(112b) Commercial Pathways for Valorization of Plastics-Derived Oils into Light Olefins Production

Advanced plastics recycling plays a crucial role in tackling plastic pollution at scale and promoting a circular economy, particularly for mixed contaminated packaging polymers that are challenging for mechanical recycling. Challenges and limitations with existing technologies have prompted the exploration of alternative advanced recycling techniques to address the limitations of pyrolysis in creating a more sustainable and efficient plastic recycling landscape.

The unique properties of supercritical water make it a valuable reaction media for various chemical processes, offering advantages in terms of enhanced reaction rates, increased dissolution, selective reactions, minimization of catalysts and improved heat and mass transfer. In the context of plastics recycling, it facilitates superior processing of heterogeneous feedstocks and complex polymers, resulting in improved product yields and quality. These attributes can increase the efficiency and profitability of plastic recycling, by generating high-value products that can offset disadvantages of previous recycling technologies. Additionally, independent LCAs have demonstrated that the use of supercritical water results in class leading greenhouse gas (GHG) reduction and feedstock resource utilization amongst all plastics recycling technologies.

Integrating plastic-derived oils as co-feeds in ethylene plants offers a promising path to greater sustainability and circularity in light olefins and petrochemical production. However, this approach requires overcoming challenges related to process compatibility and product quality. Successful integration depends on careful feedstock selection, potential pretreatment of plastic oils, and continuous innovation to maximize the use of these renewable resources. By incorporating recycled materials, ethylene plants can reduce dependence on virgin fossil feedstocks, supporting environmental goals and advancing the circular economy by diverting plastic waste from landfills.

Economically, using recycled feedstocks can boost profitability by lowering raw material and waste management costs, while also helping companies meet evolving ESG standards aimed at reducing plastic pollution and promoting responsible resource use. KBR has developed a comprehensive solution that includes end-of-life plastic sorting, recycling, and treatment options that integrate seamlessly into existing ethylene plants. This vision empowers the petrochemical sector to play a critical role in advancing a circular economy, creating a beneficial synergy between innovation, economic growth, and environmental stewardship, and contributing to a more sustainable future.