Six things to know before launching an advanced recycling project

By breaking down these materials into their basic molecular components, these technologies make it possible to convert waste into new base materials, reducing or eliminating the need for virgin feedstock. Implementation of advanced recycling processes should be approached with care. In some cases, the unit operations and design considerations are different than those common to refineries or petrochemical complexes. Additionally, the technology licensors are rarely in a position to fully understand how their process will be integrated into an existing chemical complex. The licensors are rightly focused on their core technology. For these projects to be successful, owners and licensors need the support of an engineering and construction partner that understands the nuances of technology integration.

Managing information voids and experience gaps

A project’s success can be negatively impacted by a lack of information and understanding. It is necessary to identify and understand project knowns and unknowns at an early stage to minimise change and churn as the project advances through a gated work process. This can be accomplished by using a structured knowledge transfer process. Such a process provides a holistic method for evaluating project requirements from core process technology to utility systems and material logistics. This article will outline a number of factors that are important to know before beginning an advanced recycling project.

Portions of advanced recycling processes need controlled environments

With some exceptions, many refining and petrochemical processes are well understood steady-state processes performed in outdoor settings. The location and climate of the facility can dictate nuances in design, but most major unit operations have had years of optimisation and refinement.

In contrast, some aspects of advanced recycling projects may be performed in controlled indoor environments. Feedstock receiving, storage and preparation should be kept dry and away from wind. Additionally, portions of the process can be sensitive to colder climates, so locating unit operations inside buildings can simplify piping, insulation and heat tracing requirements for the project. However, for processes that increase capacity by adding parallel equipment trains, more processing space under roof is needed, which complicates layout, maintenance access and expandability for the future.

These considerations add to design and construction costs and are not always included in the licensor’s cost estimates. They may also impact utility design requirements.

Material handling systems require customised designs

Hydrocarbon processors have deep experience with pumps, compressors, piping networks and other equipment needed to transport gases and liquids through a facility. These processors may be less familiar with the material handling systems associated with waste plastic feedstocks, intermediates and final products.

This article was originally published in the November 2023 issue of Hydrocarbon Engineering magazine. To read the full article, sign in or register for a free subscription.

Written by Chris Ploetz and Kevin Syphard, Burns & McDonnell, USA.

Read the article online at: https://www.hydrocarbonengineering.com/special-reports/27112023/six-things-to-know-before-launching-an-advanced-recycling-project/