The BASF Conversion Process

The BASF process requires pretreatment. Plastics are separated from non-plastics, ground and agglomerated. The agglomerate is fed into the process. 

The liquefied plastic fraction is heated to over 400 °C. This leads to cracking of the plastic into components of different chain lengths. Gases count for 20%-30% and oils for 60%-70% they are separated by distillation. Any naphtha produced is treated in a steam cracker, resulting in monomers like ethylene and propylene that are recovered. Such monomers can be used to produce plastics again. The heavy fractions can be processed into synthesis gas or conversion coke and then be transferred for further use. At most 5% of the input is converted into a mineral fraction. It is likely that this consists mainly of the inorganic additives in plastics. 

The process is fairly robust. As for one of the main problematic inputs, chlorine from PVC, the plant was able to handle MPW with the regularly occurring PVC content of 4%-5%. This implies a chlorine tolerance of some 2.5%. As for the emissions and resource use, Heyde and Kremer (a.6) have carried out an extensive study. All emissions will comply with local regulations. 

As for processing costs, the BASF process would require a gate fee of 160 per tonne for a 

000 tonnes/year plant and a fee of 250 per tonne for a 150,000 tonnes/year plant. To our knowledge BASF has not disclosed a more detailed cost structure. 

---