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What is advanced recycling?

Advanced plastics recycling, also called chemical recycling, refers to several different technologies that convert post-use plastics into their original building blocks, specialty polymers, feedstocks for new plastics, fuels, waxes, and other valuable products.

By using advanced recycling to produce these outputs, we help preserve the plastics’ original value and conserve use of fossil-based resources.

Are there significant emissions or byproducts created during advanced recycling?

The processes used in advanced recycling of used plastics either use chemicals or thermal processes in the absence of oxygen so emissions from advanced recycling are generally considered very low.

While some manufacturing processes have the potential to result in environmental discharges, emissions from facilities that use a common advanced recycling technology (pyrolysis) were found to be typically lower compared to many industrial and commercial facilities, such as food manufacturing, hospitals, and universities. This same technology produces a non-hazardous byproduct that can be managed similarly to other solid waste, resulting in waste reduction of approximately 90 percent.

Are plastics burned during advanced recycling?

No. Advanced recycling technologies often use thermal energy (heat), but instead of combusting the plastics, their physical form is altered to form new chemicals, fuels and products. Advanced recycling is a manufacturing process: raw materials (used plastics) are processed to make new products (plastics, chemicals, fuels, etc.), like other manufacturing facilities.

What are the benefits of advanced recycling?

The environmental and economic opportunities of advanced recycling are enormous.

Advanced recycling can contribute significantly to a circular economy in which plastics are repurposed rather than disposed, which helps keep plastics out of the ocean/environment and harnesses their inherent value to create valuable new products. For example, making ultra-low sulfur diesel fuel from used plastics could decrease the consumption of water by 58 percent and the use of traditional energy sources by 96 percent, according to a 2017 study from Argonne National Laboratory.

In addition, advanced recycling can contribute to national and local economies, especially in areas with little or no existing infrastructure to manage and recycle waste. A recent report by Closed Loop Partners (CLP), an organization that invests in the development of the circular economy, found there is tremendous demand for the products of advanced recycling. (See more below under: Is advanced recycling economical?)

Is advanced recycling economical?

Many of the technologies used in advanced recycling already have been deployed economically in various industrial processes including the production of industrial waxes. Of course, regardless of the technology, collecting, sorting, and processing used plastics presents many challenges, similar to those inherent in mechanical recycling. However, given the broad range of outputs from advanced recycling, the markets for advanced recycling are expansive (see products/outputs and customers above), and recent research has demonstrated vast opportunities both at home and abroad.

For example, a 2019 report by the Closed Loop Partners (CLP), an organization that invests in the development of the circular economy, found there is tremendous demand for the products of advanced recycling. CLP: “Our analysis indicates that these technologies could meet an addressable market with potential revenue opportunities of $120 billion in the United States and Canada alone (emphasis added).” CLP identified 60 technology providers with significant potential for growth, along with 250 investors and strategic partners engaged with them and notes: “Technology providers are operating profitably with higher margins as they mature and scale.”

Is chemical recycling different than other terms such as advanced recycling and recovery?

The terms advanced recycling and recovery, transformational technologies, and chemical recycling, are interchangeable. All of these terms help differentiate advanced recycling from the more widely known recycling processes that use mechanical technologies to recycle used plastics.

How is advanced recycling different from traditional mechanical recycling?

Mechanical recycling typically uses technologies that retain the original physical form of used plastics; that is, the plastic material (resin) remains mostly the same during mechanical recycling. The used plastics typically are sorted, cleaned, shredded, melted, and then re-extruded into plastic pellets. These pellets are then used in new plastic packaging and other products.

Advanced recycling typically alters the physical form of used plastics, either by dissolving the plastic with chemicals or using heat to break down plastics into their original components. The results are plastics in a purified form or chemical products and feedstocks that are then used to create new plastics, fuels or other products.

Will advanced recycling replace mechanical recycling?

No. Mechanical and advanced recycling are complementary approaches that have different inputs and outputs. For example, mechanical recycling works well for specific resins and forms like bottles and containers, and is well-suited to produce plastics for new durable uses such as pipe, railroad ties and pallets. However, some plastics are difficult to sort and process mechanically. Plus it’s more challenging to use mechanically recycled plastics in food contact applications and packaging. Advanced recycling facilities also have the potential to adjust their outputs depending on fluctuations in market demand.

