BlueAlp technology | Chemical Recycling | Pyrolysis

Gamechanger technology for plastic circularity

Making all plastic circular and sustainable

BlueAlp Technology has been developed to give all plastic waste a potentially infinite life as a new feedstock for future plastics and chemicals. Employing chemical-based conversion upcycling, it takes old plastic that cannot be recycled mechanically and gives it commercial value. This makes it economic to recycle every piece of plastic, and to do this over and over, endlessly.

Currently, burning old plastic sends an estimated 850 million metric tonnes of greenhouse gases into the atmosphere each year. The benefits of ending this alone would be huge, even before you factor in the amount that is dumped in landfills or which finds its way into our rivers and oceans.

Chemical upcycling will play an increasing role in overall plastic recycling.

Chemical recycling technologies are increasingly viewed as the gamechanger in the drive to decarbonize the way we live and move to a more sustainable and circular model. Traditional mechanical recycling is very effective with monostreams,

such as PET used in drinks bottles, that plastic must be clean, sorted, of high quality and of the correct type. Even then, the potential for recycling is limited as recycling degrades the plastic until it becomes unfit of its original purpose or unacceptable to the consumer.

Chemical upcycling of plastic feedstock

Chemical recycling benefits vs. mechanical recycling

Chemical recycling, more accurately known as upcycling, expands on mechanical recycling in a number of ways. It can be used to process more types of plastic. That plastic can be older and dirtier using BlueAlp Technology. These are important benefits towards less plastic pollution of our land and seas.

Of the three ways to chemically recycle plastic – dissolution, depolymerization and conversion – BlueAlp Technology is based on the last of these.

Our patent-protected technology heats and cracks the plastic feedstock in an oxygen-free heating process. The resulting raw material – a fossil-free oil – can be used make the new plastics and chemicals we require without extracting yet more virgin fossil fuels. In this way we can meet people’s needs while at the same time decarbonizing society and transforming plastic from a CO2 problem into a circularity solution.

Optimum quality and no overcracking

Within the field of advanced plastic recycling, BlueAlp Technology is increasingly recognized as the best and most efficient way to turn plastic waste into a new raw material. This is because we have made a number of changes to the conventional pyrolysis process. The key difference is the use of ‘slow-cracking’ or gradual heating to ensure each plastic is cracked at its optimum temperature.

This prevents the overcracking of the hydrocarbons and so optimizes output – both quantity and quality. The infographic below gives an overview of the key differences between traditional pyrolysis-based plastic recycling and the BlueAlp process.

7 reasons to choose the BlueAlp technology.

7. High safety

Highest oil and gas safety standards applied, enabling integration of the site on a chemical complex.

1. Wide range of plastics

Difficult to recycle waste consisting of wide mix of plastic feedstock, resulting in higher feedstock availability and lower prices.

2. Continious process

Continuous liquid phase pyrolysis results in high control and efficient operation.

6. No catalysts

No catalysts required.

3. High oil quality

Highest possible pyrolysis oil quality due to the combination of patented features to remove contaminants and optimal process control.

5. Scalable technology

No heat transformer limitations enable scaling up of single reactor train to fifty kilotons, resulting in economies of scale (capital and operating costs).

4. Efficient energy balance

Low energy usage due to optimal cracking process (low heat flux).

1. Wide range of plastics

Difficult to recycle waste consisting of wide mix of plastic feedstock, resulting in higher feedstock availability and lower prices.

2. Continious process

Continuous liquid phase pyrolysis results in high control and efficient operation.

3. High oil quality

Highest possible pyrolysis oil quality due to the combination of patented features to remove contaminants and optimal process control.

4. Efficient energy balance

Low energy usage due to optimal cracking process (low heat flux).

5. Scalable technology

No heat transformer limitations enable scaling up of single reactor train to fifty kilotons, resulting in economies of scale (capital and operating costs).

6. No catalysts

No catalysts required.

7. High safety

Highest oil and gas safety standards applied, enabling integration of the site on a chemical complex.

Operational since 2014

The first successful demonstration of what would become BlueAlp Technology after, involved a pilot production plant of around 3 kt, back in 2014. Six years of development later, we launched our first commercial prototype plant, with Renasci & Den Hartog, in 2020. This prototype can process around 17 kt of plastic feedstock per year.

Meeting all industry standards in 2022

The design of our plant is now aligned with the petrochemical industry standards. It can accept a wider range of feedstock, and reliability has taken a further leap forward with the introduction of a sparing philosophy that enables economic and reliable operation. The capacity has grown too, to 70 kt a year.

The next generation is coming

Today we are working on future versions of the BlueAlp Technology, based on our roadmap. Our goals are a further cracker integration and a full decarbonization of our operation. Resulting in our ambition to upcycle 1 million tons by 2025 to new valuable and sustainable feedstock .

All these enhancements make BlueAlp Technology simply the best chemical upcycling solution available today. And the work we are doing today will ensure this remains the case going forward.

Safe, continuous process which
can be remotely operated. Easy scalable.

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