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MATTERExecution 

MATTER: MECHANICAL AND THERMOCHEMICAL RECYCLING OF MIXED PLASTIC WASTE

The MATTER-project, a two-year Catalisti-ICON project (2018-2019), wants to evaluate the recycling of mixed (post-consumer) plastic waste streams and to use the generated data to develop a decision supporting framework. The MATTER-project is a cooperation between four companies (Indaver, Borealis, Bulk.ID and ECO-oh!), Ghent University (4 research groups) and University of Antwerp (2 research groups). Organizations such Fost+, Plarebel and OVAM will be closely involved in the project execution.

AIM

Within the MATTER-project, technical and market-based criteria will be developed to support an optimal plastic waste management system. More specifically, the project will focus on the P+ fraction (all plastics packaging waste) of the extended P+MD collection and recycling scheme. Partners from across the whole value chain are included in the project consortium: separation and pretreatment (Indaver and Bulk.ID), mechanical recycling (Borealis and ECO-oh!) and thermochemical recycling (Indaver and Borealis). Sustainability analyses will enable the development of a decision-supporting framework.

IMPACT

By generating general knowledge on the recycling of mixed plastic waste and specific knowledge on the optimization of the P+MD recycling scheme, the valorization of the project is twofold. On short-term, the collection of an extra 50.000-150.000 tons of mixed plastic waste is expected for the P+MD scheme, most of which are packaging materials for which not always alternatives to incineration are available today. The results of the MATTER-project will therefore be essential for the development of sustainable recycling solutions for this significant amount of waste. In the longer run, the general recycling knowledge can result in extra activities on the processing of other plastic waste fractions.

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RECYCOATExecution 

With view on circular economy, recycling of products after use is key. Currently merely 30% of our plastic and textile waste is being recycled. The vast majority of recyclable products are actually one component materials, circumventing the necessity of a separation step.

Coated and laminated materials are difficult to recycle because of their hybrid nature: the coating layer is difficult to separate from the bulk material or the coating layer can be cured to prevent melting or dissolution in conventional solvents.

The current routes for end-of-life of “complex”-composite products are mainly focusing on burning or converting into RDF pellets (Refuse Driven Fuel). The energy content and presence of a fusible fraction (carrier and possibly also coating) explain why this waste disposal method is widely spread. Another commonly used route is mechanical reduction via shredders and subsequent use as filler material.

The project RECYCOAT aims to investigate various technologies to separate the different layers present in complex coated or laminated (multilayer) materials (in particular textiles and plastics). The focus is on developing a good design (eco-design) of the multi-layered products and/or altering the chemistry of the coating or adhesive layer. The material should be developed in such a way that maximum separation (i.e. recycling) is made possible: the different layers present in the complex material must be completely separable from each other.

An example of such a technology is an adapted adhesive layer of a carpet allowing separation in boiling water. After 30 seconds the secondary backing is split off.

This collective project, funded by Catalisti, started beginning of March and will run for two years. Companies are still welcome to join the user committee of the project. For more information, please contact us.

Ine De Vilder (textile) – ivi@centexbel.be

Isabel De Schrijver (plastic) – ids@centexbel.be

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CO2PERATEExecution 

All renewable CCU based on formic acid integrated in an industrial microgrid

The 2030 framework for climate and energy policies contains a binding target to cut greenhouse gas emissions in EU territory by at least 40% below 1990 levels by 2030, and has the ambition to further reduce them by 80-95% by 2050. As theoretical limits of efficiency are being reached and process-related emissions are unavoidable in some sectors, there is an urgent need to develop efficient carbon capture and utilisation systems. In the past, most research has focused on the capture and storage of carbon dioxide (CO2), also referred to as Carbon Capture and Storage (CCS). CCS is a technology directed to CO2 abatement and removes carbon from the economy. In addition to CCS, CO2 can also be transformed into valuable added products. This is known as carbon capture and utilization (CCU). Since the use of CO2 as a carbon feedstock has the potential to create attractive business cases for production of chemicals, more and more novel CCU technologies are being reported and the range of CO2-derived products is expanding. However, these emerging technologies all have different technology readiness levels (TRL) and a comparison for different technologies is missing.

