From plastic to oil: Brazil to receive a new chemical recycling plant
The ENESPA Group and FLUXO, its exclusive representative and distributor in the country, will supply a unique chemical recycling plant on skids to the Alberto Luiz Coimbra Institute of Postgraduate Studies and Engineering Research at the Federal University of Rio de Janeiro (COPPE/UFRJ).
The acquisition, supported by the Leopoldo Américo Miguez de Mello Research, Development and Innovation Center (CENPES/PETROBRAS), aims at scientific research and the development of sustainable technologies to transform plastic waste into high value-added products for the chemical and petrochemical industries.
With operations scheduled for the second half of this year, the installation of the KUBUS plant in a renowned institution such as COPPE represents a strategic step towards realizing ENESPA's vision of consolidating chemical recycling as a central pillar of the circular economy, in addition to mitigating the challenges associated with the inadequate disposal of plastic in the country, generating benefits for future generations.
ENESPA operates an identical plant in Tangstedt, Germany, to further advance the technology. According to Julian Dick, Project Manager at ENESPA, research is crucial to unlocking the full potential of chemical recycling. “With this plant, we are laying the foundations for further steps towards the development of the Circular Economy.”
Chemical and petrochemical engineers from both the national and international markets have reason to closely monitor this innovation, as it represents a significant milestone in the development of cleaner technologies and the effective implementation of the circular economy in industry. The modular nature of the skid-mounted plant makes it particularly interesting for other research institutes and laboratories in the chemical and petrochemical industries, facilitating the replication and adaptation of the technology to different contexts.
How the KUBUS Plant Works: Turning Plastic into Oil
KUBUS will be equipped with a shredder and a flare system for the thermal oxidation of non-condensable gases, ensuring the safety and efficiency of the process. With a processing capacity of up to one ton per day of polyolefin-based plastic waste, ENESPA’s innovative “plastic to oil” technology converts the material into high-quality pyrolysis oil (PPO).
To start the process, plastic waste, composed predominantly of Polyethylene (PE) and Polypropylene (PP), is compacted in an extruder. The molten material is then subjected to a pyrolysis reaction in a tubular reactor at controlled temperatures between 400°C and 500°C. The vapor resulting from pyrolysis is then liquefied in a two-stage condensation system, culminating in the production of pyrolysis oil. The non-condensable gases are discharged from the system in the form of pyrolysis gas with a high energy content, which, after treatment, can be used to generate energy and optimize plant efficiency.
Production of valuable raw materials from plastic waste
- Extrusion module: Thermal degradation of plastic waste in a hermetically sealed container;
- Pyrolytic reactor: Thermochemical decomposition in a controlled environment without oxygen;
- Residual discharge: Discharge of non-pyrolyzable elements;
- Condensation module: Transformation of pyrolysis vapors into pyrolytic oil (PPO).
“It’s a way to connect research, industry and sustainability. A virtuous cycle that starts in laboratories and can transform the way we deal with plastic waste in Brazil and around the world.”
Hideo Hama, president of FLUXO
Strategic partnership drives innovation and industrial development
FLUXO and COPPE have signed an agreement that provides for the availability of the plant for testing plastic samples provided by potential customers, in addition to the issuance of detailed technical reports, prepared by the university, assessing the technical and economic feasibility of implementing pyrolysis plants in their regions. For these customers, both FLUXO and ENESPA are interested in directing the pyrolysis oils produced to potential end users, fostering a new market for the recycled product.
Looking to the future: national production, environmental and social impact
In the future, the possibility of ENESPA equipment being manufactured by FLUXO in Brazil is being considered, which would allow access to financing through FINAME. This initiative will contribute significantly to ESG principles by strengthening the recycling value chain, promoting the inclusion of waste picker cooperatives, reducing environmental impacts associated with plastic disposal, and expanding economic opportunities linked to the commercialization of pyrolysis byproducts and the adoption of sustainable practices.
ENESPA – with a presence in Switzerland, Liechtenstein, Germany and the United States, the company is recognized for its innovative work in developing sustainable solutions for the Circular Economy. It designs, builds and operates cutting-edge technologies for the chemical recycling of plastic waste and the pyrolysis of tires, using pioneering methodology developed with the support of its own research laboratories.
COPPE - The Alberto Luiz Coimbra Institute of Graduate Studies and Research in Engineering is one of the leading centers of excellence in engineering in Latin America. Part of the Federal University of Rio de Janeiro (UFRJ) and with a strong emphasis on research and innovation, it works in close collaboration with industry, government and academic institutions in the development of technological solutions to society's challenges.
Author of the article
Ben Richters. ENESPA Technology Director
After completing his technical training and gaining initial professional experience in the automotive sector, Ben Richters began his training in mechanical engineering. As a graduate engineer, he began to focus on industrial engineering, especially in the petrochemical industry. In 2015, he became an entrepreneur in the circular economy sector based on green technology. In mid-2022, he joined ENESPA as a developer of its prototype pyrolysis plant.