Maya Ellison
Raw plastic is derived from natural, organic materials such as cellulose, coal, natural gas, salt, and crude oil. Crude oil and natural gas are the primary sources of man-made plastic due to their affordability compared to plant-based alternatives. The production of plastic begins with the distillation of crude oil in an oil refinery, separating the heavy oil into lighter components called fractions. One of these fractions, naphtha, is crucial for plastic production, as it can be converted into ethylene and propylene, the building blocks of plastic. While biobased plastics are derived from renewable sources such as carbohydrates, vegetable fats, and oils, the majority of plastic today is synthetic due to the ease of manufacturing with oil-based sources.
| Characteristics | Values |
|---|---|
| Raw materials | Crude oil, natural gas, coal, naphtha, cellulose, salt |
| Plastic type | Synthetic, biobased |
| Plastic production process | Polymerisation, polycondensation, distillation, cracking |
| Plastic production by-products | Ethane, propane, ethylene, propylene, olefins, aromatics, polymers |
| Plastic production energy consumption | 1 litre PET bottle = 2 litres water, 4 million joules energy |
| Plastic production CO2 emissions | 1 ton plastic = 3 tons CO2 |
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What You'll Learn
Crude oil and natural gas
Naphtha is a volatile mixture of liquid hydrocarbons obtained by the distillation of crude oil. It is composed of hydrocarbons ranging from C5 to C10. Naphtha is subjected to thermal decomposition at a high temperature of around 800°C in a steam cracker in the presence of water vapour. This process breaks it down into light hydrocarbons called olefins (including ethylene and propylene) and aromatics (including benzene, toluene, and xylene). These small molecules are then linked together into long molecular chains called polymers, which are the raw material for oil-based plastics.
The process of converting crude oil into plastic involves a chemical reaction that creates ethane and propane, two organic gases that are the "building blocks" of plastic. This usually takes place in refineries. The ethane and propane are then broken down into smaller molecules during the "cracking" phase, turning into ethylene and propylene, respectively.
The petrochemical industry uses natural gas and naphtha from oil refining operations as its primary raw materials. Natural gas is also a significant feedstock for plastic production in North America. The expansion of shale drilling in the United States has increased the production of crude oil and natural gas, which is expected to lead to a surge in plastic production.
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Coal
Plastic is derived from natural, organic materials such as cellulose, coal, natural gas, salt, and crude oil. While crude oil and natural gas are the most common sources of synthetic plastics, coal is also a significant raw material in the production process.
The use of coal in plastic production has come under scrutiny due to its environmental impact. Studies have shown that the carbon footprint of plastics has doubled since 1995, with coal-based emissions for plastic production quadrupling during that period. This has led to concerns about the growing environmental footprint of plastics driven by coal combustion.
While coal plays a significant role in plastic production, there is a growing interest in using more sustainable and renewable raw materials. These include biomass sources such as corn, sugarcane, and soybeans, which can be converted into bio-based plastics through processes like fermentation and polymerization. Additionally, initiatives like the Circular Plastics Alliance in Europe aim to increase the use of recycled plastics and promote a circular economy for plastics.
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Carbohydrates, starch, vegetable fats and oils
Plastic is either synthetic or biobased. Synthetic plastics are derived from crude oil, natural gas, or coal. In contrast, biobased plastics come from renewable sources, including carbohydrates, starch, vegetable fats and oils, bacteria, and other biological substances.
Carbohydrates
Carbohydrates are a renewable source of biobased plastics. They can be derived from polysaccharides, such as corn starch or rice starch, and sugars from sugar cane.
Starch
Starch is another key renewable resource for biobased plastics. It is cheap, abundant, and renewable. Starch-based bioplastics are often blended with biodegradable polyesters to produce starch/polylactic acid, starch/polycaprolactone, or starch/Ecoflex blends. These blends are used for industrial applications and are compostable. Starch-based films, made mainly from thermoplastic polyesters, are used for packaging, such as magazine wrappings, bubble films, and food packaging.
