It began with a feasibility study on the subject of "Fish-box Recycling" in 2001.
In 2002 CreaCycle GmbH and the Fraunhofer Institute for Process Engineering and Packaging (IVV) in Freising decided to combine their competencies in a cooperation aimed at "Plastic/Raw-Material Recycling with a Solvent-based Technology" (selective extraction).
As result CreaCycle and Fraunhofer Institute IVV developed together the CreaSolv® Process, based on standard process technology (patented by Fraunhofer Institute).
Proprietary CreaSolv® Formulations with the lowest risk potential possible for user and environment (ideally not to be classified according to GHS criteria) dissolve selectively the target polymer. This reduces besides the hazard also the cost for the equipment. After the cleaning from impurities the desired polymer precipitates when a special CreaSolv® Precipitation agent is added. The ingredients of our formulations are commercially available and are not research products.
The CreaSolv® Process does not fall into the classification "Chemical or Feedstock Recycling", because the chemical structure of the polymer chains remains unchanged, whereas chemical reactions produce other substances. The dissolution of plastics is a physical reaction, because the substance (plastic) only changes its physical state from solid to liguid, and this can also be reversed again. It is for this reason why the CreaSolv® Process has to be classified as "Material Recycling".
- Dissolution - After sorting by polymer type the plastic waste is shredded and dissolved in a vessel with a tailored CreaSolv® Formulation. The target polymer and certain impurities dissolve.
- Cleaning - Insoluble impurities are separated to produce a clear solution. The impurities will be waste-handled or can be recycled if they contain valuable substances.
- Precipitation - By changing the solubility property of the solution only the polymer drops out and can be regained.
- Extrusion - The dried recycled polymer is extruded into new polymer granulates with similar properties like the virgin material, thus allowing it to be used in the original application.
- Distillation - The solution is collected and distilled in order to recycle the CreaSolv® Formulation. The remaining insoluble impurities are collected to be waste-handled or recycled if they contain valuable substances.
- Regeneration - The recycled CreaSolv® Formulation is again used for the dissolution of plastic waste.
The volume of solvents used is very small in relation to the processed plastic (<1%), because the CreaSolv® Formulation is run in a closed-circuit and routinely recycled, whereas the relatively small volume of impurities is separated and concentrated. With its energy balance this process performs very well in environmental impact assessment studies. The smallest plant has a capacity between 2-4.000 tons annually.
Expanded plastics like polystyrene (EPS) can be collected already dissolved in special CreaSolv® Formulations, thus achieving a higher freight density and transport cost reduction. The dissolved plastic can be further processed and recycled immediately in the CreaSolv® Process.
During the following years the CreaSolv® Process was tested for different plastics, valuable raw-materials and problems and modified.
Download CreaSolv® Process Infographic
Recycling of EPS Insulation waste, contaminated with persistent organic pollutants (HBCD).
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For more information please read about the PolyStyrene Loop Project - Link
Recycling of Metal-Plastic Compounds and Hybrid Materials.
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For more information please check the Forcycle Project (2014 - 2016) - Link