What is the role of traditional and advanced recycling in achieving a “circular economy?”

The term “circular economy” refers to an economic model in which materials are repurposed after use rather than disposed.

A circular economy differs from the prevailing economic model in which materials are largely disposed after use, which results in large amounts of valuable materials either buried in landfills or littering our ocean and landscape. In a sustainable, circular model, used plastics are recovered and repurposed rather than disposed… a model that not only helps keep plastics out of the environment but also harnesses their inherent value to create new products.

Both traditional and advanced recycling can contribute significantly to a circular economy by repurposing used plastics. Ongoing and emerging advances in mechanical recycling are capturing more types of post-use plastics, while advanced recycling is poised to capture primarily used plastics that are not widely recycled today. This combination will help achieve the America’s Plastic Makers’ goal of recycling and recovering 100 percent of used plastic packaging in the U.S. by 2040.

What types of products (outputs) are created from advanced recycling?

Advanced recycling of plastics can create multiple high value products, including new plastics (polymers); monomers for new plastics; naphtha for new plastics and chemicals; basic chemicals such as methanol that can be used for windshield wiper fluid and cleaning products; transportation fuels for aviation and automobiles; waxes for candles and crayons; and other products like synthetic crude oil.

Who are the customers for the products of advanced recycling?

Manufacturers of industrial and consumer products have the ability to use the products created from advanced recycling. Companies already purchasing the products of advanced recycling or have announced agreements to do so include: BP, Gatorade, H&M, L’Oréal, Procter & Gamble, PepsiCo, Unilever, and more. Both United and Delta airlines have announced ventures to produce fuels from used plastics. In addition, some chemical companies are integrating these products and processes into their manufacturing and supply chains, such as Americas Styrenics, BASF, Dow, Eastman, LyondellBasell, and SABIC.

What types of technologies are used to process plastics in advanced recycling?

There are three primary categories of advanced recycling technologies that process used plastics into new plastics and products.

  • Purification – Used plastic is dissolved in a solvent to remove additives, resulting in a purified near virgin plastic.
  • Decomposition/depolymerization – The molecular bonds of used plastic are broken, resulting in molecules (monomers) from which plastics are made.
  • Conversion – The molecular bonds of used plastic are broken and recombined, resulting in hydrocarbons and chemical feedstocks similar to products made by petroleum refining. 

What types of used plastics (inputs) are processed during advanced recycling?

Multiple types and mixes of plastics can undergo advanced recycling, including polyethylene terephthalate (packaging, clothing), polystyrene (packaging, insulation), polyethylene (packaging, films), polypropylene (packaging, pipes, textiles), electronics (cell phones, electronic hardware), and other mixed plastics.

What are some of the leading organizations engaged in advancing advanced recycling?

Leading companies working to scale advanced recycling have formed the Advanced Recycling Alliance for Plastics (ARAP). ARAP members include innovative companies engaged in the business of developing and commercializing advanced recycling technologies, plastic resin manufacturers, converters and brands converters collaborating to develop advanced recycling solutions, and other companies providing consulting services to the advanced recycling industry. The ARAP develops and advocates for public policy approaches that will more rapidly scale advanced recycling technology, educates the plastics value chain on the tremendous opportunities in advanced recycling, and educates key stakeholders and policymakers on the environmental and economic benefits of scaling and commercializing advanced recycling across the world.

How can I keep current on news, trends and happenings on advanced recycling?

Follow the Advanced Recycling Alliance for Plastics on Twitter @Adv_Recycling and join the conversation via the Advanced Recycling Alliance for Plastic LinkedIn page.

Are there other sources of good information on advanced recycling?

Yes. Growing advanced recycling to ensure more plastics are recycled and recovered is a high priority of America’s Plastics Makers and the Advanced Recycling Alliance for Plastics. Therefore, we work closely with Closed Loop Partners, the Sustainable Packaging Coalition, The Recycling Partnership, and the Association of Plastic Recyclers. We are also proud to have a cross-Atlantic alliance with Chemical Recycling Europe. All these organizations share our goal of reusing and repurposing post-use plastics into new plastics, chemicals, fuels and other products.

» Learn more about the Advanced Recycling Alliance for Plastics

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