Limited utilization options for secondary plastics may restrict their circularity

Tracing fossil-based plastics, chemicals and fertilizers production in China

Phasing down fossil fuels is crucial for climate mitigation. Even though 80-90% of fossil fuels are used to provide energy, their use as feedstock to produce plastics, fertilizers, and chemicals, is associated with substantial CO2 emissions. However, our understanding of hard-to-abate chemical production remains limited. Here we developed a chemical process-based material flow model to investigate the non-energy use of fossil fuels and CO2 emissions in China. Results show in 2017, the chemical industry used 0.18 Gt of coal, 88.8 Mt of crude oil, and 12.9 Mt of natural gas as feedstock, constituting 5%, 15%, and 7% of China's respective total use. Coal-fed production of methanol, ammonia, and PVCs contributes to 0.27 Gt CO2 emissions ( ~ 3% of China's emissions). As China seeks to balance high CO2 emissions of coal-fed production with import dependence on oil and gas, improving energy efficiency and coupling green hydrogen emerges as attractive alternatives for decarbonization.

A US perspective on closing the carbon cycle to defossilize difficult-to-electrify segments of our economy

Electrification to reduce or eliminate greenhouse gas emissions is essential to mitigate climate change. However, a substantial portion of our manufacturing and transportation infrastructure will be difficult to electrify and/or will continue to use carbon as a key component, including areas in aviation, heavy-duty and marine transportation, and the chemical industry. In this Roadmap, we explore how multidisciplinary approaches will enable us to close the carbon cycle and create a circular economy by defossilizing these difficult-to-electrify areas and those that will continue to need carbon. We discuss two approaches for this: developing carbon alternatives and improving our ability to reuse carbon, enabled by separations. Furthermore, we posit that co-design and use-driven fundamental science are essential to reach aggressive greenhouse gas reduction targets.

Waste LCA and the future

Life cycle assessment (LCA) models quantifying the environmental aspects of waste management have become an integral part of waste management decision-making over the last two decades and have provided ample knowledge on both environmental benefits and drawbacks in the way we handle waste. Waste management and LCA modelling of waste management systems will soon be challenged by profound changes necessary in our societies and sectors to meet sustainable development goals. Foreseen changes in energy, material, and nutrient provision will directly and indirectly affect waste management in terms of its operation and goals. This study reflects on anticipated changes in society and industrial sectors and how these changes may affect waste management and LCA modelling of waste management systems in terms of waste input, the modelling of technologies and systems and exchanges of energy, materials, and nutrients, as well as how it may affect impact assessment and the interpretation of results. The study provides practical recommendations for LCA modelling of future waste management systems, which will hopefully lead to robust assessments that can support decision-making in an evolving society subject to great changes.

Legacy and Emerging Plasticizers and Stabilizers in PVC Floorings and Implications for Recycling

Hazardous chemicals in building and construction plastics can lead to health risks due to indoor exposure and may contaminate recycled materials. We systematically sampled new polyvinyl chloride floorings on the Swiss market (n = 151). We performed elemental analysis by X-ray fluorescence, targeted and suspect gas chromatography-mass spectrometry analysis of ortho-phthalates and alternative plasticizers, and bioassay tests for cytotoxicity and oxidative stress, and endocrine, mutagenic, and genotoxic activities (for selected samples). Surprisingly, 16% of the samples contained regulated chemicals above 0.1 wt %, mainly lead and bis(2-ethylhexyl) phthalate (DEHP). Their presence is likely related to the use of recycled PVC in new flooring, highlighting that uncontrolled recycling can delay the phase-out of hazardous chemicals. Besides DEHP, 29% of the samples contained other ortho-phthalates (mainly diisononyl and diisodecyl phthalates, DiNP and DiDP) above 0.1 wt %, and 17% of the samples indicated a potential to cause biological effects. Considering some overlap between these groups, they together make up an additional 35% of the samples of potential concern. Moreover, both suspect screening and bioassay results indicate the presence of additional potentially hazardous substances. Overall, our study highlights the urgent need to accelerate the phase-out of hazardous substances, increase the transparency of chemical compositions in plastics to protect human and ecosystem health, and enable the transition to a safe and sustainable circular economy.

