For decades, plastic recycling has been riddled with complexities. Many plastic containers, especially those composed of multi-layered films, have traditionally been deemed unrecyclable. This is due to the difficulty in separating these layers and the degradation that occurs during the recycling process. Consequently, most of this plastic waste is incinerated, producing energy but contributing to air pollution. Alternatively, it is sent to landfills where it can take hundreds of years to decompose, all the while releasing harmful chemicals into the environment. In this context, where solutions seemed scarce and ineffective, the world continues to produce a staggering 348 million tons of plastic annually, with millions of tons making their way into oceans, threatening marine life and ecosystems.
Figure 1: A young girl works at a plastic recycling factory in Dhaka, Bangladesh (source: Transparency International)
Introducing Carboliq: A Revolutionary Approach to Plastic Waste
However, amidst this grim outlook, Carboliq, a company founded in 2021, has developed a groundbreaking solution. Carboliq’s Direct Liquefaction technology is poised to reshape how we handle plastic waste. This innovative process doesn’t merely attempt to recycle plastic but transforms it into a valuable resource—oil. Unlike traditional recycling methods, which often require intense heat and pressure, Carboliq’s method operates at relatively low temperatures and with much lower energy input.
The company’s method works by converting a wide variety of plastics, including previously unrecyclable materials, into oil. This oil, called Circular Liquid Resource (CLR), can then be used to produce new plastic products, effectively closing the loop in the lifecycle of plastic. But how does Carboliq achieve this?
The Direct Liquefaction Process: From Waste to Resource
The process begins by sorting plastic waste to remove impurities like metals, stones, and sand. Once purified, the plastic is shredded and dehydrated before being introduced into a large reactor filled with an oil bath. Here, the magic happens. A catalyst is added to the mix, and the long polymer chains in the plastics are broken down into shorter chains. As these chains break down into smaller pieces, they turn into vapor, which is then cooled and collected as oil.
For every ton of plastic waste, Carboliq’s process yields an impressive kilogram of oil. This oil can then be used to create new, high-quality plastic products such as packaging, medical supplies, or other essential goods. Not only does this process give plastic a second life, but it also represents a significant reduction in the environmental footprint associated with plastic waste.
A Circular Economy in Action
Carboliq’s vision is rooted in the concept of the circular economy. Unlike the traditional linear economy, where resources are used once and then discarded, a circular economy seeks to continually reuse materials, keeping them in the production cycle for as long as possible. Carboliq’s Direct Liquefaction process is a perfect example of this concept in action.
In partnership with “Südpack”, in the flexible packaging industry, Carboliq has secured its place as a leader in sustainable innovation. Südpack, which has acquired a majority stake in Carboliq, sees immense potential in integrating this technology into its operations. The collaboration aims to replace fossil-based raw materials with Carboliq’s recycled oil, a crucial step towards reducing the industry’s dependency on virgin plastic.
Addressing the Global Plastic Crisis
The scale of the plastic waste problem is staggering. With over 4.4 million tons of plastic waste produced each day for example just in the USA alone, and only half of it being used for energy generation, there is a pressing need for more sustainable solutions. On a global scale, 90% of ocean debris is plastic, and much of this waste originates from countries with insufficient waste management infrastructure. Carboliq’s technology, capable of processing mixed, contaminated, and even multi-layered plastics, offers a versatile solution that could significantly reduce the amount of plastic entering landfills and oceans.
Moreover, the environmental implications of plastic waste are dire. In addition to harming marine ecosystems and contributing to biodiversity loss—over a million seabirds and 100,000 marine animals die annually due to plastic ingestion or entanglement—plastic waste is also a driver of climate change. As plastics degrade, they release methane and ethylene, potent greenhouse gases that exacerbate global warming.
Figure 2: These countries will dump the most plastic into the oceans (source: welt)
A Broader Perspective: Other Companies Tackling Plastic Waste
Although Carboliq’s technology offers a new solution, concerns remain about potential unintended consequences. There are fears that efficient processes for converting plastic into oil could reduce the incentive for companies to invest in sustainable packaging innovations. If the industry knows that plastic waste can easily be converted into valuable resources, there may be less pressure to minimize plastic use. This presents a complex challenge – on the one hand, technologies such as Carboliq’s are crucial to tackling the plastic waste crisis, but the long-term solution also requires a reduction in plastic production.
At the same time, other companies and research collaborations are also making significant strides in addressing plastic waste. For example, the RePlastic project, a collaboration between researchers from the Danish Technical University (DTU) and industry partners, has demonstrated that even the most mixed and impure plastic waste fractions can be converted into valuable oil using pyrolysis. This process heats plastic in a low-oxygen environment, breaking it down into pyrolysis oil, which can be used to create new plastic products or as an additive in fuel.
This approach shows that, like Carboliq, other technologies are emerging that can handle different types of plastics, even those that are traditionally difficult to recycle. Unlike traditional recycling, which requires extensive sorting and cleaning, pyrolysis can handle mixed and dirty plastics, making it a highly versatile solution as well.
However, despite the success of these technologies, the core problem remains relying solely on recycling solutions could hinder broader efforts to reduce plastic production and improve packaging design. The goal should be a balanced approach – leveraging innovative recycling technologies while actively working to reduce our overall plastic dependence.
Low Energy, High Impact: The Environmental Benefits
One of the key advantages of those process is its energy efficiency. Traditional plastic recycling processes are energy-intensive, requiring high temperatures and pressures. In contrast, Direct Liquefaction operates at lower temperatures and pressures, significantly reducing the energy input required. This not only makes the process more sustainable but also more cost-effective, making it a viable solution for large-scale plastic recycling.
The oil produced through this process is not only a substitute for fossil fuels but also retains many of the essential properties of crude oil. This means it can be used in the production of new plastics that are indistinguishable in quality from those made with virgin materials. Thus, oil can be used to produce high-grade products, including medical-grade packaging like blood bags, where material purity and quality are critical.
The Future of Plastic Recycling
As the demand for plastics continues to rise—the need for sustainable alternatives to fossil fuels has never been more urgent. Carboliq’s and Replastic process represents a crucial step towards meeting this demand in a way that minimizes environmental harm. By turning plastic waste into a valuable resource, the plastics industry can reduce reliance on non-renewable resources.
Looking ahead, the potential for scaling this technology is immense. If adopted globally, it could drastically reduce the amount of plastic waste that ends up in oceans and landfills, while also providing a sustainable source of raw materials for the plastics industry. In a world where less than 10% of plastic waste is currently recycled, innovations like Direct Liquefaction offer hope for a cleaner, more sustainable future.
Conclusion: A New Era for Plastics
Carboliq is a recycling company—who choose a new way of thinking about waste. By transforming plastic waste into a valuable resource, the company is showing that sustainability and innovation can go hand in hand. As the world grapples with the mounting plastic crisis, Direct Liquefaction provides a scalable, environmentally friendly solution that could redefine how industries handle plastic waste. The future of plastics, it seems, is no longer disposable—it’s circular.
