Modular Micro-Plant for Plastic Waste Valorisation

The project explores a modular micro-plant for plastic waste valorisation based on a simple principle:

not every plastic waste stream should be forced into the same recycling process.

Incoming plastic waste would first be identified, characterised and classified. Each fraction could then be directed towards the most suitable available valorisation route according to its composition, condition and technical suitability.

The objective is therefore not to maximise the amount of plastic sent to pyrolysis, but to maximise the useful valorisation of each incoming material stream.

One possible route is controlled pyrolysis for suitable fractions such as selected LDPE, HDPE and PP streams.

Other fractions that are unsuitable or inefficient for pyrolysis could be redirected towards alternative material-recovery routes instead of becoming residual waste.

One of the additional routes currently being explored is the production of T-Wood-type recycled composite material, using suitable plastic fractions together with compatible materials to create useful secondary products.

The modular concept could integrate:

• plastic waste reception and identification,

• sorting and feedstock preparation,

• separation according to suitable valorisation route,

• controlled pyrolysis of appropriate fractions,

• material and mechanical recycling,

• recycled composite-material production,

• T-Wood-type applications,

• traceability of input materials and resulting outputs,

• and future integration of additional valorisation technologies.

The architecture is intended to remain open: if another recycling or recovery technology provides a better technical, environmental or economic solution for a specific plastic fraction, that route could be incorporated into the system.

The project is currently at an engineering and validation stage. The integrated micro-plant has not yet been demonstrated as an industrial installation, and process performance, product quality, environmental impact and economics still require experimental validation.

I am looking for research, engineering and industrial partners with expertise in plastic sorting, polymer science, recycling technologies, composite materials, pyrolysis, thermochemical conversion, process engineering, automation, environmental assessment, industrial safety and pilot-scale testing.

A key objective is to develop a robust decision pathway capable of determining the most appropriate valorisation route for each incoming plastic fraction.