Maya Ellison
Converting plastic back into oil is an innovative way to address the global plastic waste problem while also harnessing the energy stored within plastic. This process involves using machines that employ temperature-controlled electric heaters to transform plastic into crude gas, which can then be refined into oil. One such machine, developed by Japanese company Blest, is small yet efficient, producing nearly one liter of oil from every kilogram of plastic. Similarly, a machine developed by Adrian Griffiths in the UK can recycle plastic into oil in under a second. These advancements in technology offer a promising solution to the environmental concerns surrounding plastic waste.
| Characteristics | Values |
|---|---|
| Process | Pyrolysis, HiCOP, anhydrous pyrolysis, thermal cracking, chemical recycling, mechanical recycling |
| Temperature | Above 350 degrees Celsius |
| Energy efficiency | Not energy efficient, but more energy efficient than recycling or burning plastic waste |
| Emissions | Fewer emissions than incinerating plastics |
| Feedstock | Plastic containers, bottles, bags, waste plastic |
| Output | Oil, diesel, kerosene, gasoline, naphtha, wax |
| Cost | $50-60 per barrel |
| Environmental impact | Reduced waste, reduced pollution, reduced dependence on foreign oil sources |
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What You'll Learn
Pyrolysis machines
The plastic-to-oil conversion process involves placing plastic waste into a large bucket inside the machine, where the temperature slowly rises to melt the plastic and turn it into a gas. This gas then passes through a tube into a water-filled container, where it cools and forms oil. Pyrolysis machines can produce a liquid oil with a high heating value resembling conventional diesel. This product can be used to power vehicles and machinery when refined and blended with conventional fuels.
One such pyrolysis machine is the Blest Machine, invented by scientist Akinori Ito. The machine can turn one kilogram of plastic waste into one litre of oil and is claimed to have little byproduct, such as CO2 emissions. However, there are some unanswered questions regarding the extent of its reduced CO2 emissions and what happens to discarded chemical compounds during the conversion process.
Another example of a pyrolysis machine is the BLL-30 model, which can reduce 4,380 to 5,840 tons of waste plastic annually. This machine also captures and reuses the gases generated, minimising emissions and reducing the carbon footprint associated with traditional plastic disposal methods.
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Mechanical recycling
The mechanical recycling of plastic waste involves physically recycling the plastic through sorting, washing, and grinding. This approach requires the plastic waste to be clean and typically yields lower-quality products with a strong odour and unattractive colours. Mechanical recycling is the dominant method of plastic waste processing in Japan, accounting for 21% of the country's total plastic waste processing.
However, mechanical recycling has limitations. It can only process specific types of plastic, and the recycling process can be expensive due to the high costs associated with it. For example, recycling one metric ton of plastic bags costs $4,000. Additionally, the products resulting from mechanical recycling are often lower quality than the original plastic, with undesirable characteristics such as strong odours and unattractive colours.
Despite these challenges, mechanical recycling plays a significant role in Japan's plastic waste management, and there is potential for further development and improvement in this area. By optimizing the mechanical recycling process and addressing its limitations, it may be possible to increase the efficiency and effectiveness of plastic waste conversion, contributing to a more sustainable and environmentally friendly approach to plastic waste management.
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Chemical recycling
One example of chemical recycling is the process developed by Japanese company Blest, which has created a machine that converts several types of plastic into oil. The machine uses a temperature-controlled electric heater to convert plastic into crude gas, avoiding the generation of CO2 that occurs when plastic is burned. This crude gas can be used to power household appliances or refined further for use in vehicles.
Another example is the chemical recycling plant established by the Mitsubishi Chemical Group (MCG Group) in collaboration with ENEOS Corporation. This plant collects used plastics and uses chemical recycling to convert them into oil, which is then used as a raw material in ENEOS's oil refining facilities and the MCG Group's naphtha crackers. The MCG Group is also exploring the use of supercritical water to break down plastics into oil, which can be separated according to its boiling point.
