Periodic Reporting for period 1 - ELECTRO (Electrified conversion of plastic waste into olefins & downstream integration)
Okres sprawozdawczy: 2022-09-01 do 2024-02-29
Less than 20 % of plastic is recycled in Europe, the rest ends up in landfills or is incinerated. In this context, eLECTRO “Electrified conversion of plastic waste into olefins and downstream integration” started in September 2022. This project will demonstrate new technology that connects the waste and petrochemical industries to provide a sustainable and scalable circular solution with a low carbon footprint for olefin and polyolefin production. eLECTRO will prioritise plastic waste streams by combining a modular extruder for the optimal pre-treatment of mixed plastic waste (MPW) with an electrically heated reactor for the catalytic pyrolysis of MPW. The produced pyrolysis oil will be used as a feed for steam crackers. The project will test the technology using waste streams from the Republics of Korea and Indonesia.
The main objective of the eLECTRO project is to demonstrate a revolutionary technology concept that links the waste and petrochemical industry and provides them with a sustainable, low GHG footprint and scalable circular solution for olefin and polyolefin production.
It resulted in seven sub-objectives:
• Demonstrate eLECTRO’s integrated waste to olefin process at TRL 7,
• Leverage eLECTRO’s electrified value chain to reduce CO2 emissions by 90%,
• Maximize renewable energy use through electrification and grid integration,
• Guide eLECTRO’s scalability to economically viable valorization of 200 kta MPW,
• Replicability by studying waste streams from different EU countries, Korea and Indonesia and assessing key locations for eLECTRO circular hubs,
• Dissemination, learning and training next generation Waste management engineers,
• Closing the full cycle by transforming waste back into materials (polyolefins).
To reach these objectives, eLECTRO brings together 12 European partners and 1 extra-European partner (Figure 1): Industrials, small and medium enterprises, research institutes and universities working on the 7 independent Work Packages. Besides the “Ethics requirements”, the “Project management”, and the “Dissemination, training, exploitation and communication”, all the other Work Packages are technical. They correspond to the whole chain of plastic recycling starting from the MPW collection and supply up to the downstream integration (Figure 2).
The main objective of the eLECTRO project is to demonstrate a revolutionary technology concept that links the waste and petrochemical industry and provides them with a sustainable, low GHG footprint and scalable circular solution for olefin and polyolefin production.
It resulted in seven sub-objectives:
• Demonstrate eLECTRO’s integrated waste to olefin process at TRL 7,
• Leverage eLECTRO’s electrified value chain to reduce CO2 emissions by 90%,
• Maximize renewable energy use through electrification and grid integration,
• Guide eLECTRO’s scalability to economically viable valorization of 200 kta MPW,
• Replicability by studying waste streams from different EU countries, Korea and Indonesia and assessing key locations for eLECTRO circular hubs,
• Dissemination, learning and training next generation Waste management engineers,
• Closing the full cycle by transforming waste back into materials (polyolefins).
To reach these objectives, eLECTRO brings together 12 European partners and 1 extra-European partner (Figure 1): Industrials, small and medium enterprises, research institutes and universities working on the 7 independent Work Packages. Besides the “Ethics requirements”, the “Project management”, and the “Dissemination, training, exploitation and communication”, all the other Work Packages are technical. They correspond to the whole chain of plastic recycling starting from the MPW collection and supply up to the downstream integration (Figure 2).
After 18 months of effort, eLECTRO has already accomplished significant achievements:
The conversion of MPW to py-oil has been started using real MPW at the PRYME pilot plant located at LCT UGent premises in Ghent. Both feedstock and produced py-oil have been analysed and characterised by UGent. PRYME will use similar feedstock in the TRL7 unit in Rotterdam. In parallel small quantities of MPW feedstocks have been identified and selected from South Korea and Indonesia to be exported to Belgium. These feedstocks will later be tested on the pilot scale eLECTRO setup to prove the replicability and economic viability of the technology. The production of py-oil will be further optimised using a kinetic process model developed by Polimi and the use of specific catalysts developed by AUTH. On their side, VTT is developing a MODIX extruder at pilot-scale to allow extrusion pre-treatment of various challenging and heterogeneous MPW materials for pyrolysis. Finally, the plant dedicated to make this transformation of MPW into py-oil at large scale ran for the first time in January 2024.
To valorise the py-oil produced, eLECTRO worked on a methodology to simulate the pre-fractionation train using literature data of the detailed composition of a py-oil sample. Simulations with COILSIM1D for the obtained fraction were performed. Also, we performed steam cracking tests for methodology development with a kind of artificial feed and used filtration technologies to test influences on contaminations. A lab-scale cracking unit is currently being assembled and will soon enter its startup phase.
The py-oil needs to be converted electrically in an RDR. Models of this device are currently built to better understand its limitations and to enhance its productivity. RDR pilot redesign has been started with pre-study and feasibility phase. One pilot installation has been completed, which already exceeds the performances of conventional resistive heaters.
To anticipate the market release, we worked on the planification of the future electrical needs, on the performances to be reached using LCA and on the societal acceptance. The estimations showed that the electrical needs should be similar to the production of one nuclear power plant and that using only renewable energy will be too challenging. Alternative or hybrid solutions should be identified. The LCA has started with the inventory data collection as there is a lack of experimental models. Regarding the societal acceptance, internal interviews have been conducted and are being treated.
