Challenges and opportunities in molecular recycling of reversible polymers

Josse KunstKiduara B.V.9 November 2020

© Copyright Kiduara B.V.

All polymers are equal, but some polymers are more equal than others

Source: Plastics The Facts 2019

The chemical reaction to create polymers out of monomers is in some cases reversible (e.g. for polycondensation polymers).

Key examples of such reversible polymers are:

Polyester (PET)Polyamide 6 (PA6)Polylactic acid (PLA)

This makes them especially well placed to use molecular recycling to create a closed loop.

Let’s have look at some examples

Arizona

California

24 ML$ of investment32 ktons/year of existing carpets recycling capacity

USA is major producer and consumer of carpet worldwide.

US Carpets have high PA6 containing carpets, (avg. 36%)

Based on PP primary

Standards SBR type latex, high filler content, easy to separate

Existing collector systems

AQUAFIL CARPET RECYCLING UNITS – USA FIRST

SYNERGIES WITH EXISTING LOCAL COLLECTORS … TO SEPARATE THE 3 KEY CARPET COMPONENTS

#ACR

CLOSING THE LOOP

Carpet waste regeneration

* The list is not complete but is continuously updated feeded by the continuous data collection

Type and chemical family

of contaminant

Potential source Maximum

acceptable

Calcium Carbonate, CaCO3 Latex Filler 2,0 % max

AlOH3 flame retardant filler 0,2% max

Polyester types PET is used in tufting and backing layers of Carpet 4,0% max

Bitumen Used in backing layer of EU Carpets 1,0% max

Polyamides 6,6 and other PA NOT type 6,

including copoliamides Coming from not correct sorting of the Carpet 0,50%

PVC and other chlorinated compounds Carpet with PVC baking < 1 ppm

Phtalates Esters, 16 different compounds in SVHC Plasticizers for PVC and for other plastic materials 0,1-0,2% max

Polycyclic Aromatic Hydrocarbons Bad quality of the selected Bitumen in backing tiles 0,01%

Perfluorinated and Polyfluorinated chemicals (PCFs) Water, oil and stain repellent and soil release <10 ppm

Heavy metals: Cr (VI), Pb, Ni, Cd, Cu Pigments, stabilizers, inorganic fillers Specific limit for each

Boron and its compounds used in the SBR latex <0,1%

Antimony ( Sb ) and its compounds PET Preliminary backing or in Backing in tiles <0,01%

Azo-Dyes; Disperse dyes; <0,05%

Flame retardants, like Bromo/Chorine compounds Possible use in the Lattex <0,025%

EXAMPLES OF PRODUCT INSIDE A CARPET

WHYPolyester is one of the most common plastics.Because they are colored or contaminated or contain additives,91% of all polyester products are not recycled.

The result: 64 billion kilograms of waste, year after year, contributing to the growing plastic waste mountain.

HOWWe CuRe any type of used polyester by removing the color and converting it into clear pellets with the sameproperties as virgin grade polyester.

WHATOur ground-breaking CuRe technology for polyester rejuvenation offers low energy recycling for all usedpolyester. Recovering polyester waste in a fully circular chain.

The ChallengePolyester Case – CuRe

Technology

Many ways to break down polyester, even more initiatives

Glycolysis

Methanolysis

BHET and/or oligomers

DMT

Hydrolysis MEG, PTA

Enzymatic MEG, PTA

Technology Output Many Initiatives

CuRe Consortium offers a one stop shop

SortingCollectionWashing, Shredding

Mechanical Recycling

RetailPolyester

Rejuvenation

Design4Recycling with rPET

Design4Recycling with polyester

specialties

Energy as early indicator for competitiveness

Comparison of Molecular Recycling Technologies

Technology Type of Feed CAPEX OPEX CO2

MechanicalTransparent

bottles++++ ++++ ++++

ODR, Food trays,

Textile, Carpet+++ +++ +++

++++ = Excellent

+++ = Good

++ = Fair

+ = Poor

Glycolysis ODR, Food trays, ++ ++ ++

Methanolysis ODR, Food trays, ++ + ++

Output

PET

PET

BHET

DMT

Initiatives

Many

DSM,

Morssinkhof,

Cumapol

Ioniqa, JE

Plan, Garbo

Loop

Flake to Resin Transparent flakes +++ +++ +++PET limited

HydrolysisODR, Food trays,

Textile+ + +

Source a/o K-PET @ GEPET 2019

MEG,

PTA

Enzymatic unclear + + +++MEG,

PTA

GR3N

Carbios

Molecular Recycling a very promising part of systemic change but lots of other actions are necessary as well

1. RETHINKThink different, think in systems, think in social innovation

2. REDESIGNModify design to increase, make it modular, use

renewable materials

3. REDUCEImprove efficiency of production process wrt materials

and energy

4. REUSEUse the product without modification again

5. REPAIRFix the product so it can continue to be used

6. REFURBISHRenovate and replace key parts so performance is like new

again

7. REMANUFACTUREUse old parts in manufacturing of new products

8. REPURPOSEUse product for a new purpose

9. RECYCLEProcess the materials so they can be reused

10. RECOVERRecover the energy stored in the materials

© Copyright KiduaraBV 2019

www.kiduara.com

Josse.kunst@kiduara.com+31-6-83642875