PolyCycl, a startup dedicated to circular economy solutions, has launched its patented Contiflow Cracker Generation VI, a revolutionary chemical recycling pyrolysis technology. This homegrown innovation addresses India's escalating plastic waste issue by converting hard-to-recycle plastics, such as single-use grocery bags and food-contaminated packaging, into food-grade polymers, renewable chemicals, and sustainable fuels.

Source: The Machine Maker

The Generation VI technology is protected by several international patents. The Contiflow Cracker integrates the company’s continuous thermo-chemical pyrolysis process with its proprietary PyOilClean refining technology. This synergy transforms low-quality plastics into liquefied hydrocarbon oils, which are then purified to remove contaminants like halogens and hetero-atoms. The resulting chemical feedstocks serve as versatile raw materials for the petrochemical industry, facilitating the production of various premium low-carbon materials, including circular polymers.

Amit Tandon, Founder and CEO of PolyCycl, pointed out that India generates over 10 million tonnes of plastic waste each year, with over 40% made up of single-use plastics. He stressed that traditional recycling methods often fail to effectively manage this waste, resulting in blocked drains, littered streets, and polluted waterways.

PolyCycl’s technology breaks down thin plastics into their molecular building blocks (oligomers), which can be reformed into new virgin-quality materials. The system boasts impressive conversion rates of 65-75% and produces chemical feedstocks acknowledged for their compatibility with the circular economy by numerous global petrochemical firms.

The patented design of the technology’s continuous process allows for scalable development, with modular lines capable of processing between 15 and 100 tonnes of plastic daily. This innovative method also offers significant cost efficiencies, with capital expenditures reduced by as much as half to one-fourth compared to competing technologies in Europe and the US, while maintaining project EBITDA above 50%. PolyCycl’s goal is to establish a closed-loop recycling system that enables commonly used plastics to be endlessly recycled without quality degradation, thereby eliminating the need for down-cycling, incineration, or landfilling at the end of their lifecycle.