ADVANCED MATERIALS & PROCESSES | JULY/AUGUST 2023 29 strategies are part of a holistic approach that, over the past five years, has transformed the company. Through sustainable innovation, company officials say their aim is “to build a better circle—and a better planet.” INVESTING IN MOLECULAR RECYCLING Eastman’s technologies are forms of chemical recycling it calls molecular recycling because materials are broken down to the molecular level. The company practiced molecular recycling decades ago, primarily recycling x-ray films and proving that this technology could operate profitably on a commercial scale (Fig. 3). Eastman now practices polyester renewal technology (PRT) using that same depolymerization technology: methanolysis. The company has retained the know-how (including some of the same scientists and engineers) from earlier years and has continued to refine and improve the technology. Here’s how it works: Methanolysis can be used to recycle certain kinds of plastic waste, especially those that contain polyethylene terephthalate (PET). Methanolysis of plastic converts these polymers into their respective monomers, which can then be used to produce new high-performance materials. First, plastic waste is sorted, cleaned, and shredded. The shredded plastic then undergoes methanolysis, where it is mixed with methanol and a catalyst, which helps break down the polymer chains. Using a specific temperature and pressure, methanol reacts with the plastic to produce the monomers. Methanolysis generates monomers including dimethyl terephthalate (DMT) and monoethylene glycol (MEG) from PET, which are separated from the reaction mixture through distillation or other processes. The recovered monomers are then used as building blocks to synthesize new plastics. Eastman is nearing completion of a $250 million methanolysis facility at its largest manufacturing site in Kingsport, Tenn., which will be operational later this year. In addition, plans have been announced for two other PRT facilities: a $1 billion investment to build a facility in France and another in the U.S. The plan is to announce the location of the U.S. site within the year. Altogether, the company will invest more than $2 billion in these three facilities. Eastman is determined to bring materials circularity into the mainstream by proving that molecular recycling can recycle complex plastics and that these technologies are scalable, better for the environment, preserve natural resources, and are a good investment. The Kingsport PRT facility will be one of the world’s largest plastic- to-plastic molecular recycling sites, with a goal to recycle 250 million pounds of plastic annually by 2025. Fig. 3 – Eastman salvaged x-ray films using molecular recycling technology 40 years ago. Fig. 2 – Graphical breakdown showing where today’s 300 million metric tons of plastic ends up. Currently, only 12% is mechanically recycled.
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