The conversion of MPW to py-oil has been started using real MPW at the PRYME pilot plant located at LCT UGent premises in Ghent. Both feedstock and produced py-oil have been analysed and characterised by UGent. PRYME will use similar feedstock in the TRL7 unit in Rotterdam. In parallel small quantities of MPW feedstocks have been identified and selected from South Korea and Indonesia to be exported to Belgium. These feedstocks will later be tested on the pilot scale eLECTRO setup to prove the replicability and economic viability of the technology. The production of py-oil will be further optimised using a kinetic process model developed by Polimi and the use of specific catalysts developed by AUTH. On their side, VTT is developing a MODIX extruder at pilot-scale to allow extrusion pre-treatment of various challenging and heterogeneous MPW materials for pyrolysis. Finally, the plant dedicated to make this transformation of MPW into py-oil at large scale ran for the first time in January 2024.
To valorise the py-oil produced, eLECTRO worked on a methodology to simulate the pre-fractionation train using literature data of the detailed composition of a py-oil sample. Simulations with COILSIM1D for the obtained fraction were performed. Also, we performed steam cracking tests for methodology development with a kind of artificial feed and used filtration technologies to test influences on contaminations. A lab-scale cracking unit is currently being assembled and will soon enter its startup phase.
The py-oil needs to be converted electrically in an RDR. Models of this device are currently built to better understand its limitations and to enhance its productivity. RDR pilot redesign has been started with pre-study and feasibility phase. One pilot installation has been completed, which already exceeds the performances of conventional resistive heaters.
To anticipate the market release, we worked on the planification of the future electrical needs, on the performances to be reached using LCA and on the societal acceptance. The estimations showed that the electrical needs should be similar to the production of one nuclear power plant and that using only renewable energy will be too challenging. Alternative or hybrid solutions should be identified. The LCA has started with the inventory data collection as there is a lack of experimental models. Regarding the societal acceptance, internal interviews have been conducted and are being treated.
The eLECTRO project has started well with impressive progress made by all parties. The progress on the lower TRL is as expected substantial, among others via advanced characterization of feedstock and products, the development of new active materials and catalysts, etc.
In terms of technical impact, eLECTRO foresees to demonstrate fully electrified technologies at TRL 7 for the production of pyrolysis oil from MPW. Multiple 60 kta MPW units will be constructed with a py-oil production of 40 kta. The electrified steam cracking technology will result in the production of olefins and aromatics, and might save 200 Mta CO2 on its own (based on a 450 kta MPW plant). The developed concepts might enable the use of 100% renewable energy sources and should result in a GHG emissions reduction in the overall lifecycle of at least 60%.
The most impressive progress which has been achieved so far is the launch of the Pryme Rotterdam pilot plant (TRL 7) for the production of py-oil and the successful steam cracking tests with the Coolbrook’s RotoDynamic ReactorTM pilot at the Brightlands site. Related to the latter, the tests have validated the potential of RDR Technology to replace traditional fossil fuel-based cracker furnaces with electric RDR units in the petrochemical industry. Based on the positive results Coolbrook will continue the performance testing and optimization of the RotoDynamic Reactor Technology in 2024 and thereafter.
In terms of societal impacts, eLECTRO has observed that circular plastics economy is characterised by a number of cross-cutting issues that are evident in current policy debates and associated academic literature. However, in this complex context, it is unclear how to integrate whose and what type of cross-cutting issues in technology development to generate societal impact. The project coordinator is heavily involved in all these discussions and in particular with the concept of mass balance allocation and different scenario’s (fuel exempt, etc.)
This makes eLECTRO unique in acknowledging the complexity of achieving societal impacts. To address this complexity, it is developing a strategy for integrating cross-cutting issues into technology development. The strategy suggests that all actors involved in, and associated with eLECTRO and its technologies need to become aware of their responsibility to integrate cross-cutting issues into the technologies considered. Communication between all stakeholders is essential to make progress on this topic. By pursuing this strategy, eLECTRO creates lasting and transformative societal and socioeconomic impact.
In terms of technical impact, eLECTRO foresees to demonstrate fully electrified technologies at TRL 7 for the production of pyrolysis oil from MPW. Multiple 60 kta MPW units will be constructed with a py-oil production of 40 kta. The electrified steam cracking technology will result in the production of olefins and aromatics, and might save 200 Mta CO2 on its own (based on a 450 kta MPW plant). The developed concepts might enable the use of 100% renewable energy sources and should result in a GHG emissions reduction in the overall lifecycle of at least 60%.
The most impressive progress which has been achieved so far is the launch of the Pryme Rotterdam pilot plant (TRL 7) for the production of py-oil and the successful steam cracking tests with the Coolbrook’s RotoDynamic ReactorTM pilot at the Brightlands site. Related to the latter, the tests have validated the potential of RDR Technology to replace traditional fossil fuel-based cracker furnaces with electric RDR units in the petrochemical industry. Based on the positive results Coolbrook will continue the performance testing and optimization of the RotoDynamic Reactor Technology in 2024 and thereafter.
In terms of societal impacts, eLECTRO has observed that circular plastics economy is characterised by a number of cross-cutting issues that are evident in current policy debates and associated academic literature. However, in this complex context, it is unclear how to integrate whose and what type of cross-cutting issues in technology development to generate societal impact. The project coordinator is heavily involved in all these discussions and in particular with the concept of mass balance allocation and different scenario’s (fuel exempt, etc.)
This makes eLECTRO unique in acknowledging the complexity of achieving societal impacts. To address this complexity, it is developing a strategy for integrating cross-cutting issues into technology development. The strategy suggests that all actors involved in, and associated with eLECTRO and its technologies need to become aware of their responsibility to integrate cross-cutting issues into the technologies considered. Communication between all stakeholders is essential to make progress on this topic. By pursuing this strategy, eLECTRO creates lasting and transformative societal and socioeconomic impact.