechanical industries, manufacturers, and national governments.

Here are several strategies for fostering this collaboration:

Shared vision and goals

• Establishing Common Objectives: All stakeholders must align on shared goals for sustainability, such as reducing carbon emissions, increasing resource efficiency, and promoting circularity. This could involve commitments to specific targets for waste reduction, resource recovery, and emissions reductions.
• Long-term Planning: Developing joint long-term strategies that encompass research, development, and deployment of sustainable technologies can facilitate a cohesive approach to achieving Net Zero.

Innovation and research collaboration

• Joint Research Initiatives: Foster partnerships between industries and governments to fund and conduct research on sustainable materials, recycling technologies, and energy-efficient processes. This can include public-private partnerships (PPPs) that leverage resources from both sectors.
• Technology Transfer: Encourage the sharing of best practices and technologies between industries, especially in areas such as carbon capture and storage (CCS), renewable energy integration, and sustainable manufacturing processes.

Circular supply chains

• Design for Circularity: Collaboration on the design of products and materials that facilitate recycling, reuse, and remanufacturing. This includes developing standards for materials that can be easily recycled or repurposed.
• Closed-Loop Systems: Implementation of closed-loop systems where waste from one industry becomes a resource for another. For example, using waste plastics as feedstock for chemical processes or converting CO2 emissions into useful products.

Regulatory frameworks and incentives

• Supportive Policies: National governments should create and enforce regulations that encourage circular economy practices, such as extended producer responsibility (EPR) laws, waste reduction targets, and incentives for using recycled materials.
• Financial Incentives: Implementation of tax breaks, subsidies, or grants to support companies investing in sustainable technologies and practices can help to lower the financial barriers to adopting circular economy approaches.
• Investing in Infrastructure- Recycling and Waste Management Facilities: Investment in advanced recycling facilities and waste management infrastructure to process materials more efficiently and effectively. This includes developing capabilities for chemical recycling and other innovative recycling technologies.
• Renewable Energy Integration: Encouraging investments in renewable energy sources to power industrial processes, reducing reliance on fossil fuels and lowering overall emissions.

Education and workforce development

• Training Programs: Development of training programs to equip the workforce with the skills needed for sustainable manufacturing, recycling, and circular economy practices. This can help facilitate the transition to a more circular economy.
• Public Awareness Campaigns: Increasing public awareness around the importance of circular economy principles and sustainable practices. Educating consumers can drive demand for sustainable products and practices.

Pilot projects and demonstration initiatives

• Testing New Models: Implementation of pilot projects that demonstrate the feasibility of circular economy practices. These projects can serve as proof of concept and provide valuable insights for scaling up successful initiatives.
• Collaboration on Standards: Working together to establish industry standards and certifications for sustainable practices, which can help build trust and encourage adoption among manufacturers and consumers.

Data sharing and transparency

• Open Data Initiatives: Encourage the sharing of data related to resource use, emissions, and waste generation among industries and governments. Transparency can drive accountability and inform better decision-making.
• Lifecycle Assessment (LCA): Promoting the use of LCA tools to evaluate the environmental impact of products and processes, helping industries make informed choices about materials and designs.

The transition to a circular economy and achieving Net Zero emissions requires a concerted effort from all stakeholders involved.

By fostering collaboration between the fossil fuel industry, chemical and mechanical industries, manufacturers, and national governments, it is possible to develop innovative solutions that enhance sustainability, reduce waste, and minimise carbon emissions. This integrated approach will not only contribute to environmental goals but also create economic opportunities and drive innovation in a rapidly changing global landscape.

Francis Akpata
Director at Majlis Energy

*Legal Disclaimer. The views expressed, and responsibility for the content of this publication, lie solely with the authors.