The iCAREPLAST project tackled the challenge of cost and energy-efficient recycling of non-recyclable plastics and composites from urban waste. By converting heterogeneous plastic mixtures into valuable chemicals, including (alkyl)aromatics, through sequential catalytic and separation processes, the project showcased the transformative potential of innovative chemical recycling. Alongside valuable chemical products, the process yielded carbon char and a pure CO2 stream, offering economic sustainability, operational flexibility, and a reduced CO2 footprint. This was achieved through advanced oxycombustion units with heat recovery, AI-driven predictive control, and real-time optimization.
The pilot plant demonstrated the feasibility of processing over 100 kg/h of plastic waste. Advanced sorting, pre-treatment, and pyrolysis, supported by prior demonstrations and deep consortium expertise, laid the groundwork for this achievement. The iCAREPLAST solution bolstered the circular economy by significantly increasing recycled plastic volumes, with an initial target of treating 12 million kilograms annually. Recovered aromatic fractions and hydrocarbon-rich liquid and gaseous streams were valorized, maximizing material and energy efficiency while minimizing environmental impact.
EMI Twente contributed to this groundbreaking effort by applying commercially available organic solvent nanofiltration (OSN) membranes to purify and polish pyrolysis liquids. To achieve this, the team designed and constructed an in-house ATEX-compliant OSN pilot plant, bridging the gap between lab-scale innovation and pilot-scale validation. This custom-built system not only confirmed the viability of lab-scale results but also demonstrated the potential for industrial application.
By embracing this challenge, EMI Twente showcased its commitment to innovation and sustainability, proving that membrane technology can play a vital role in solving some of the world’s toughest industrial problems.
