Catalytic conversion of HDPE-PCR to high-value paraffin waxes

Overview

Upcycling+ Inc has developed a groundbreaking process for the catalytic conversion of high-density polyethylene post-consumer resin (HDPE-PCR) into high-value paraffin waxes. This continuous-flow, solvent-free method achieves over 90% yield at temperatures below 300 °C. The process is highly efficient, with integrated vapor-phase transport-based separation that removes the need for additional purification steps. Our technology is designed to produce waxes suitable for coating and adhesive applications, offering significant commercial potential.

Technical specifications

• Catalytic process: Utilizes a continuous stirred-tank reactor (CSTR) with an auger feed system for plastic, allowing continuous production.
• Catalyst control: Catalyst structure is tailored to produce specific wax properties, such as melting point and viscosity, through controlled reaction conditions.
• High yield and purity: The process has been validated using DOE-funded research, demonstrating high yield and purity without contaminants from plastic waste streams.
• Product properties: Produces paraffin waxes with melting points between 50 °C and 60 °C, adjustable by altering reaction parameters like H2 pressure and catalyst contact time.

Technology readiness level

The technology is at TRL 5, having been successfully demonstrated at lab scale with reactors ranging from 0.3 L to 4 L. The next steps involve scaling up to pilot-scale production of approximately 1 ton of HDPE-PCR per day, further validating the process's commercial viability.