The main objective of the project is the development of technologies for the conversion of CO2 to value-added chemicals using catalysis and renewable energy. To benchmark, compare and develop the various technologies, the formation of formic acid was selected as the initial target. Formic acid is the first product of the hydrogenation of CO2 towards value-added chemicals. In the project, the development of 4 catalytic routes (homogenous & heterogeneous catalysis, photochemical plasma-catalysis, electrochemical catalysis and bio-catalysis) is planned, enabling the sustainable synthesis of formic acid and more complex value-added chemicals (Single Cell Proteins, etc.). Sustainability is the common denominator of the different routes investigated in the project as they will enable the creation of a circular economy using (i) abundant reagents: CO2, H2O and electricity produced by surplus of renewable energies production through electrolysis and (ii) sustainable catalysts: earth-abundant metals will be used in homogeneous and heterogeneous catalysis, in photochemical and electro-catalytic syntheses, and set-ups will fully exploit renewable electricity. Finally, the potential of enzymatic catalysts (microbes and bacteria) will be exploited to use nitrogen from waste water sources to produce organic molecules of added value and microbial proteins for feed/food applications. At the end of the project, the partners want to be able to select the best technology  (CO2 source, purity and intended product, availability of excess electricity) for the conversion of CO2. A decision support framework will be developed to support this decision process. Via a techno-economic analysis, the different catalytic routes towards formic acid will be benchmarked against each other and against the classical process via base-catalyzed carbonylation of methanol.

The second objective is the valorization of formic acid. On the one hand, formic acid will be used as a building block for the bio-catalytic production of value-added chemicals such as Single Cell Proteins. On the other hand, formic acid is considered as a H2 carrier to propose a circular economy with CO2 and H2/electricity generated from renewable sources (POWER to CHEMICALS): when renewable sources (solar, wind, …) produce energy surplus, this energy can be converted in H2 (through electrolysis) that is chemically converted with CO2 into formic acid. When utilizing the H2 upon conversion of formic acid, CO2 is released and can be used recycled/reused with a new supply of H2 for the formation of formic acid generating a true circular approach.

This project has the ambition to strengthen the position of Flanders in terms of research into CO2-based processes and materials. The relevance of this cluster SBO project is further emphasized by an industrial advisory board, who are eager to implement the results and create economic valorisation. Current members of the advisory board include: 3M, Alco Biofuel, Arcelor Mittal, Avecom, Borealis, Cargill, Eastman, ENGIE Laborelec, Hydrogenics, INEOS, Messer, Monsanto, Nutrition Sciences and Smart Bioprocess.

Project type: cSBO
Approved on: 14/12/2017
Duration: 01/03/2018 – 01/03/2022
Total project budget: EUR 2.612.101
Subsidy: EUR 2.612.101
Partners:  VITO logo blends
 

Advisory Board:

 

                             

 

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ATTRACTDefinition 

Alternatives to chemical treatment techniques for cooling towers

In general, there are three major issues an industrial cooling water system may encounter: corrosion, deposition/scaling, and microbial growth. Because these problems can have a direct, negative impact on the value of the entire process, a wide range of cooling water chemicals is used to provide protection against these cooling system challenges. These cooling water chemicals, however, might pose an environmental burden when the cooling water is discharged in surface water. Catalisti is initiating a collective research project on alternatives to chemical treatment techniques for cooling towers to demonstrate and benchmark available technologies for biocide-free treatment of cooling water (as a direct alternative of liquid sodium hypochorite, i.e. bleach). In addition, apart from biocide-free treatment, alternative corrosion chemicals can also be investigated (depending of the interest that is expressed by the participating companies).

If your company is interested in this project, please send an email to Luc Van Ginneken (lvanginneken@catalisti.be).

