A New Technology Disrupting the Plastic Recycling Sector—Solvent-Based Dissolution Recycling

Solvent dissolution is a unique physical recycling method that uses solvent mixtures to separate contaminants—such as dyes, adhesives, or metals—from plastics, leaving behind pure polymers for reuse. Based on the target material separated by the solvent during this process, two primary pathways have emerged: 1. Dissolution Delamination: Utilizes solvents to dissolve the adhesive layer between polymer and metal (e.g., in multilayer packaging, solar panels, battery casings, automotive panels, and aluminum packaging). Dissolution delamination is the first commercially viable technology for recycling multilayer packaging; it typically recovers all plastic components and broadens physical recycling applications to waste streams such as automotive or battery waste. 2. Selective Dissolution: Uses solvents to separate polymers from contaminants, dyes, and additives. This technique significantly expands recyclability across all waste plastics—including textile waste. Innovations in selective dissolution include the use of supercritical fluids, which alter liquid- and gas-phase properties to greatly enhance efficiency and reaction speed. Unlike pyrolysis and depolymerization, solvent dissolution purifies polymers from mixtures without breaking them down into monomers. The diagram below illustrates the advantages of solvent dissolution recycling: by eliminating downstream refining steps, solvent dissolution reduces CO₂ emissions, energy consumption, and water usage substantially compared with pyrolysis and depolymerization. Its major advantage lies in achieving high polymer recovery yields while minimizing environmental impact. Compared with pyrolysis and depolymerization, solvent-based recycling is estimated to increase polymer recovery yields across all plastics by 50% and 26%, respectively. Performance and Environmental Impact of Different Plastic Recycling Technologies Although solvent dissolution does not handle multiple plastic types simultaneously—as pyrolysis does—the wide variety of solvents available in the market offers virtually unlimited potential for recycling diverse plastics. Academic research has yielded abundant discoveries of new solvent–polymer combinations. Meanwhile, companies such as Purecycle and Polystyvert have commercialized solvent-based processes for polypropylene (PP) and polystyrene (PS) over the past few years, advancing this technology toward industrial deployment. Solvent dissolution plays a vital role in improving the recyclability of plastic types traditionally overlooked by conventional recycling methods—especially in the transportation sector. 【Focus on Solvent Dissolution Recyclers】 • Polystyvert: Uses cumene oil as an organic solvent to recycle polystyrene (PS) and acrylonitrile–butadiene–styrene (ABS) copolymers. Addressing PS’s susceptibility to degradation during mechanical recycling and the under-prioritization of ABS recycling, Polystyvert leverages its low-toxicity, high-yield solvent system to produce recycled plastics whose greenhouse gas emissions are over 90% lower than those of virgin plastics. • Purecycle: One of the largest commercial solvent dissolution recyclers, employing supercritical solution butane technology to recycle polypropylene (PP). Purecycle has successfully commissioned its flagship first factory in Ohio, with an annual production capacity of up to 49,000 metric tons of recycled PP. • APK: The industry’s first commercial multilayer plastic recycler, acquired in August this year by LyondellBasell Industries (LYB). APK integrates air-classification technology into its recycling process, enabling it to handle various multilayer plastics—particularly excelling in recycling low-density polyethylene (LDPE), polypropylene (PP), and polyamide (PA). Following financial challenges associated with scaling up, LYB’s acquisition is expected to usher APK into a new phase of development.

Plastic Chemical Recycling and Dissolution Technologies and Markets—2022 Edition

The chemical recycling market is poised for significant growth. This objective, third-party technical and market research report comprehensively surveys suppliers’ technologies and fully catalogs both existing plants and future plans. Chemical recycling is gaining strong momentum, and its increasing maturity will benefit the entire industry. More favorable announcements will follow—though not all planned initiatives will ultimately be realized. According to IDTechEx, pyrolysis and depolymerization plants are projected to recycle over 20 million metric tons of plastic waste annually by 2033—a substantial figure requiring massive investment and sustained engagement from stakeholders across the value chain. Despite this large projected throughput, the global context remains sobering: fossil-based plastic production continues to rise, reaching 429 million metric tons per year according to OECD 2019 data, underscoring the urgent challenge of plastic waste management. While chemical recycling can contribute to closing the loop in a circular economy, it represents only one piece of the broader global puzzle. Economic viability remains a key challenge for chemical recycling—not only due to process-related factors (e.g., yield, required plastic types and forms, and economies of scale), but also because of infrastructure availability, policy frameworks, and macroeconomic trends. Most plastic chemical recycling targets fast-moving consumer goods (FMCG) packaging—a sector experiencing continuous growth in product volume. However, chemical recycling applications extend well beyond FMCG packaging to include textiles, automotive parts, electronic devices, and more. Moreover, numerous R&D-stage and early-commercial chemical recycling technologies are beginning to exert tangible commercial influence. These include microwave- and enzyme-assisted depolymerization, hydrothermal methods, and development of novel polymers. This report provides detailed analysis and assessment of these emerging technologies’ progress. Dissolution Secondary Recycling Secondary recycling refers to recovering and reusing plastics without breaking their chemical bonds. Mechanical recycling is well known but not always applicable—and often degrades recyclability. An emerging alternative involves selectively dissolving polymers followed by precipitation to yield purified polymers. Ideally, this is a low-energy process, and the recovered polymers retain properties closer to those of virgin materials. Like chemical recycling, dissolution recycling faces clear barriers and significant challenges. Yet many manufacturers are actively pushing technological and manufacturing readiness forward, gradually integrating into established processing facilities. Both solvents and process conditions in dissolution recycling involve critical proprietary know-how and must be specially tailored. A range of plastic dissolution recycling technologies are currently under development—with PS, PP, and PET standing out as particularly prominent. This report delivers in-depth analysis of dissolution recycling technologies, participating companies, operational plants, economic feasibility, environmental impact, and market outlook. IDTechEx Market Analysis – Ten-year market forecasts for pyrolysis, depolymerization, gasification, and dissolution technologies—segmented by polymer type. – Environmental impact and economic feasibility assessments for each technology. – Evaluations of key players—including partnerships, funding, and capacity expansion plans. – Success case studies spanning single-use plastics in FMCG packaging, textiles, automotive components, electronic devices, and more. – Overviews of recycling solutions and development status for major polymers, including: PP, PET, PS, PE, PU, PMMA, PA, PC, and PLA.

ReVentas Plans 750,000 Tonnes of Dissolution Recycling Capacity by 2036

4 days ago

ReVentas aims to license its dissolution recycling technology globally, targeting 750,000 tonnes of capacity by 2036 to meet PPWR recycled content targets for food-contact polyolefins.

icis

ReVentas Plans 750,000 Tonnes of Dissolution Recycling Capacity

icis

ReVentas Plans 750,000 Tonnes of Dissolution Recycling Capacity by 2036

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