Recycled LDPE Production from Mixed Plastic Waste

This report presents the economics of Recycled Polyethylene (rPE) production from mixed plastic waste. In the process examined, polyethylene is recovered from mixed plastic waste through selective dissolution and purification in organic solvents. The PE-rich mixed plastic (containing over 90 wt% PE) is shredded and treated with a solvent that selectively dissolves polyethylene. Through filtration and precipitation steps, the PE is separated from other resins and impurities. After drying, the recycled PE is separated from the solvent and pelletized. A high recovery of the polyethylene in the feedstock is achieved, resulting in a product yield of about 90% relative to the feedstock mass.

The report provides a comprehensive study of LDPE production and related LDPE production cost, covering three key aspects: a complete description of the LDPE production process examined; an in-depth analysis of the related LDPE plant capital cost (Capex); and an evaluation of the respective LDPE plant operating costs (Opex).

The LDPE production process description includes a block flow diagram (BFD), an overview of the industrial site installations, detailing both the process unit and the necessary infrastructure, process consumption figures and comprehensive process flow diagrams (PFD). The LDPE plant capital cost analysis breaks down the Capex by plant cost (i.e., ISBL, OSBL and Contingency); owner's cost; working capital; and costs incurred during industrial plant commissioning and start-up. The LDPE plant operating costs analysis covers operating expenses, including variable costs like raw materials and utilities, and fixed costs such as maintenance, labor, and depreciation.