The benefits of chemical recycling include its potential to reduce fossil fuel consumption, create a circular economy, and address the growing problem of plastic waste. However, one challenge is the large amount of energy required to induce the oil conversion reaction, as well as the need for efficient systems for collecting and sorting waste plastics.
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HiCOP method
The HiCOP method is a groundbreaking technology that converts plastic waste into valuable crude oil. It is a catalytic cracking method that uses catalysts already employed in petroleum refining to break down plastic molecules into smaller pieces, eventually converting them into hydrocarbon gases. These gases are then concentrated into crude oil.
The process was developed and patented by Kaoru Fujimoto, a professor emeritus at the University of Tokyo and the University of Kitakyushu, and Xiao-Hong Li, a professor at the University of Kitakyushu. The HiCOP method offers a faster decomposition process at lower temperatures than conventional thermal decomposition methods, resulting in high-quality hydrocarbon oil with less or no wax content. This enhanced fluidity of the oil is advantageous during winter, as it mitigates previous issues associated with petroleum solidification in storage tanks.
The environmental benefits of the HiCOP method are significant. It reduces carbon emissions associated with traditional plastic disposal methods and offers a viable alternative to fossil fuels. By converting plastic waste into crude oil, the HiCOP method reduces the burden on landfills and addresses the growing demand for sustainable energy sources. The oil produced through this method is abundant in gasoline and diesel, making it suitable for transportation, boilers, powering heavy machinery, and providing energy in remote areas.
Additionally, the HiCOP method has economic implications. It creates opportunities for industries to embrace green technology, driving innovation and job creation in the recycling sector. The oil produced through the HiCOP method contains abundant naphtha, a raw ingredient for plastic, further enhancing its economic value. The HiCOP-200 is the first commercially available waste plastic oil converter that utilizes this technology, with plans to begin operations in 2025.
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Environmental impact
Plastic waste pollution is a serious problem, with plastic production increasing and only a small percentage of the 400 million tonnes of plastic produced annually being recycled. Most of the plastic ends up in landfills, and the oceans suffer from extreme pollution, with the Pacific Ocean dubbed the "Great Pacific Garbage Patch".
The process of converting plastic back into oil can help to reduce the environmental impact of plastic waste. Recycling plastic reduces oil usage, CO2 emissions, and waste disposal. It also helps to address the problem of limited fossil fuel sources, as it provides an alternative source of energy.
The HiCOP method, developed by Japanese researchers, uses catalysts to break down plastic molecules into smaller pieces, eventually converting them into crude oil that is abundant in gasoline and diesel. This process produces no secondary pollution, as the residue is transformed into emulsified heavy oil, and the vent gas is recycled for electricity generation.
However, the main challenge with recycling plastic, including for the production of pyrolysis oil, is waste collection and transportation. Additionally, the cost of recycling plastic can be high, and the process of converting plastic into oil may be expensive and inefficient due to the limited types of plastic that can be recycled.
Overall, the environmental impact of converting plastic back into oil depends on various factors, such as the efficiency of the recycling process, the energy source used for the conversion, and the fate of the resulting crude oil. While it can help reduce plastic waste and provide an alternative to fossil fuels, the overall environmental impact also depends on the demand for and use of the resulting oil products.
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Frequently asked questions
Plastic can be converted back into oil using a temperature-controlled electric heater, which turns the plastic into crude gas. This crude gas can then be used to power gas-based household appliances or vehicles.
The machine created by Japanese company Blest converts plastic classes 2, 3, and 4 (polyethylene, polystyrene, and polypropylene) into oil.
Converting plastic waste into oil helps address the global plastic waste problem while harnessing the high energy value of plastic. The oil produced can be used to power appliances and vehicles, providing economic and environmental benefits.
Yes, there are several companies working on this technology. For example, Blest has installed over 60 machines in Japan and a handful abroad, and a UK startup is also testing a machine that converts plastic waste into oil.