Phase Morphology and Mechanical Properties of Super-Tough PLLA/TPE/EMA-GMA Ternary Blends

The inherent brittleness of poly(lactic acid) (PLA) limits its use in a wider range of applications that require plastic deformation at higher stress levels. To overcome this, a series of poly(l-lactic acid) (PLLA)/biodegradable thermoplastic polyester elastomer (TPE) blends and their ternary blends with an ethylene-methyl acrylate-glycidyl methacrylate (EMA-GMA) copolymer as a compatibilizer were prepared via melt blending to improve the poor impact strength and low ductility of PLAs. The thermal behavior, crystallinity, and miscibility of the binary and ternary blends were analyzed by differential scanning calorimetry (DSC). Tensile tests revealed a brittle-ductile transition when the binary PLLA/20TPE blend was compatibilized by 8.6 wt. % EMA-GMA, and the elongation at break increased from 10.9% to 227%. The "super tough" behavior of the PLLA/30TPE/12.9EMA-GMA ternary blend with the incomplete break and notched impact strength of 89.2 kJ∙m-2 was observed at an ambient temperature (23 °C). In addition, unnotched PLLA/40TPE samples showed a tremendous improvement in crack initiation resistance at sub-zero test conditions (-40 °C) with an impact strength of 178.1 kJ∙m-2. Morphological observation by scanning electron microscopy (SEM) indicates that EMA-GMA is preferentially located at the PLLA/TPE interphase, where it is partially incorporated into the matrix and partially encapsulates the TPE. The excellent combination of good interfacial adhesion, debonding cavitation, and subsequent matrix shear yielding worked synergistically with the phase transition from sea-island to co-continuous morphology to form an interesting super-toughening mechanism.

The role of chemical and solvent-based recycling within a sustainable circular economy for plastics

Chemical and solvent-based recycling of plastic waste may help overcome some of the challenges faced by predominantly applied mechanical recycling techniques. This study quantifies the environmental impacts of chemical and solvent-based recycling as a function of varying process parameters and product composition using life cycle assessment. Furthermore, potential benefits and impacts on a system level are determined. To that end, a high-resolution material flow analysis is conducted for the reference system of Switzerland, covering all main plastic types and applications. In a scenario for the year 2040, we employ environmentally beneficial mechanical recycling where possible and convey suitable remaining waste streams to chemical or solvent-based recycling processes. Applying chemical or solvent-based recycling as a complement to maximum mechanical recycling, instead of thermal treatment with energy recovery, may achieve a reduction in the climate change impact of the system ranging from less than 10 % to almost 40 %. For achieving high environmental benefits, proper process choice and configuration are crucial. Dissolution or depolymerization provide higher benefits relative to other chemical recycling processes, but can only treat certain waste streams and require prior sorting into plastic types. Pyrolysis and gasification appeared to only have the ability to achieve substantial benefits over incineration if their output products can substitute high-impact chemicals and provided that efficient heat transfer and recovery is warranted when implemented on a large scale. As industrial-scale plants for chemical or solvent-based plastic recycling are still lacking, the upscaling potential and the environmental benefits achievable in practice are highly uncertain today.

Polyolefin Recyclates for Rigid Packaging Applications: The Influence of Input Stream Composition on Recyclate Quality

In order to shift to a circular plastics economy, high quality recyclates are required to effectively substitute virgin materials. Current approaches to empirically quantify the substitutability for recyclates are mainly limited by the abundance of virgin material grades along with a lack of adequate application-specific property profiles. In contrast, this work aims for a holistic analysis of the substitution potential of polyolefin recyclates intended for rigid packaging applications. This approach is fundamentally based on the classification of virgin polyolefins into different application-specific sub-groups with defined property windows derived from supplier data sheets, which allows for a generalization within one polymer type without neglecting the various available material grades. Moreover, the findings should provide valuable information for improvements of quality-defining process steps along the value chain of mechanical recycling. Therefore, it is of great importance to correlate the input stream composition of the investigated recyclates with the obtained qualities. The investigation of the substitution potential for selected recyclates clearly highlights the necessity of functional recycling for enhanced quality levels, which especially affects the sorting step in the recycling value chain. This work illustrates that a homogeneous waste stream directly correlates with a high substitution potential. Thus, the development of economically viable sorting strategies which take the functionality of plastic waste products into account must be targeted in future research. Furthermore, the development of detailed application-specific property windows in a joint effort with manufacturers should be pursued, as it allows for a meaningful empirical quantification of the substitutability for recyclates obtained from mechanical recycling.