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CAPRAExecution 

Upgrading steel mill off gas to caproic acid and derivatives using anaerobic technology

One of the greatest challenges of the 21st century is the drastic reduction of greenhouse gas (GHG) emissions to the atmosphere to minimize/mitigate the impact of global climate change. The European Union is taking up a leading role by imposing stringent emission regulations to all member states and industries. The European Emissions Trading System (EU ETS) forms the basis of the EU’s policy to combat climate change, and requires industries in Europe to decrease their GHG emissions year by year, to reach a 43% lower emission level in 2030, compared to 2005. A crucial aspect to achieve the emission reduction is the transition to a carbon-neutral economy, in which the emission of CO2 to the atmosphere is avoided.  

In this context, the possibility to capture CO2 at point sources, which account for 45% of the emissions in Europe, and transforming it into added-value products, is gaining attention. The steel industry sector is one of the largest GHG contributors. In their strive for GHG emission reduction, strategies such as improvements in energy efficiency, resource recycling, utilization and recovery have already been implemented, but further emission reduction can only be achieved by capturing CO2 emissions. Valorisation of CO2 into chemical building blocks is possible through biological or chemical processes. Biotechnology is in particular a very interesting way to valorise these waste gases due to their low energy requirements and mild reaction conditions. Traditional disadvantages of biotechnology, such as low yields, low substrate affinity and low selectivity have been overcome in recent years.  

ArcelorMittal is exploring the use of syngas fermentation technology as part of the CO2 emission reduction strategy, with pilot projects at the plant in Gent. New fermentation technologies of industrial gases have been tested at pilot scale and are ready for scale up. Many of them are focussing on the fuel market to take off their fermentation products, and are facing a low revenue from the end products, which sometimes require an energy-intensive distillation process to meet the quality standards. The CAPRA-technology  is offering an alternative to avoid this expensive distillation, and  turns the fermentation products into a high value chemical.  

The composition of syngas fermentation broth, a dilute mixture of ethanol and acetic acid, with a high ethanol/acetic acid ratio, makes it an ideal substrate for further biological upgrading through anaerobic conversions. Ethanol/acetic acid mixtures can be transformed to medium-chain carboxylic acids by biological chain elongation, resulting in a bio-oil with higher value (more than double) compared to fuel. This bio-oil, composed mainly of caproic and caprylic acid, readily phase-separates, circumventing energy-intensive distillation, and facilitating downstream processing of the final product. The bio-oil can be further processed in the chemical industry, where sources of caproic and caprylic acid are rare, while interest is growing.  

As of today, the feasibility of converting syngas effluents to C6-C8-rich oils has been proven through a limited number of studies and solely at lab-scale. To pave the road for the development of a process to upgrade syngas fermentation effluent via biological chain elongation, a number of research questions and challenges need to be addressed. Also, little is known about the chemical conversion routes to produce high-value, marketable products from the generated bio-oil. Furthermore, the optimal approach to assess the sustainability and profitability of new processes in the bio-economy is lacking.  

The CAPRA project brings together industrial and academic partners with the required expertise to solve these research challenges: ArcelorMittal, OWS, Proviron, CMET (Ghent University), EnVOC (Ghent University) and VITO. The CAPRA project will:  

  • Assess the critical operational parameters of the biological chain elongation process to determine 1) the best product recovery system; 2) the required nutrient additions for the chain elongation process; and 3) the optimal operational conditions (CMET, OWS);
  • Scale-up the chain elongation process to lab-pilot level, to upgrade real syngas fermentation effluent to a medium-chain carboxylic acid bio-oil at the kilogram scale, in a continuous process (OWS, CMET, ArcelorMittal);
  • Transform the produced bio-oil into high-quality added-value products for different applications such as plasticisers (Proviron); 
  • Evaluate the process value chain based on its sustainability and profitability, using newly developed tools (EnVOC, VITO, OWS; with input from ArcelorMittal, CMET, Proviron). 

The research carried out within CAPRA will bring the valorisation of syngas fermentation products well beyond the state-of-the-art, delivering to the steel industry a technology to capture CO2 into added-value products. For instance, the coupling of the CAPRA process to a syngas fermenter converting the off-gas of AM Gent would result in the production of 35,000 tonne caproic acid oil per year, showing the high potential of the CAPRA value chain. Also, CAPRA develops a new biotechnological platform that can be translated to other industrial sectors, such as waste management. This has the potential to generate employment and strengthen the role of Flanders as a leading region in the bio-economy.   

