Circular Economy for Plastics

Polycycl’s flagship technology enables an endless plastic-to-plastic recycling loop, whereby used plastics such as flexible grocery bags and discarded ketchup bottles can be upcycled to make virgin food-grade polymer resins.

POLYCYCL

Closing The Loop

At the heart of the plastic waste problem is the linear take-make-dispose model of consumption, where products are manufactured, bought, used briefly and then thrown away.

PolyCycl’s technology transforms lower-grade plastics, destined for landfills into high value hydrocarbon oils. These oils serve as raw materials for producing new circular plastics, eco-friendly chemicals and renewable fuels that find application across industries, transport and aviation.

Plastic-to-Plastic
Circular Economy

TAKE

Crude oil is extracted from
the ground for manufacturing
of virgin plastics.

make

Manufacturing of plastic
resin and products.

use

Consumption of plastics
products leading to
generation of trash.

dispose

Most waste plastics end up in landfills

Unrecyclable polyolefin plastics
[150+ million tons per annum]

POLYGREEN OILTM

Feedstock for manufacturing
of virgin plastics

CONTIFLOW
CRACKERTM

Patented, fully continuous
technology for recycling
landfill plastics.

Take
Make
Use
Dispose
1

Take

Crude oil is extracted fromthe ground for
manufacturing of virgin plastics.

Make
Use
Dispose
2

Make

The extracted crude is used for manufacturing of different plastic resins and products.

Use
Dispose
3

Use

The consumption of plastic products leads to generation of waste.

Dispose

Dispose

Most waste plastics end up in landfills.

4

Chemical Recycling

Chemical Recycling
with Polycycl’s
Contiflow CrackerTM

Patented technology for recycling landfill plastics to circular refinery feedstocks.
Take
Make
Use
Dispose
1

Take

Crude oil is extracted from the ground for
manufacturing of virgin plastics.

Make
Use
Dispose
2

Make

The extracted crude is used for manufacturing of different plastic resins and products.

Use
Dispose
3

Use

The consumption of plastic products leads to generation of waste.

Dispose

Dispose

Most waste plastics end up in landfills.

4

Chemical Recycling

Chemical Recycling
with Polycycl’s
Contiflow CrackerTM

Conversion of waste plastics extracted from landfills to refinery feedstocks for manufacturing of circular polymers.

Polycycl - Technology Overview

Extraction and Pre-Processing
of Waste Plastics

Proprietary know-how towards segregation and pre-treatment of
low-grade polyolefin waste plastics from municipal and landfill waste
streams using automated and water-less methodology.

1

Primary Cracking

Fully-continuous conversion process with

‍Patented AutoCharRemovalTM  technology for
continuous expulsion of solids from the reactor and
prevention of fouling of inner walls

3

Distillation and Energy Integration

Condensation of hydrocarbon vapours and separation
into liquid fractions as per offtake specification.
Integration of energy embedded in product off-gas back
into the upstream conversion processes.

5

Storage & Distribution

Purified pyrolysis oils are stored in large
containers and pumped to trucks for
onward distribution to end-markets.

7
2

Feeding

Continuous feeding system doses the
prepared plastics to the conversion
process at a constant metered rate

4

Secondary Cracking

Hydrocarbon vapours obtained from prior
stage are selectively cracked to trim the
longer  and heavier chains, with an objective
to obtain “lighter” product oils.

6

PyOil CleanTM : Oil Refining

Proprietary Purification Process for refining
of generated pyrolysis oils towards reduction
of organic and inorganic contaminants, wear
metals, particulate matter and moisture.

Polycycl’s Contiflow CrackerTM

Polycycl

Technology Overview

Process Overview

1

Extraction & Pre-Processing
of Waste Plastics

Proprietary know-how towards segregation and pre-treatment of low-grade polyolefin waste plastics from municipal and landfill waste streams using automated and water-less methodology.

