Breaking new ground in the circular economy with plastic waste as a source of raw materials

BASF is breaking new ground in plastic waste recycling with its ChemCycling project. Chemical recycling provides an innovative way to reutilize plastic waste that is currently not recycled, such as mixed or uncleaned plastics. Depending on the region, such waste is usually sent to landfill or burned with energy recovery. But chemical recycling offers another alternative: Using thermochemical processes, these plastics can be utilized to produce syngas or oils. The resulting recycled raw materials can be used as inputs in BASF’s production, thereby partially replacing fossil resources.

BASF has for the first time manufactured products based on chemically recycled plastic waste and is thus one of the global pioneers in the industry. “A responsible use of plastics is crucial to solve the world’s waste problem. This applies to companies as well as to institutions and consumers. With chemical recycling we want to make a significant contribution in reducing the amount of plastic waste,” said Dr. Martin Brudermüller, Chairman of the Board of Executive Directors and Chief Technology Officer (CTO) of BASF SE. “With our ChemCycling project, we are using plastic waste as a resource. In this way, we create value for the environment, society and the economy. We have joined forces with partners throughout the value chain to establish a working circular model,” said Brudermüller. BASF is collaborating closely with its customers and partners, which range from waste management companies to technology providers and packaging producers, to build a circular value chain.

From waste to cheese packaging and fridge components

BASF is already developing pilot products, including mozzarella packaging, refrigerator components and insulation panels, with 10 customers from various industries. Manufacturing products that meet high quality and hygiene standards – which are specifically required for food packaging for example – is possible because the ChemCycling products supplied by BASF have exactly the same properties as products made from fossil resources. Stefan Gräter, head of the ChemCycling project at BASF, sees great potential: “This new way of recycling offers opportunities for innovative business models for us and our customers, who already place great value on products and packaging made from recycled materials but who cannot or do not want to make any compromises when it comes to quality.” As a next step, BASF plans to make the first products from the ChemCycling project commercially available.

BASF Verbund offers ideal conditions for ChemCycling

At the beginning of the production chain, BASF feeds oil derived from plastic waste by an oiling process into the Production Verbund. BASF gets this feedstock for the pilot products from the partner Recenso GmbH, Germany. As an alternative, syngas made from plastic waste can also be used. The first batch of this oil was fed into the steam cracker at BASF’s site in Ludwigshafen in October. The steam cracker is the starting point for Verbund production. It breaks down or “cracks” this raw material at temperatures of around 850 degrees Celsius. The primary outputs of the process are ethylene and propylene. These basic chemicals are used in the Verbund to make numerous chemical products. Under the mass balance approach, the share of recycled raw material can be mathematically allocated to the final certified product. Each customer can select the allocated percentage of recycled material.

Technological and regulatory challenges

Both the market and society expect industry to come up with constructive solutions to deal with plastic waste. Chemical recycling is an innovative complement to other recycling and waste management processes. “We need a wide range of recovery options for plastic waste, since not every solution is suitable for each type of waste or possible for each product application. The first choice should always be the solution that performs best in a life cycle assessment,” explained Andreas Kicherer, sustainability expert at BASF.

However, technological and regulatory conditions must be met before the project is market-ready. For one thing, the existing technologies to transform plastic waste into recycled raw materials such as pyrolysis oil or syngas must be further developed and adapted so that consistently high quality is assured. Furthermore, regional regulatory frameworks will considerably influence to what extent this approach can be established in each market. For example, it is essential that chemical recycling and the mass balance approach are recognized as contributing to the fulfillment of product and application-specific recycling targets.

Responsible handling of plastic waste is crucial

Plastics offer many benefits in technical applications, medicine and everyday life and they are often a better alternative to other materials. The challenge lies in responsibly managing post-consumer plastics. Functioning waste management systems and responsible consumer behavior with regard to plastics are crucial to solving problems such as pollution from plastic litter. To this end, BASF is involved in various projects at the association level and internationally. For example, the company is member of the World Plastics Council and participates in two programs of the Ellen MacArthur Foundation. Furthermore, BASF has implemented Operation Clean Sweep®, an international initiative of the plastics industry to prevent the loss of plastic pellets, flakes and powder in the environment. BASF’s new ChemCycling project is another milestone in the responsible use of resources and an example of how BASF is specifically addressing global challenges while also helping its customers to reach their goals.