Project type: ICON
Approved on: 26/10/2017
Duration: 01/01/2018 – 31/12/2020
Total project budget: EUR 1.023.079
Subsidy: EUR 521.334
Partners:  VITO logo blends
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SuMEMSExecution 

Sustainable membrane technology-based solutions for solvent-rich wastewater treatment

Today, huge amounts of waste water from chemical/pharmaceutical companies is transported for incineration at specialised facilities, even though these companies have large on-site waste water treatment plants. Companies as Janssen and Omnichem thus have to treat in this way several 1000s of tons per year per factory. Currently, biodegradation of these streams via conventional waste water treatment is excluded, since these waste water contain (1) Active Pharmaceutical Ingredients (API’s), (2) other ecotoxic substances, (3) too large volumes of solvent and/or salts, and/or (4) traces of metals such, as Zinc or Palladium as remainders of homogeneous catalysts.  This forced external waste water incineration represents not only a high financial cost, but also a detrimental environmental impact.

Membrane technology is world-wide considered as a very powerful method to treat different types of waste water. However, for the treatment of the challenging, recalcitrant, salt- and solvent-rich waste waters of this project, high-performance nanofiltration membranes with sufficient solvent-resistance and/or extreme pH stability will be required. Although during the last two decades quite some research effort has taken place in this field, few applications have so far found their way to industrial implementation. This can generally be ascribed to the novelty of the technology. However, for this specific case,  the multitude of requirements for the membranes mentioned above, makes the treatment extra challenging, emphasizing the limited process understanding/predictability, and high uncertainties with respect to scalability and long-term robustness.

This project aims at realising a breakthrough in this field by developing innovative, efficient and economic membrane-based technology solutions for the sustainable treatment of these very complex solvent-rich waste waters in a holistic approach. The partners envision that the most optimal processes will be hybrid processes combining appropriate, robust membranes in synergy with powerful pre- or post-treatment (e.g. adsorption, advanced oxidation or others), allowing a (semi)-continuous on-site treatment of large volumes of waste with minimal effort. The intention is that the purified water can be processed in the existing waste water treatment plant, and, where possible, valuable compounds as precious metals can be recuperated. This will not only decrease costs, but close material loops and add to a more circular economy.

Project type: ICON
Approved on: 26/10/2017
Duration: 01/08/2015 – 31/01/2020
Total project budget: EUR 1.520.228
Subsidy: EUR 1.271.039
Partners:
KULEUVEN_CMYK_LOGO VITO logo blends
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PROFITExecution 

The PROFIT project will reverse engineer products with recycled content and define and produce feedstock from recycling which are fit for use.
Starting from applications and plastic products the project will define properties and specifications for feedstock.
Using these specifications, novel separation techniques will be developed for 2 different complex and mixed plastic waste streams.
This approach throughout the value chain and through reverse engineering allows a cost effective and efficient process. Water management and use of chemicals will be optimized through water purification techniques. Using Life cycle analysis, these any claims on efficiency and sustainability will be continuously monitored.

 

Project type: ICON
Approved on: 01/12/2016
Duration: 01/01/201 – 31/12/2019
Total project budget: EUR 622.182
Subsidy: EUR 403.337
Partners:                     
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SymbioseCompleted 

Symbiose: matchmaking voor circulaire economie en grondstoffen
Symbiose is een matchmaking platform om industriële nevenstromen een hoogwaardigere toepassing te geven, volgens het principe van Lansink. Dit wordt bereikt via actieve workshops, bedrijfsbezoeken en een interactieve databank.

Het Symbiose-project startte in september 2012 en werd gesubsidieerd door het Agentschap Innoveren en Ondernemen tot en met december 2015. Catalisti maakte actief deel uit van de uitvoering van het project van september 2014 tot december 2015.