2

Feeding

Continuous feeding system doses plastics to the process at a constant mass flowrate.

3

Primary Cracking

Fully-continuous conversion process with patented AutoCharRemovalTM  technology for continuous expulsion of solids from the reactor and prevention of fouling of inner walls

4

Secondary Cracking

Secondary cracking of vapours to achieve narrower carbon distribution as per requirements of offtake specification.

5

Distillation and Energy Integration

Condensation of hydrocarbon vapours and separation into liquid fractions as per offtake specification. Integration of energy embedded in product off-gas back into the upstream conversion processes.

6

PyOil CleanTM : Oil Refining

Proprietary process for refining of generated pyrolysis oils towards reduction of organic and inorganic contaminants, wear metals, particulate matter and moisture.

7

Storage & Distribution

Storage and pumping of generated oils
and futher distribution for various applications

1PolyOlefinExtractTM

Extraction & Pre-Processing
of Waste Plastics

Proprietary know-how towards segregation and pre-treatment of low-grade polyolefin waste plastics from municipal and landfill waste streams using automated and water-less methodology.

1PolyOlefinExtractTM

Feeding

Continuous feeding system doses plastics to the process at a constant mass flowrate.

2Contiflow CrackerTM

Primary Cracking

Fully-continuous conversion process with patented AutoCharRemovalTM  technology for continuous expulsion of solids from the reactor and prevention of fouling of inner walls

2Contiflow CrackerTM

Secondary Cracking

Secondary cracking of vapours to achieve narrower carbon distribution as per requirements of offtake specification.

2Contiflow CrackerTM

Distillation and Energy Integration

Condensation of hydrocarbon vapours and separation into liquid fractions as per offtake specification. Integration of energy embedded in product off-gas back into the upstream conversion processes.

3PyOilCleanTM

PolyGreen Oil - For a
Circular Economy

Proprietary process for refining of generated pyrolysis oils towards reduction of organic and inorganic contaminants, wear metals, particulate matter and moisture.

3PyOilCleanTM

Storage & Distribution

Storage and pumping of generated oils
and further distribution for various applications

FEEDSTOCK EXTRACTION AND PRE-TREATMENT

Recovery of mixed waste plastics from landfill waste using proprietary know-how.

PolyCycl has developed a pre-treatment methodology that extracts hard-to-recycle polyolefin plastics from landfills and legacy waste heaps. The process removes organics, textile, paper, fibres and metals while also dropping mud and dirt using non-wetting methods.

PolyGreenOilTM from waste plastics

Applications and End Markets

Qualified petrochemical feedstock for
manufacturing  of virgin plastics
Retail-ready, drop-in diesel blendstock for
use in industrial furnaces and boilers.
Upgradable to transportation
and aviation fuel.
Feedstock for manufacturing of green chemicals:
‍BTX, Linear Alkyl Benzene, Mesitylene etc.

PolyGreen Oil TM
From Waste Plastics

Applications and End Markets
Qualified petrochemical
feedstock for manufacturing of
virgin plastics.
Retail-ready, drop-in diesel
blendstock for use in industrial
furnaces and boilers.
Upgradable to transportation
and aviation fuel.
Feedstock for manufacturing of
green chemicals: BTX, Linear
Alkyl Benzene, Mesitylene etc.

Applications
of Polygreen Oil

Applications of Polygreen OilTM

Refined hydrocarbon oils for use as petrochemical feedstock and/or drop-in industrial blendstocks

Qualified petrochemical feedstock for manufacturing  of virgin plastics

Retail-ready, drop-in diesel blendstock for use in industrial furnaces and boilers.

Upgradable to transportation and aviation fuel.

Feedstock for manufacturing of green chemicals: BTX, Linear Alkyl Benzene, Mesitylene etc.

Case Studies

Publications and Reports

Life Cycle Assessment of emissions from chemical recycling of waste plastics vis-a-vis alternate disposal options.

