[ECO]Converting CO2 and Waste to Bioplastics

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New technologies enabling waste to bioplastic conversion and CO2 capture could revolutionize plastic manufacturing while addressing environmental challenges.

New research reveals innovative approaches to plastic manufacturing that could help address both greenhouse gas emissions and waste management challenges. The findings, detailed IDTechEx’s latest report “

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,” examine how companies are transforming carbon dioxide and waste materials into

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through waste to bioplastic conversion technologies.

The plastics industry currently consumes approximately 8% of global oil production, with projections indicating this could rise to 20% by 2050. With only 9% of plastic being recycled globally and over eight million tonnes entering oceans annually, alternative production methods are becoming increasingly critical.

Energy consumption in waste to bioplastic conversion varies significantly by process. Traditional plastic production requires approximately 65 megajoules per kilogram of plastic produced. In comparison, current waste to bioplastic processes consume between 80 to 130 megajoules per kilogram, though technological improvements are gradually reducing this gap. The higher energy requirements primarily stem from preprocessing waste materials and maintaining precise biological conditions during conversion.

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Several companies are pioneering CO2-to-plastic and waste to bioplastic technologies, with significant breakthroughs in conversion efficiency. California-based Newlight Technologies has developed AirCarbon, a thermoplastic created by combining captured atmospheric CO2 with methane from agricultural waste. Their proprietary waste to bioplastic process uses naturally occurring microorganisms to convert greenhouse gases into a material that matches the performance of fossil fuel-based plastics. The company reports that each kilogram of AirCarbon produced sequesters 88 kilograms of CO2, making it carbon-negative at scale. Their pilot facility processes up to 100 tons of waste annually into bioplastic products, with plans to expand capacity tenfold by 2026.

******* materials science company Covestro has introduced cardyon®, a polyurethane plastic containing up to 20% CO2. Their waste to bioplastic conversion technology reduces petroleum consumption by incorporating CO2 captured from industrial emissions, potentially saving up to 20 million metric tons of CO2 annually if implemented across their full production line. Covestro’s process represents a significant advancement in catalytic chemistry, enabling CO2 molecules to react efficiently with conventional raw materials at relatively low temperatures and pressures, reducing the overall energy requirements for production.

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With waste to bioplastic production, these men in Indonesia may not have to do so much of this. Photo by OCG Saving The Ocean on Unsplash

The waste to bioplastic sector continues expanding, with multiple approaches emerging. Mango Materials produces biodegradable polyhydroxyalkanoates (PHA) from methane collected from landfills and wastewater treatment facilities. Their process requires approximately 100 megajoules per kilogram but achieves a 60% reduction in greenhouse gas emissions compared to traditional plastic production.

Biofase manufactures plastics from avocado waste, while Dutch company Paques Biomaterials converts wastewater and organic residues into PHA. AgroRenew transforms agricultural waste from watermelon, pumpkin, and cantaloupe into biodegradable plastics by converting crop waste to micron dust before creating biopolymers.

Despite these innovations, significant challenges remain in waste to bioplastic conversion. The process requires substantial energy and water resources, potentially offsetting environmental benefits. Current water consumption ranges from 5 to 10 cubic meters per ton of bioplastic produced, compared to 1.8 cubic meters for conventional plastics. The infrastructure needed for collecting, processing, and refining diverse waste streams presents logistical and economic hurdles, with initial facility setup costs ranging from $50 million to $200 million.

Cost remains a primary barrier to widespread adoption. Current production costs for CO2 and waste-derived bioplastics exceed those of traditional plastics by 150-300%. Market projections indicate bioplastics will constitute only 1.7% of global plastics production by 2035, highlighting the need for continued innovation and investment. Industry analysts suggest that achieving price parity with traditional plastics would require a minimum ten-fold increase in production scale.

Scaling these technologies requires extensive collaboration between government agencies, industry leaders, and research institutions. Policy measures such as carbon pricing and sustainable material subsidies could accelerate adoption. Several countries have implemented supportive policies: Italy offers a 30% tax credit for waste to bioplastic facilities, while Japan provides direct subsidies covering up to 50% of equipment costs for bioplastic manufacturers.

While CO2 and waste-derived bioplastics show promise in addressing environmental challenges, their success depends on overcoming technical, infrastructural, and economic obstacles. These emerging technologies represent potential solutions for reducing greenhouse gas emissions and waste, contributing to a more sustainable and circular economy. Industry experts project that with continued technological advancement and supportive policies, waste to bioplastic conversion could achieve cost parity with traditional plastics by 2040.

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