Frontier Advances in Chemical Material Recycling and Reuse Technology

Frontier Advances in Chemical Material Recycling and Reuse Technology

Research indicates that material recycling technologies are evolving towards intelligence and high-value applications, providing key technical support for sustainable development. Based on global core journals in the chemical industry, this article consolidates post-2025 advancements related to the progress of chemical material recycling technologies. It covers two main directions: universal plastics and high-performance materials. The former includes large-scale recycling technologies such as pyrolysis oil production, catalytic conversion, and intelligent sorting, aiming to achieve a circular plastic economy. The latter involves cutting-edge solutions like closed-loop recycling of carbon fiber composites and high-value utilization of wind turbine blades, breaking through bottlenecks in recycling high-performance materials.

I. Plastic Recycling and Circular Utilization

1. Pyrolysis Technology for Converting Waste Plastics into Usable Oil

QM Recycled Energy (QMRE) has developed a pyrolysis technology that converts one kilogram of waste plastic into one liter of usable oil. Approximately 12% of the raw material is converted into gas, supplying 70% of the energy required for system operation. The remainder turns into carbon ash, which can be used in road construction materials. QMRE plans to establish 100 sites in the UK, each capable of processing 10-20 tons of waste plastic daily. However, QMRE has received limited government support and has not secured public funding .

2. Reactive Additives for Upcycling rPET, rPE, and rPP

Nexam Chemical provides reactive additives for masterbatches, such as IV enhancers and MFR modifiers, used for upcycling and modifying recycled polyethylene terephthalate (rPET), recycled polyethylene (rPE), and recycled polypropylene (rPP). This addresses challenges in processing and performance. The patented "reactive recycling" technology rebuilds and restores material properties during processing at recycling centers. By reconstructing polymer chains, it increases melt strength and viscosity, allowing use in higher-end products. It also improves process stability and mechanical properties.

3. Innovative Application of Water in Plastic Waste Recycling

Researchers from Seoul National University of Science and Technology significantly enhanced the efficiency of catalytically converting polyolefins into high-value fuels by adding water to a ruthenium-based catalyst. This research demonstrates an innovative application of water resources in plastic waste management, bringing new hope to the plastic recycling field.

4. Dielectric Sensing Technology for Plastic Recycling Industry Upgrade

The Avidens alliance addresses performance fluctuations in post-consumer recycled (PCR) plastic processing by integrating multidisciplinary expertise across the plastic value chain. Core member Sensxpert provides dielectric sensing technology and AI analysis tools to monitor molecular-level flow and solidification of PCR materials in real-time, enabling dynamic adjustments during production. Schwarz Plastic Solutions contributes injection molding expertise, translating real-time data into on-site process optimization. Other members support material characterization, mold design, material supply, and data management. This cross-disciplinary, data-driven approach helps manufacturers transform unstable PCR plastic from a risk factor into a reliable strategic advantage.

5. EU ReBioCycle Project for Bioplastic Sorting and Recycling

The ReBioCycle project establishes three complementary hubs in the Netherlands, Italy, and Spain, with partial implementation in Ireland. Each hub focuses on different technology routes and Technology Readiness Levels (TRL), including mechanical recycling, chemical recycling, enzymatic recycling, and microbial recycling. The project targets polylactic acid (PLA), polyhydroxyalkanoates (PHA), and their composites, operating at a demonstration scale in real environments. It aims to show that recycling can produce bioplastics of equal or higher quality for use in higher-value products.

II. Recycling and Reuse of High-Performance Materials

1. Closed-Loop Recycling for Carbon Fiber Reinforced Plastics (CFRP)

A research team from the University of Southern California Dornsife College of Letters, Arts and Sciences developed a high-value recycling process for composites used in aircraft, automotive panels, and light rail vehicles. This technology uses a chemical-biological synergistic strategy to achieve closed-loop recycling of CFRP while maintaining the integrity of mechanical properties. This process is groundbreaking, demonstrating the potential of fungal biocatalysis in waste valorization and establishing a new method for composite recycling by recovering both fiber and matrix components as high-value products.

2. Reusing Waste Wind Turbine Blades in High-Performance Flame-Retardant Epoxy Composites

Sichuan University research transformed discarded wind turbine blades into an efficient flame retardant, Fr@WGE@PDA, for epoxy composites via surface modification. With 20wt% Fr@WGE@PDA, the composite's tensile strength decreased slightly compared to pure EP but remained better than most literature values, with significantly improved flame retardancy. The composite showed different thermal degradation patterns in different atmospheres. Polythiazyl (PSZ) catalyzed char formation, increasing residue amount and thermal stability. Fr@WGE@PDA also reduced heat release rate and total heat release, enhancing fire safety by reducing volatile organic emissions. The composite improves fire safety through three synergistic mechanisms: catalytic char formation, flammable gas dilution, and radical trapping.

3. Breakthrough in Recycling Toray Polyamide 66 (PA66)

Toray deployed a proprietary depolymerization technology using subcritical water (temperature slightly below water's critical point of 374°C, under high temperature and pressure, capable of dissolving and hydrolyzing organic compounds). This technology can uniformly and efficiently depolymerize PA66 resin into raw material monomers within minutes. Previously, demonstration projects for chemical recycling of PA6, primarily involving recovered caprolactam monomer, were advancing. Toray stated it would develop comprehensive polyamide recycling technologies covering both PA6 and PA66 and plans to expand chemical recycling applications from textiles and automotive materials to other industrial uses.

III. Conclusion

We are well aware that the flame retardancy challenges of recycled materials are far greater than those of virgin materials. To address your concerns, Yinsu Flame Retardants goes beyond single products. We specialize in efficient compounding and synergistic flame retardant technologies, offering tailor-made phosphorus-nitrogen, phosphorus-silicon, and composite antimony flame retardant solutions. These products effectively overcome the instability of recycled material composition, ensuring consistent flame retardant performance. Choosing Yinsu means selecting a partner capable of tackling complex challenges and creating greater value for you.