DISSOLV: Pioneering circular PVC with INEOS Inovyn
Through the DISSOLV project, INEOS Inovyn aims to strengthen Europe’s PVC recycling, with an ambition to achieve industrial-scale circular PVC (R-PVC) by 2030 under the leadership of Eric Romers and Yannick Vandendael. The role of innovation brokers including Catalisti (Flanders) the Flemish-Walloon cooperation programme BEL-COO, has been vital in the creation of the DISSOLV consortium, initiated by Beaulieu International Group. To strengthen the project’s technical and commercial development, INEOS Inovyn has launched two next generation PVC pilot plants at their Jemeppe-sur-Sambre site in Belgium, of which one will be used for DISSOLV.
Eric Romers explained that the DISSOLV consortium formed when Beaulieu International Group required a partner to produce rejuvenated PVC from PVC waste, and recognising INEOS Inovyn’s innovative dissolution technology approached the company. This collaboration provided access to PVC waste, facilitating further development and closing the recycling loop. Beaulieu International Group, which produces textile flooring, expanded this to include Sioen (tarpaulins), Empire Carpets (carpets), Centexbel (analysis and testing) and ExxonMobil (plasticisers valorization), forming a value chain consortium where each party benefited from working together and could leverage their collective expertise.
Learning from experience
INEOS Inovyn previously operated Vinyloop™, a PVC recycling plant in Italy from 2002 to 2018. This successfully extracted PVC from cables and tarpaulins, but was shut down due to the evolving REACH legislation, which prohibits the recycling of products containing specific plasticiser additives, such as DEHP. Vinyloop™ provided valuable insights and lessons that have helped guide the company’s progress with DISSOLV.
DISSOLV’s technical process
Yannick Vandendael outlined DISSOLV’s two-step process for flooring, tarpaulins and carpets: separation and extraction by dissolution. The first step separates the fabric fibres from the PVC coating, a process successfully demonstrated in Ferrara and in the second, plasticisers are extracted from the PVC. The consortium aims to close the loop by remanufacturing towards the original applications, flooring-to-flooring, tarpaulins-to-tarpaulins, and carpets-to-carpets, using rejuvenated PVC.
Challenges and innovations
Eric Romers highlighted the technical challenges of achieving PVC emulsion properties from recovered material. The goal is to achieve a high percentage of recycled content in new products, a significant leap from previous downcycling initiatives where recycled PVC was only used for lower-grade products such as pallets and street furniture.
When you sit around a table with people who have been working in PVC for 20 years, you don't always get the right results. You need different views to make progress.
Breakthrough moments
Frequent brainstorming sessions examining complex challenges, have helped to accelerate project breakthroughs. The team successfully extracted additives such as fillers, stabilisers and plasticisers, paving the way for the production of high quality rejuvenated PVC resin. This innovation-driven approach has fostered a dynamic and motivated team, which has been crucial in overcoming the project’s technical hurdles.
Strategic collaboration
The development project, supported by VLAIO and SPW Recherche via the BEL-COO programme, and partners such as Centexbel and ExxonMobil, highlight the importance of collaboration. Centexbel provides essential analysis and testing, while ExxonMobil explores the reconversion of extracted plasticisers into reusable products. This comprehensive approach ensures that all extracted materials are valorised, minimising waste and maximising sustainability.
Alone you can do a lot, together you can make a difference and serve the whole PVC industry.
Economic and environmental impact
While the costs of producing recycled PVC compared to virgin material are higher today, external factors such as European regulations, landfill closures and rising incineration costs are expected to drive higher demand for recycled materials. The consortium is focused on the benefits of reducing CO2 emissions by diverting PVC waste from incineration, in line with wider environmental objectives.
Future outlook
The project begins with pre-consumer waste to fully understand each process step, which will then move onto post-consumer waste processing in collaboration with Beaulieu International Group, Sioen and Empire Carpets. Its ambition is to establish an industrial-scale recycling unit by 2030, demonstrating the viability and benefits of a circular economy for PVC that can’t be mechanically recycled.
Driven by innovative thinking, collaboration and an ambitious goal, the DISSOLV consortium is poised to revolutionise the PVC industry by making circularity a practical reality and support Europe’s vital green transition.
After his retirement in May 2024, Yannick ended his contract as Project Circle Director, with Eric taking over the role.
About the Project DISSOLV
- DISSOLV will drive the development for PVC waste from flooring, carpets and tarpaulin applications which cannot be recycled today, due to the presence of textile fibers and legacy additives.
- HBC.2023.0384
- Project type: BEL-COO
- Timing: 01/10/2023 - 01/10/2026
- Innovation Programme: Circularity and Resource Efficiency