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| U.S Plastic-to-Fuel |
Plastic Production and the Growing Waste Problem
Plastic has become ubiquitous in modern society due to its low cost and
versatility. However, the massive amount of plastic waste has become a serious
environmental issue with no long-term solutions in sight. The United States
produces over 35 million tons of plastic waste each year, less than 10% of
which is recycled. The majority ends up in landfills or incinerated, releasing
greenhouse gases and toxic chemicals into the air and soil. With plastic
production expected to double over the next twenty years, addressing plastic
pollution has become a pressing challenge.
Enter Plastic-to-Fuel Technology
A promising emerging solution is plastic-to-fuel technology. This process
converts non-recyclable plastic into synthetic crude oil, diesel, or gasoline
using pyrolysis. Pyrolysis heats plastic in an oxygen-free environment,
breaking the long hydrocarbon chains into shorter molecules similar to crude
oil. The synthetic fuel can then be further refined and used in vehicles
without modification to engines. Several U.S. companies are commercializing
this technology to tackle plastic waste at scale and provide a sustainable fuel
source.
Renewables Bioplastics Leads the Way
Renewables Bioplastics near Atlanta is the largest U.S
Plastic-to-Fuel pilot plant in North America. Since opening in 2018,
they have processed over 7,500 tons of plastic into over 300,000 gallons of
synthetic crude oil and diesel. They source non-recyclable plastics like
wrappers, containers and bags that would otherwise go to landfill from
municipal programs. The fuel is then sold to help power trucks and machinery.
The company aims to have their first commercial-scale plant operational by 2023
with the capacity to process 30 tons of waste plastic per day.
Agilyx Scales Up in Oregon
Oregon-based Agilyx scales plastic recycling through pyrolysis in large
facilities. Since establishing their first commercial plant in 2018 near
Portland, they have processed over 11,000 tons of polystyrene and flexible
plastics into over 5 million gallons of synthetic crude oil. This oil is then
refined into hydrocarbon materials to make new products like plastic lumber
that can be used in playsets and boardwalks. Agilyx opened their second plant
in 2021 with the goal of recycling 100,000 tons annually. They employ
proprietary technology that can break down a variety of plastics, colors and
contaminants.
New Life for Plastic in Texas
Another leader is Nexus Fuels near Dallas, Texas. Partnering with oil
refineries and retailers, Nexus has processed over 6,000 tons of plastic since
2018. They convert bales of mixed plastics from recycling centers into
ultra-low sulfur diesel that meets ASTM standards without any blending. This
drop-in fuel can immediately replace fossil-based diesel in trucks, ships and
other vehicles. Nexus plans to triple their capacity to 10 tons per day by
2023. They estimate their operations have the same carbon reduction impact as
removing over 1,000 cars from the road annually.
Support From Policymakers
With the environmental and economic promise of plastic-to-fuel, U.S.
policymakers are stepping in with beneficial policies and regulations. For
example, the Infrastructure Investment and Jobs Act signed in 2021 provides
$350 million for expanded plastic recycling technologies like pyrolysis over
the next 5 years. Several states like California incentivize the production of
renewable fuels from waste feedstocks through Low Carbon Fuel Standard credits.
As plastic-to-fuel matures, fuel standards and regulations are also adapted to
qualify the output for wide-scale use. With continued scaling and innovation,
this emerging industry aims to not only address plastic pollution but supply
sizable volumes of renewable liquid fuels.
Challenges and Room for Growth
While the technology for plastic-to-fuel via pyrolysis exists at a commercial
level, adoption faces key challenges that companies continue working to
overcome. Consistent and high volumes of plastic waste feedstocks need to be
secured. More refined fuel outputs that meet widespread distribution and use
standards like gasoline remain to be demonstrated at large scale. Supply chain
management and integration into existing oil infrastructure present logistical
hurdles. Economics remain sensitive to waste plastic and fuel prices. However,
with policy momentum and growing real-world operating experience, these
companies expect plastic-to-fuel to become fully cost-competitive this decade
as one effective solution within a circular economy for plastics. Significant
growth potential also exists to export U.S. pyrolysis technology and operations
globally to high plastic waste regions like Asia and Africa facing their own
pollution crises. With continued advancements, plastic-to-fuel holds promise to
turn trash into treasure on a massive scale.
In summary, as plastic pollution grows into an urgent crisis, U.S. companies
are demonstrating the viability of a sustainable solution through
plastic-to-fuel technology at commercial scale. By converting non-recyclable
plastic waste into renewable synthetic crude oil and fuels, this emerging
industry aims to provide a long-term solution to the plastic waste problem
while supplying low-carbon alternatives to fossil fuels. With ongoing innovation,
supportive policies and demand for recycled materials, plastic-to-fuel shows
great potential to establish a new plastics economy and carbon-neutral fuel
supply chain in the coming decades.
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