Vegetable Fats and Oils
Vegetable fats and oils are lipids that can be derived from plants or animals and used as a source of biobased plastics.
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Bacteria and other biological substances
While most plastics are derived from natural, organic materials such as cellulose, coal, natural gas, salt, and crude oil, biobased plastics are made from renewable products like carbohydrates, starch, vegetable fats and oils, bacteria, and other biological substances.
Scientists have been studying the inner workings of bacteria for a long time, as they are very easy to grow and control. In recent years, they have reached a point where bacteria can be manipulated genetically and metabolically to change what they consume and produce. For instance, researchers at Harvard University have been experimenting with microbe-based plastics since 2017. They have engineered microbes that consume carbon dioxide produced by the burning of fossil fuels and hydrogen gas, and use them to produce a class of biodegradable fatty acid polymers. These polymers are then purified and used to manufacture a wide range of biodegradable products, leaving a much smaller environmental footprint than plant-based bioplastics.
Another example of bacteria-based plastic production is the discovery of a species of bacteria called Ideonella sakaiensis, which has developed a taste for a certain type of plastic called polyethylene terephthalate (PET). Following this discovery, many genetic scientists have experimented with Ideonella sakaiensis to improve its efficiency in breaking down plastics. For instance, researchers at the University of Portsmouth have re-engineered a plastic-eating enzyme called PETase to break down plastic bottles in days, rather than months. This enzyme was then combined with another similar enzyme, MHETase, to form a 'super-enzyme' that can digest plastic up to six times faster than normal.
While these developments in bacteria-based plastic production and plastic waste management are promising, there are still some drawbacks. For example, the amount of plastic waste produced globally is immense, and it would be challenging to produce enough bacteria to digest all the plastic waste that is already present in the environment, let alone the new plastic waste that is continuously being generated. Additionally, bacteria digest plastic very slowly, and the process of heating the bacteria to accelerate their digestion of plastic can be costly and environmentally detrimental.
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Shale drilling
Plastic is derived from natural, organic materials such as cellulose, coal, natural gas, salt, and crude oil. Crude oil is a complex mixture of thousands of compounds and needs to be processed before it can be used. The production of plastics begins with the distillation of crude oil in an oil refinery, which separates the heavy crude oil into groups of lighter components called fractions. Each fraction is a mixture of hydrocarbon chains that differ in terms of the size and structure of their molecules. One of these fractions, naphtha, is a vital compound for plastic production.
The increased availability of crude oil and natural gas from shale drilling has significant implications for the plastics industry. The distillation of crude oil yields various fractions, including naphtha, which is a vital feedstock for petrochemical crackers that produce the basic building blocks for plastics. These crackers break down the complex hydrocarbons into simpler molecules through high temperatures and pressure, without the use of a catalyst. The resulting molecules, such as ethylene and propylene, are then used to create polymers, which are the core ingredients of plastic products.
The use of shale drilling to extract crude oil and natural gas for plastic production highlights the complex interplay between resource extraction and environmental sustainability. While shale drilling can provide a domestic source of raw materials for the plastics industry, it also contributes to carbon emissions and poses risks to the environment and surrounding communities. As the demand for plastics continues to grow, it is essential to consider the impact of extraction methods and the need for more sustainable practices in the industry.
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Frequently asked questions
Raw plastic is derived from natural, organic materials such as cellulose, coal, natural gas, salt, and crude oil.
The process of making plastic involves the distillation of crude oil in an oil refinery, separating it into lighter components called fractions. One of these fractions, naphtha, is crucial for plastic production. Through polymerisation or polycondensation, these fractions are converted into hydrocarbons, which are then turned into chemicals used to make plastic.
There are two main types of plastic: synthetic plastics and biobased plastics. Synthetic plastics are derived from crude oil, natural gas, or coal, while biobased plastics come from renewable sources such as carbohydrates, starch, vegetable fats and oils, bacteria, and other biological substances.