A high-resolution dynamic probabilistic material flow analysis of seven plastic polymers; A case study of Norway

Plastic pollution has long been identified as one of the biggest challenges of the 21st century. To tackle this problem, governments are setting stringent recycling targets to keep plastics in a closed loop. Yet, knowledge of the stocks and flows of plastic has not been well integrated into policies. This study presents a dynamic probabilistic economy-wide material flow analysis (MFA) of seven plastic polymers (HDPE, LDPE, PP, PS, PVC, EPS, and PET) in Norway from 2000 to 2050. A total of 40 individual product categories aggregated into nine industrial sectors were examined. An estimated 620 ± 23 kt or 114 kg/capita of these seven plastic polymers was put on the Norwegian market in 2020. Packaging products contributed to the largest share of plastic put on the market (∼40%). The accumulated in-use stock in 2020 was about 3400 ± 56 kt with ∼60% remaining in buildings and construction sector. In 2020, about 460 ± 22 kt of plastic waste was generated in Norway, with half originating from packaging. Although ∼50% of all plastic waste is collected separately from the waste stream, only around 25% is sorted for recycling. Overall, ∼50% of plastic waste is incinerated, ∼15% exported, and ∼10% landfilled. Under a business-as-usual scenario, the plastic put on the market, in-use stock, and waste generation will increase by 65%, 140%, and 90%, respectively by 2050. The outcomes of this work can be used as a guideline for other countries to establish the stocks and flows of plastic polymers from various industrial sectors which is needed for the implementation of necessary regulatory actions and circular strategies. The systematic classification of products suitable for recycling or be made of recyclate will facilitate the safe and sustainable recycling of plastic waste into new products, cap production, lower consumption, and prevent waste generation.

Net-zero transition of the global chemical industry with CO2-feedstock by 2050: feasible yet challenging

Carbon capture, utilization and storage (CCUS) have been projected by the power and industrial sectors to play a vital role towards net-zero greenhouse gas emissions. In this study, we aim to explore the feasibility of a global chemical industry that fully relies on CO₂ as its carbon source in 2050. We project the global annual CO₂ demand as chemical feedstock to be 2.2-3.1 gigatonnes (Gt), well within the possible range of supply (5.2-13.9 Gt) from the power, cement, steel, and kraft pulp sectors. Hence, feedstock availability is not a constraint factor for the transition towards a fully CO₂-based chemical industry on the global basis, with the exception of few regions that could face local supply shortages, such as the Middle East. We further conduct life cycle assessment to examine the environmental benefits on climate change and the trade-offs of particulate matter-related health impacts induced by carbon capture. We conclude that CO₂ captured from solid biomass-fired power plants and kraft pulp mills in Europe would have the least environmental and health impacts, and that India and China should prioritize low-impact regional electricity supply before a large-scale deployment of CCUS. Finally, two bottom-up case studies of China and the Middle East illustrate how the total regional environmental and health impacts from carbon capture can be minimized by optimizing its supply sources and transport, requiring cross-sectoral cooperation and early planning of infrastructure. Overall, capture and utilization of unabatable industrial waste CO₂ as chemical feedstock can be a feasible way for the net-zero transition of the industry, while concerted efforts are yet needed to build up the carbon-capture-and-utilization value chain around the world.

Recycling of plastic wastes generated from COVID-19: A comprehensive illustration of type and properties of plastics with remedial options

Plastic has contributed enormously to the healthcare sector and towards public health safety during the COVID-19 pandemic. With the frequent usage of plastic-based personal protective equipment (PPEs) (including face masks, gloves, protective body suits, aprons, gowns, face shields, surgical masks, and goggles), by frontline health workers, there has been a tremendous increase in their manufacture and distribution. Different types of plastic polymers are used in the manufacture of this equipment, depending upon their usage. However, since a majority of these plastics are still single-use plastics (SUP), they are not at all eco-friendly and end up generating large quantities of plastic waste. The overview presents the various available and practiced methods in vogue for disposal cum treatment of these highly contaminated plastic wastes. Among the current methods of plastic waste disposal, incineration and land filling are the most common ones, but both these methods have their negative impacts on the environment. Alongside, numerous methods that can be used to sterilize them before any treatment have been discussed. There are several new sorting technologies, to help produce purer polymers that can be made to undergo thermal or chemical treatments. Microbial degradation is one such novel method that is under the spotlight currently and being studied extensively, because of its ecological advantages, cost-effectiveness, ease of use, and maintenance. In addition to the deliberations on the methods, strategies have been enumerated for combination of different methods, vis-à-vis studying the life cycle assessment towards a more circular economy in handling this menace to protect mankind.

