PET is widely used in plastics and textiles leading to over 20 Mt/y of complex waste worldwide for which no closed-loop recycling is viable today. Most complex waste is landfilled or incinerated. There is an urgent need to develop a circular solution to convert complex PET wastes from plastics and textiles back into high-added value products. WHITECYCLE unites 3 brand-owners, 1 PET converter, 2 waste managers, 1 digital deeptech for smart sorting, the world leading enzymatic recycling SME, 1 LCA company, 3 UNIs/RTOs, 1 cluster and 1 management firm. They aim to demonstrate two new processes combining strong scientific and industrial know-how: (i) innovative identification, sorting and separation technologies that will dramatically increase the PET content of complex waste streams to 80%, and (ii) a disruptive enzymatic recycling process that is expected to yield pure PET monomers sustainably even for impure waste streams. PET monomers obtained will be repolymerised and recycled. Thus, 2 t of waste will be used to demonstrate 3 highly technical PET-containing pilot series: 100 tyres, 1,500 m of lay-flat hoses and 400m2 of multicomponent fabric that will be coated and used to manufacture 4 lines of technical garments. Process design kits, LCA and production cost estimates will be provided to PET manufacturers and waste management companies for rapid deployment and assure social acceptance. First projections show that WHITECYCLE’s recycled PET will be competitive with virgin PET. The project will conduct a full circle loop from real complex waste feedstock to representative product of the 3 use-cases at TRL 5. Then, a strong upscale study will allow the process steps to reach TRL 6 to 8. By 2030, WHITECYCLE will enable the annual recycling of more than 2 Mt of PET, which corresponds to the amount of additional recycled PET needed to meet the EU’s 2030 targets. This will reduce emissions by around 2.06 Mt CO2eq and avoid the landfilling of more than 1.8 Mt of PET.

Approximately 70% of European plastic waste (18.5 mt/year) is not being recycled due to technical or economic reasons and are thus sent to landfill (27%) or incinerated (42%). This situation affects negatively the environment in terms of pollution and greenhouse gases emissions, as well as social perception regarding waste management, consumer’s products industry and policy makers. iCAREPLAST addresses the cost and energy-efficient recycling of a large fraction of today’s non-recyclable plastics and composites from urban waste. Heterogeneous plastic mixtures will be converted into valuable chemicals (alkylaromatic) via chemical routes comprising sequential catalytic and separation steps. This multistage process will also yield carbon char and a pure CO2 stream as products, whilst it will present improved economic sustainability, operational flexibility and lower CO2 footprint thanks to (i) the energetic valorisation of gas by-products through innovative oxycombustion units integrated with efficient heat recovery; and (ii) the use of AI predictive control and real time optimisation. iCAREPLAST aims to demonstrate (TRL-7) the whole technology for plastic waste valorisation in a pilot plant able to process >100 kg/h of plastic. Advanced upstream waste sorting, pre-treatment and pyrolysis is strongly backed by previous demonstration activities and knowhow of the consortium, with profound knowledge of waste management and recycling market. iCAREPLAST solution will enforce circular economy by substantially increasing the amount of recycled plastics to produce commodity products that can be used for virgin-quality polymers production or as raw materials for other processes in petrochemicals, fine chemicals, automotive and detergent/surfactants industries. As a result of its initial exploitation we will treat 250,000t of plastic waste which otherwise would have become landfill, converting it into 1,500t of alkylaromatics and 1,000t of aromatics.