CHAPTER ONE - INTRODUCTION
1.1 BACKGROUND
Polyethylene Terephthalate (PET), a semi-crystalline polyester, is a well-known polymer
exhibiting properties such as durability, lightweight, and excellent barrier properties against
moisture, gases, and contaminants. Due to these favorable characteristics, PET has been widely
used in various industries for the production of food packaging, photographic films, cosmetic
packaging, and other containers. As a result, the production of PET is expected to grow at an
average annual growth rate of about 3% from 2023 to 2028. This growth could potentially lead
to a 50 mtpa increase in production compared to 2023 levels. However, PET is non-
biodegradable, and its widespread use has resulted in persistent waste accumulation in landfills
and natural ecosystems. Without effective recycling strategies, PET accumulation may
exacerbate environmental pollution (Wang et al., 2020).
Traditional recycling methods for PET, such as mechanical recycling, often lead to a degradation
of polymer properties due to repeated thermal and mechanical stresses. This quality deterioration
limits the recyclate’s usability in high-value applications, ultimately prompting a shift toward
chemical recycling. Chemical recycling processes, particularly glycolysis, offer an attractive
alternative by depolymerizing waste PET into its original monomers. Glycolysis converts PET
into bis(2-hydroxyethyl) terephthalate (BHET) using glycols like ethylene glycol under catalytic
conditions. The recovered BHET can be repolymerized into PET of almost 95% purity or used to
synthesize other high-value polymers, closing the loop in a circular economy and reducing
reliance on fossil-derived raw materials (Zhang et al., 2022).
The glycolysis process involves several key reaction parameters such as temperature, pressure,
catalyst type, and glycol-to-PET molar ratio. Optimizing these parameters is critical to achieving
high conversion efficiency, product purity, and energy efficiency. For instance, the selection of
an appropriate catalyst can significantly lower the activation energy and enhance the selectivity
toward BHET formation. Recent advancements in catalyst development have shown promising
results with metal-based catalysts and novel nanostructured catalysts that operate effectively at
lower temperatures, thus reducing energy consumption (Liu et al., 2021). Additionally, precise
control of reaction conditions through process intensification techniques has further improved
the overall efficiency of the glycolysis process.
1.2 PROBLEM OF STATEMENT
Due to their overproduction and consumption, PET plastics have become widespread in society,
consistently ranking among the top five most dangerous trash items collected globally. PET
plastics are normally not considered to be harmful but the accumulation of its waste, particularly
from single-use bottles, in landfills and marines after use disrupts the ecosystem thereby
degrading the soil and water quality. Additionally, PET plastics are a major source of carbon
emissions. PET is produced from petrochemical components such as BHET and ethylene glycol,
which come from crude oil and natural gas. The extraction, refining, and processing of these raw
materials are very energy intensive, releasing considerable amount of CO2 and methane into the
atmosphere. These emissions potentially lead to increase in global warming and climate change.
The damaging impact of PET plastic pollution on human life and ecosystem is evident, and
tackling this problem requires a robust recycling strategy.
Chemical recycling through catalytic glycolysis has emerged as a promising approach to
depolymerize PET into bis(2-hydroxyethyl) terephthalate (BHET), which can be repolymerized
into new PET or utilized in other high-value applications (Ghosal and Nayak, 2022). Despite
advancements in catalyst development aimed at enhancing the efficiency of PET glycolysis,
large-scale industrial implementation remains limited due to challenges in process optimization,
reactor design, energy consumption, and economic viability (Ghosal and Nayak, 2022). A
comprehensive plant design that addresses these challenges is essential to facilitate the efficient
conversion of PET waste into BHET.
1.3 MAIN OBJECTIVES
To design a plant for the production of recycled BHET from waste PET through catalytic
glycolysis.
1.4 SPECIFIC OBJECTIVES
The specific objectives of this project are to;
1. Perform a comprehensive literature review
2. Draw a process flow diagram for the production of BHET through Catalytic
Glycolysis
3. Carry out material and energy balance of the plant and individual units
4. Design various units within the plant
5. Assess the environmental impact of the Glycolysis process and its contribution to
sustainable development.
6. Draw a process and instrumentation diagram
7. Evaluate the economic viability of the proposed design
1.5 SIGNIFICANCE OF STUDY
The plant design seeks to address the severe environmental issues connected with the
accumulation of PET plastics by novel catalytic glycolysis process. This research is significant
for its potential to contribute to environmental sustainability, resource recovery, and the
improvement of recycling strategies.
REFERENCES
Liu, H., Zhang, L., & Chen, Y. (2021) ‘Advances in Catalytic Glycolysis of Waste PET’,
Journal of Chemical Technology & Biotechnology, 96(5), pp. 1542–1550.
https://doi.org/10.1002/jctb.6543
Wang, Y., Li, M., & Zhou, S. (2020) ‘Efficient Glycolysis of Waste PET for High-Purity
BHET Production’, Waste Management, 120, pp. 105–114.
https://doi.org/10.1016/j.wasman.2019.09.012
Zhang, Q., Sun, H., & Yang, J. (2022) ‘Industrial-scale Catalytic Glycolysis of PET: Process
Design and Optimization’, Chemical Engineering Journal, 430, 132414.
https://doi.org/10.1016/j.cej.2021.132414