Further information about ChemCycling can be found on the company’s website.

About BASF

At BASF, we create chemistry for a sustainable future. We combine economic success with environmental protection and social responsibility. The more than 115,000 employees in the BASF Group work on contributing to the success of our customers in nearly all sectors and almost every country in the world. Our portfolio is organized into four segments: Chemicals, Performance Products, Functional Materials & Solutions and Agricultural Solutions. BASF generated sales of more than €60 billion in 2017. BASF shares are traded on the stock exchanges in Frankfurt (BAS), London (BFA) and Zurich (BAS). Further information at www.basf.com.

The first publicly available electric charging station was presented on 19 May in Tiszaújváros, by courtesy of ALTEO. At the station, two vehicles can be charged at a time, up to 22 kW per hour. It is a milestone for the city as well as for ALTEO: it is the first electric charging station at ALTEO’s portfolio.

ALTEO’s (listed at the Budapest Stock Exchange’s Premium category) environmentally conscious activity is based on the utilization of renewable energy sources. It has now expanded its portfolio with the electric charging station in Tiszaújváros. It is the city’s first charging station, accessible by everyone, 24 hours a day. The city itself, however, is not unknown for the company group: ALTEO has been operating several power plants in Tiszaújváros for years: its 29 power plant portfolio also includes the heating power plant operating in Tiszaújváros.

The station has two charging points, allowing two vehicles to be charged at the same time. The full charge takes about 2-5 hours, and the charging power can reach 22 kW per charging point, depending on the vehicle. By installing the station ALTEO could contribute to an important step towards sustainable and environmentally friendly transportation in Tiszaújváros.

ALTEO launched a carbon footprint neutralization initiative at the end of last year which has been completed by now. This spring a total of 28 fruit trees were planted by the company in the gardens of various educational institutions with the purpose to neutralize the amount of carbon dioxide emitted at the company’s Christmas event. 

ALTEO decided last year to neutralize the carbon footprint of the company’s Christmas event by planting as many trees as necessary to absorb the emitted carbon dioxide. Data showed that the company’s total footprint was 3,18 tonnes with a significant proportion – 65 % – of food and drinks consumed, followed by 32% of CO2 emission from travels. The on-site energy consumption can be accounted for only 2% of the total carbon footprint and the organization for 1%. According to the calculations – carried out by GreenDependent Association – 3.18 tonnes of carbon dioxide could be neutralized by planting a total of 28 native fruit trees.

The trees will be able to absorb the emitted carbon dioxide in about 20 years. The plantations took place in the spring of 2019 with the assistance of the Hungarian Foundation for School Gardens.

Unilever has signed a ‘plastic pact’ in the Netherlands and by that committed to reduce the plastic waste even beyond its sustainability targets. Dutch companies, NGOs and the government want to move faster than the rest of Europe. By 2025, we want all single-use products and packaging to be 100 percent recyclable. In addition, we use 20 percent less plastic by 2025 than in 1997. The new plastics strategy of Unilever already focuses on ‘better plastic, less plastic and no plastic’.

In Davos at the World Economic Forum Unilever unveiled reusable packaging innovations across nine of its brands, including four new product formats. The new products will be trialled on Loop™, a global, first-of-its-kind, waste-free shopping system that will scale the reuse models and shift consumer behaviour to help make circular packaging systems commercially viable.

Among the innovations there are refillable deodorant stick called minim. Made from stainless steel, the design is minimal, compact and sustainable, offering a new consumer experience without any unnecessary materials. Dependent on usage, the product will last on average one month, with the packaging designed to last at least 100 cycles. This means that each pack is expected to last about eight years, with the potential to save up to 100 packs from being thrown away.

Oral care brand Signal unveiled a new product format with new refillable toothpaste tablets called Tooth Tabs. The innovation also enables consumers to brush their teeth using less water: simply chew, brush as usual, rinse and smile. Zero waste, zero hassle and with a huge benefit for the planet.

Alan Jope, CEO of Unilever said: “We want to put an end to the current “take-make-dispose” culture and are committed to taking big steps towards designing our products for re-use. We’re proud to be a founding partner of Loop, which will deliver our much-loved brands in packaging which is truly circular by design.”