Win-Win: Anthropogenic circularity for metal criticality and carbon neutrality

Resource depletion and environmental degradation have fueled a burgeoning discipline of anthropogenic circularity since the 2010s. It generally consists of waste reuse, remanufacturing, recycling, and recovery. Circular economy and "zero-waste" cities are sweeping the globe in their current practices to address the world's grand concerns linked to resources, the environment, and industry. Meanwhile, metal criticality and carbon neutrality, which have become increasingly popular in recent years, denote the material's feature and state, respectively. The goal of this article is to determine how circularity, criticality, and neutrality are related. Upscale anthropogenic circularity has the potential to expand the metal supply and, as a result, reduce metal criticality. China barely accomplished 15 % of its potential emission reduction by recycling iron, copper, and aluminum. Anthropogenic circularity has a lot of room to achieve a win-win objective, which is to reduce metal criticality while also achieving carbon neutrality in a near closed-loop cycle. Major barriers or challenges for conducting anthropogenic circularity are deriving from the inadequacy of life-cycle insight governance and the emergence of anthropogenic circularity discipline. Material flow analysis and life cycle assessment are the central methodologies to identify the hidden problems. Mineral processing and smelting, as well as end-of-life management, are indicated as critical priority areas for enhancing anthropogenic circularity.

ELECTRONIC SUPPLEMENTARY MATERIAL

Supplementary material is available in the online version of this article at 10.1007/s11783-023-1623-2 and is accessible for authorized users.

Quality of recycling: Urgent and undefined

Quality of recycling is a concept used by many authors in the scientific literature and the EU legislator. However, a clear definition of what is intended for quality of recycling and a framework for operationalising it is lacking. Most studies, while proposing indicators reflecting quality, leave the concept of quality largely undefined. Such lack of clarity is an obstacle to the conception of robust policies addressing recycling and circular economy. In this article, we review the available studies investigating on recycling quality, synthetize the approaches available and conclude suggesting a way forward for research to operationalise the definition to support circular economy policy measures and monitoring. Essentially, quality is not an on/off criterion. The definition of quality of recycling should consider that quality depends on technical characteristics of the recyclate, which determine if it is adequate (thus functional) for a certain end application or not. Furthermore, it should consider that the recyclate can be used in different end applications over different markets and that can be adequate for substitution of primary resources in certain applications, but less or not in others. At system-wide level, this results in a certain degree of virgin resource substitution. To this end, preserving functionality, i.e. minimising the recyclate loss of functions via functional recycling, is key. Drawing upon studies on waste management, life cycle assessment and resource dissipation, we link the concept of functionality to substitutability of virgin resources and broader suitability in the circular economy, striving to show the linkages between different perspectives.

A high-resolution dataset on the plastic material flows in Switzerland

A material flow analysis of the main plastic types used and arising as waste in Switzerland in 2017 is conducted, including consideration of stock change. Seven main plastic application segments are distinguished (packaging; building and construction; automotive; electrical and electronic equipment; agriculture; household items, furniture, leisure and others; and textiles), further divided into 54 product subsegments. For each segment, the most commonly used plastic types are considered, in total including eleven plastic types (HDPE, LDPE, PP, PET, PS, PVC, ABS, HIPS, PA, PC, and PUR). All product life cycle stages are regarded, including the determination of the product subsegments in which the individual post-consumer secondary materials obtained from mechanical recycling are applied. The underlying data are gathered from official statistics and administrative databases, scientific literature, reports by industry organizations and research institutions, websites, and personal communication with stakeholders. The compiled data are then reconciled. All flow data are provided and depicted in two Sankey diagrams: one diagram shows the material flows on a product-subsegment level and the second one on a plastic-type level. Users may retrieve the data with a script and transfer them into a relational database. The present material flow analysis data are used as a basis for the scenario analysis in Klotz et al. [1]. Besides scenario modelling, the data can be used in conducting life cycle assessments. Both utilizations can serve as a support for designing future plastic flow systems.