Symbiose heeft met meer dan 300 organisaties en bijna 2000 stromen voor grondstoffen en technologieën voldoende kritische massa in zijn databank om een impact te kunnen maken op de Vlaamse industrie. Dit valt ook op aan de resultaten van de matchmaking activiteiten die met deze data gebeurden. Van de duizenden linken die werden gemaakt werden er een 500-tal nauwer gevolgd. Hiervan kwam er feedback van 11 bedrijven dat zij een geslaagde match maakten voor een totaal geschatte economische meerwaarde van meer dan €1.000.000/jaar.

Als men hierbij de gekende koppelingen neemt die in onderhandeling of testfase zitten overstijgt de gezamenlijke kostenbesparing de 2,5 miljoen euro. Daarboven komt nog een groot potentieel dat nu nog niet bekend is.

OVAM en VITO zetten in de komende jaren de werking van het platform verder.

Voor meer informatie kan u terecht bij Johan Gemoets (johan.gemoets@vito.be) en Andy Vancauwenberghe (andy.avemco@gmail.com) of op de website www.smartsymbiose.com

Geef uw stromen online door!
Er is de mogelijkheid uw stromen door te geven via onze template.
Stuur deze ingevuld naar info@smartSYMBIOSE.be . Wij zullen dan uw stromen ter harte nemen en kijken of er interessante of nieuwe synergiën voor uw bedrijf mogelijk zijn.
Houd tijdens het invullen indachtig dat hoe gedetailleerder de template wordt ingevuld, hoe sneller de juiste matches gemaakt zullen worden.
Veel success alvast!

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PU-RECompleted 

PU insulation Recycling (PURE): Study of the technical, economic and environmental feasibility of the recycling of construction, demolition and production waste

Framework

Polyurethane foam has been widely used as efficient insulation material in construction for many years. Yard waste and demolition waste end up in the containers with mixed constructionwaste, and after sorting are incinerated with energy recovery. The amount of polyurethane foam scrap from construction yards is still relatively small, but the volume will grow strongly in the coming years.
The PURE project will research recycling techniques for a more high-quality recovery of polyurethane foam insulation in a ‘Closing the Closest Loop’ concept. The techniques should be technically and economically feasible, but also ecologically meaningful. Recticel, Unilin and Vanheede Environmental Logistics work together on this project.

Project type: R&D Feasiblity study
Approved on: 28/05/2014
Duration: 01/09/2014 – 31/08/2015
Total project budget: EUR 201.490
Subsidy: EUR 80.596
Partners: partners
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BlueChemCompleted 


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The study BlueChem (2012-2016) investigated the technical and economical feasibility of an incubator/accelerator for sustainable chemistry in Flanders and if the Blue Gate Antwerp site (the former ‘Petroleum Zuid’ site) can be a suitable location. The study, consisted of two fases after which a final business plan and technical plan were made. Both these fases were subsidized and supported by Agentschap Innoveren & Ondernemen.

BlueChem will open in 2020 on the climate-neutral business park Blue Gate Antwerp, in the heart of one of the largest chemical clusters in the world. It is not easy in the chemical sector to convert promising innovations into new companies. It takes a lot of time, dare and money to move from a lab setting to an industrial production scale.

BlueChem offers an answer via adapted infrastructure, tailor-made services with financial support and direct access to knowledge and expertise within an extensive network of international chemical companies, renowned research centers and the five Flemish universities.

BlueChem is the right accommodation at the right place to allow pioneering ideas, with a strong focus on sustainability and the circular economy, to grow from lab experiment to new chemical companies.

The incubator offers a mix of fully equipped and customizable labs, individual offices and flexible workplaces where starters, SMEs, large companies, research centers and knowledge institutes can come together. Catalisti will also take an active role in BlueChem to detect, start and guide promising innovation projects.

For the building project, BlueChem can count on the support of the European and Flemish government. Europe invests more than 3.4 million euros through the Europees Fonds voor Regionale Ontwikkeling (EFRO). Flanders contributes 868.397 euros through the Hermes Fund. The city of Antwerp invests 4 million euros.

More information?
More specifics and contact details can be found on the BlueChem website: https://bluechem.be/