Environmental Evaluation by Life
Cycle Assessment (LCA)

Plastics manufactured using pyrolysis oil are of 100% identical quality to those manufactured using fossil fuels. Pyrolysis of mixed waste plastics emits 50% less CO2 than incineration.
BASF – Sphera Study 2020

Assessing the Life Cycle Environmental
Impacts of Post-consumer Plastic Film..

Plastics produced using chemical recycling provide 43% decrease in CO2e emissions compared to the plastics produced from fossil feedstock (5.4 tons vs 3.0 tons of CO2e) that are incinerated for energy recovery.
TCGF Study 2022

Life cycle assessment of Plastic Energy technology for the chemical recycling of..

For 1 kg of treated mixed plastic waste, the climate change potential was found to be 0.55 kg CO2-eq. when it was chemically recycled, but 1.6 kg CO2-eq. when it was incinerated for energy recovery.
Quantis- Plastic Energy Study 2020

Brightmark’s Plastics Renewal Technology Reduces Carbon..

In the U.S. 2019 scenario, the greatest benefit from plastics renewal is 82% NREt savings, followed by 46% water use savings and a 39% reduction in carbon footprint.
Environmental Clarity- Brightmark Study 2021

Environmental Evaluation by Life CycleAssessment (LCA)

Plastics manufactured using pyrolysis oil are of 100% identical quality to those manufactured using fossil fuels.Pyrolysis of mixed waste plastics emits 50% less CO2 than incineration.
BASF – Sphera Study 2020

Assessing the Life Cycle Environmental Impacts of Post-consumer Plastic Film..

Plastics that are recycled in a closed loop for re-manufacturing result in GHG emission reduction by 43%, when compared with virgin plastics derived from fossil fuels that are incinerated for energy..
TCGF Study 2022

Life cycle assessment of plastic energy technology for the chemical recycling of..

For 1 kg of treated mixed plastic waste, the climate change potential was found to be 0.55 kg CO2-eq. when it was chemically recycled, but 1.6 kg CO2-eq. when it was incinerated for energy recovery.
Quantis- Plastic Energy Study 2020

Brightmark’s Plastics Renewal Technology Reduces Carbon..

In the U.S. 2019 scenario, the greatest benefit from plastics renewal is 82% NREt savings, followed by 46% water use savings and a 39% reduction in carbon footprint.
Environmental Clarity- Brightmark Study 2021

Environmental Evaluation by Life CycleAssessment (LCA)

Plastics manufactured using pyrolysis oil are of 100% identical quality to those manufactured using fossil fuels. Pyrolysis of mixed waste plastics emits 50% less CO2 than incineration.
BASF – Sphera Study 2020

Assessing the Life Cycle Environmental Impacts of Post-consumer Plastic Film..

Plastics that are recycled in a closed loop for re-manufacturing result in GHG emission reduction by 43%, when compared with virgin plastics derived from fossil fuels that are incinerated for energy..
TCGF Study 2022

Life cycle assessment of plastic energy technology for the chemical recycling of..

For 1 kg of treated mixed plastic waste, the climate change potential was found to be 0.55 kg CO2-eq. when it was chemically recycled, but 1.6 kg CO2-eq. when it was incinerated for energy recovery.
Quantis- Plastic Energy Study 2020

Brightmark’s Plastics Renewal Technology Reduces Carbon..

In the U.S. 2019 scenario, the greatest benefit from plastics renewal is 82% NREt savings, followed by 46% water use savings and a 39% reduction in carbon footprint.
Environmental Clarity- Brightmark Study 2021

Further Reading

Solvent based purification of plastics
Our Research & Development Centre
Polycycl Awards and Recognitions
KK 16, HSIDC Estate, Kalka, Haryana
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NAVIGATION
Circular Economy for Plastics Solvent based Purification of Plastics Plastics in the Environment New Announcement - Partnership with Re Sustainability
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