All project objectives were achieved. The waste plastic raw materials were fully characterised macro and microscopically, and the pre-treatment operations were designed. The waste plastic mixture was optimised and selected to achieve high liquid yields with an adapted molecular composition. Thermal and catalytic pyrolysis tests were carried out in different reactors resulting in high liquid yields and thus maximising the content of the products. The suitability of the membranes was tested using a model mixture representing the mixture that could be obtained after pyrolysis or alkylation. Alkylation, aromatisation, and oxycombustion tests were out at lab-scale. The integration of the pre-treatment line and the solid extraction unit with the pyrolyser, the modifications of the catalytic reactor to the aromatization process and the installation of a bench-scale distillation unit were carried out. Pyrolysis tests were performed under different conditions to investigate their effect on the reaction rate, product distribution, and product quality. A pilot-scale aromatization test was conducted using the light fraction distilled from the pyrolysis liquids produced under optimal conditions and an industrial zeolitic catalyst based on ZSM-5. The steady state model of the entire iCAREPLAST process was completed. The LCA models were completed to assess environmental sustainability and LCC to include cost parameters. Market and techno-economic analyses of linear alkylbenzenes production and commercialization of BTXs, CO2 and char were carried out.
Communication and dissemination efforts included presentations at events, conferences, and fairs, as well as scientific publications. Training activities engaged students at various academic levels. iCAREPLAST is positioned within the future plastic circularity landscape, with the Project Coordinator playing a leading role in the Plastics Circularity Multiplier group.
Developed an exploitation plan to assess iCAREPLAST technologies' economic potential and market uptake. Key factors include a production capacity of 12,000,000 kg/year, a €25,000,000 investment, inflation rates, a 15-year analysis period, material and energy balance based on experiments and modelling optimization, and by-product sales (e.g. €1/kg from aromatics). The results indicate potential revenue streams and project profitability, considering these factors and market prices for generated by-products.
iCAREPLAST significantly contributes to CO2 emission reduction. The treatment of mixed plastic waste resulted in a positive impact of -0.3 kg CO2-Eq. This is achieved by substituting secondary products for those produced from virgin fossil fuels. The project included a TRL5 unit that allowed for the capture and energy valorisation of fuel-gas streams at various process points through oxycombustion, which increased the overall energy efficiency. Analyses developed revealed that energy efficiency could be improved by more than 93% compared to current recycling processes.
