Scaling Pyrolysis: The Influence of Facility Size and Substitution Ratios – Nov 2023

Introduction
In our journey through the transformative world of pyrolysis, we’ve uncovered how this advanced recycling method can revolutionise how we approach plastic waste. Now, let’s delve deeper into the significance of facility size and the intricate dance of substitution ratios that play pivotal roles in the efficacy of pyrolysis.

Pioneer vs. Nth Facilities
Facilities pioneering in pyrolysis are typically smaller, with a capacity of less than 50,000 tons/year. These trailblazers are crucial for innovation but face challenges in scaling up while maintaining low GHG emissions. On the other end of the spectrum, ‘Nth’ facilities—larger plants with capacities exceeding 50,000 tons/year—benefit from economies of scale, achieving lower GHG emissions and setting the standard for industrial pyrolysis operations.

The Logistics of Feedstock for Large Facilities
Securing feedstock for large facilities is no minor feat. Considering that a single item of flexible packaging might weigh as little as 5 grams, the sheer volume required for a facility processing over 50,000 tons annually is immense. The logistical challenges of gathering and transporting this feedstock are not just a matter of scale, but also of environmental impact.

Localised Solutions and Their Advantages
At Enval, the philosophy is one of localisation. By deploying smaller-scale units near where waste is collected, we can tap into existing waste streams, reducing the need to transport waste over long distances. This approach is exemplified by our first commercial-scale plant, strategically located on a landfill site in Mexico operated by our parent company, Greenback Recycling Technologies

With our plant positioned directly at the landfill, we have the unique advantage of immediate access to feedstock. This innovative setup allows us to process 3000 metric tonnes of flexible plastic waste annually, which would otherwise contribute to the growing mass of landfills. It’s a pioneering step towards a closed-loop system, one that not only recycles waste but does so in a manner that curtails the environmental toll of waste transportation.

Substitution Ratios and Their Impact
The substitution ratio is the percentage of pyrolysis oil used to replace traditional fossil fuels in the production of plastics. A modest 5% ratio can skirt the need for hydrotreatment, a process that removes contaminants and adds to GHG emissions. However, at a 20% substitution, hydrotreatment becomes necessary to protect equipment, impacting the overall GHG savings.

Conclusion
The scale of pyrolysis operations and the chosen substitution ratios are critical factors that determine the environmental footprint of this innovative recycling process. As we look towards the future, these considerations will guide the industry in shaping a greener, more sustainable approach to plastic production. In the next installment, we’ll explore the diverse perspectives of recyclers and producers and the broader implications for the global supply chain.