Catalytic hydrogenolysis of HDPE-PCR to produce fully refined paraffin wax
Aeternal Upcycling's technology converts HDPE-PCR into fully refined paraffin wax using catalytic hydrogenolysis, achieving up to 90% yield. The process is energy-efficient, scalable, and produces waxes suitable for candles, cosmetics, adhesives, and coatings.
Overview
Aeternal Upcycling has developed an innovative technology to convert high-density polyethylene post-consumer resin (HDPE-PCR) into fully refined paraffin wax using catalytic hydrogenolysis. This process achieves up to 90% yield, producing a white, odorless wax that is virtually indistinguishable from traditional paraffin wax in candle and cosmetic applications. The technology is versatile, allowing the production of waxes with varying melting points, making it suitable for a wide range of applications including adhesives, coatings, and cosmetics.
Technical specifications
- Catalytic hydrogenolysis efficiently breaks down HDPE-PCR polymer chains into waxes, avoiding the formation of unwanted byproducts such as coke, olefins, and aromatics.
- Energy efficiency: The process operates at lower temperatures and is less energy-intensive compared to pyrolysis, resulting in higher yields and requiring less purification.
- Scalability: The technology is designed to scale to commercial production levels, with the potential for price parity with fully refined paraffin wax.
- Environmental impact: Life cycle assessment (LCA) models show at least a 50% reduction in carbon footprint compared to conventional wax production from oil refining.
- Robust catalysts: The catalysts used are highly selective, cost-effective, and long-lived, contributing to the overall efficiency and sustainability of the process.
Technology readiness level
The technology is currently at Technology Readiness Level 4. It has been validated in a laboratory setting with demonstrated production of waxes across a range of melting points. Future validation plans include providing product samples, refining formulations based on partner feedback, and scaling up the process in collaboration with industry partners.
About Aeternal Upcycling
Aeternal Upcycling is a Chicago-based chemical recycling startup founded in 2022 that specializes in converting end-of-life plastic waste into high-value chemical products. The company utilizes a proprietary thermocatalytic hydrogenolysis process, developed by co-founders Ryan Hackler and Robert Kennedy during their research at the Argonne National Laboratory. This technology uses a platinum-based catalyst and hydrogen gas to break down stable, post-consumer polyolefins—such as HDPE, LDPE, and polypropylene—into versatile molecular building blocks. By converting these difficult-to-recycle plastics into specialized outputs like synthetic base oils, waxes, and additives, the process produces sustainable alternatives for the lubricant, cosmetics, packaging, and home goods sectors.
This technology provides a critical solution for manufacturers by offering drop-in, lower-carbon replacements for traditional, petroleum-derived ingredients. The company's synthetic base oils are designed to make high-performance industrial lubricants more affordable and accessible, helping manufacturers improve efficiency and reduce equipment downtime. By localized processing of plastic waste, Aeternal Upcycling aims to reduce supply chain dependency on global imports while significantly lowering the greenhouse gas emissions associated with conventional manufacturing. Supported by various grants and accelerator programs, including investment from the U.S. Department of Energy, the company is scaling its operations to address the massive volume of plastic waste that currently ends up in landfills or incineration.
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