Selective catalytic hydrogenolysis of recycled HDPE into high-value waxes
Re-Du Company presents a catalytic hydrogenolysis process to transform post-consumer HDPE into high-value waxes using a low-pressure, two-stage method. This innovative approach yields over 70% wax and minimizes by-products, offering a sustainable alternative for adhesives and coatings.
Overview
Re-Du Company introduces an innovative process for converting mixed post-consumer HDPE into high-value waxes through selective catalytic hydrogenolysis. This process employs a twin-screw reactive extruder equipped with a RuPt/SBA-15 catalyst, which efficiently cleaves C–C bonds at operating conditions of 330–400 °C and 10 bar H₂. The technology delivers over 70% yield of wax, with less than 10% by-products, significantly outperforming conventional pyrolysis methods. The resulting waxes, suitable for adhesives and coatings, exhibit a melting point of 90–110 °C and penetration less than 10 dmm. The process is designed to integrate seamlessly into existing packaging lines, with features like solvent and hydrogen recycling and catalyst regeneration, ensuring a reduced environmental impact.
Technical specifications
- Catalyst and Equipment: Utilizes a RuPt/SBA-15 catalyst within a twin-screw reactive extruder.
- Operating Conditions: Processes HDPE at 330–400 °C and 10 bar H₂.
- Yield and Quality: Achieves over 70% wax yield with less than 10% gaseous by-products. Waxes exhibit desired properties for industrial applications.
- Sustainability: Reduces energy consumption by approximately 40% compared to thermal routes, and delivers a 65% reduction in CO₂ emissions based on gate-to-gate life cycle assessment.
- Modularity and Integration: Fits existing extrusion lines and is capable of processing up to 50 kg per hour in a continuous demonstration setup.
Technology readiness level
The technology is currently at TRL 4, with plans to progress to TRL 7 within 18 months. The development roadmap includes lab-scale validation, pilot-scale testing, and eventual commercial-scale deployment. The process has undergone initial trials and is backed by comprehensive techno-economic and life cycle analyses, supporting its commercial viability.
About Re-Du Company
RE-DU is a recycling technology company that has developed a patented process for the chemical deconstruction of mixed plastic waste. By breaking down diverse plastic types—such as PET, PC, PU, and PA—into monomers, the company enables the transformation of previously difficult-to-recycle materials into commercially valuable chemical products. This technology eliminates the need for costly sorting of mixed waste streams and offers an efficient, cost-effective alternative to traditional plastic management systems, which often rely on outdated processes that fail to address the majority of global plastic waste.
By providing a scalable solution for chemical recycling, RE-DU aims to reduce reliance on fossil fuels and minimize the environmental impact of plastic pollution in landfills. The company serves as a partner for industries seeking sustainable chemical feedstocks and is contributing to the development of a circular economy. Supported by initiatives like the Innovation Crossroads Award and research collaboration with Oak Ridge National Laboratory, RE-DU is positioned to help transition toward a net-zero carbon society by proving that mixed plastic waste can be successfully converted into high-quality, reusable resources.
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