Upcycling Mixed Plastic Waste - Catalyst Free

One of the most severe environmental problems to date is caused by mixed plastic waste, as we are not able to mechanically or chemically recycle it.  World plastic production exceeded 330 million tons in 2018; over 50% of all plastics produced cannot be recycled based on conventional technologies.

Our company has developed a controlled de-polymerization process, using carbon based nano-elements as reactive agents to modify the carbon link dynamics, forming new chains and leveraging nano copper to remove sulfur, successfully upcycling plastic waste into fuels and new chemical compounds.

Social Impact:

Our process can transform the way plastic is disposed of and/or collected, significantly improving the lives of low-income individuals involved in waste collection and recycling throughout Latin America and the Caribbean. 

Environmental impact:

Plastic waste that reaches landfills contributes to greenhouse gas emissions; so reducing the amount of plastic that reaches a landfill will have a positive impact.

Plastic waste is a massive environmental problem, and especially critical in developing regions of the world.  In Latin America and the Caribbean environmental awareness is rising, however, there is a lack of recollecting and recycling infrastructure.  Plastic should be recyclable AND recycled (two different concepts).  According to multiple studies and industry reports, less than 25% of plastic waste is recycled.

In Latin America and the Caribbean, the scope of people affected is in direct correlation to each nations wealth, and overall waste management infrastructure.   In Argentina for example, Ceamse centralizes waste from Greater Buenos Aires metro area, however, less than 15% of plastic is recycled.  In Paraguay, landfills are within the city limits, like Cateura, where thousands of low-income families live among trash.  Most countries have poor infrastructure to process the mixed plastic waste.  Landfills are filling up and cause environmental hazards for cities, such as odors and diseases. 

The contributing factors for the plastic waste crisis are mainly related to the lack of proper infrastructure to recollect and process waste, to recycle, or to chemically recycle.  Our solution can tackle mixed plastic waste and is a breakthrough innovation to help solve this problem.

The broad scope of people who work in waste recollection and waste treatment is mostly unknown or not fully understood.  This is especially true when considering developing countries; there, a municipal landfill may employ hundreds of workers that literally sort through tons of garbage to collect small amounts of recyclable products (plastics, cans, metals, etc.) in order to survive.

The general perception is that recycling “occurs” when we dispose our plastic waste and if available, to a plastic specific waste bin or container.  However, this is just the beginning of the cycle.

Our solution plans to build infraestructure to process mixed plastic waste.  This will address the fundamental flaw of the mixed plastic waste process, while creating eco friendly qualified jobs.

We plan to build awareness in communities by setting recycling targets, and turn that plastic waste into valuable products.  This will possitively affect the supply chain, and help decouple from fossil fuels.

Companies are looking to diversify and find cost effective alternatives from traditional fossil fuels, while meeting specific requirements on the product, like sulfur content.  Our testing has proven that our products are equal and/or superior to the traditional fossil fuels.

Our value proposition allows us to deliver an ecofriendly energy solution, alternative to traditional fossil fuels. Compared to other upcycling technologies, or plastic-to-fuel companies in this rapidly emerging industry, we are the only energy solution that can tackle all types of plastics, including mixed and currently non-recyclable plastics, with no need to shred or wash, and to produce low & zero-sulfur fuels and chemical products from up cycled plastic waste.

Technology

We have developed a proprietary carbon nano element based chemical recycling applied technology: the shape and length of the carbon elements enables us to effectively restore carbon chains to the desired lengths, as the fuel compounds are being created in the reactor.  This key factor enables us to use all mixed plastic waste as raw material, in an efficient and cost effective process, leading to higher quality fuels and products.

Our process: 

1. Allows for all kinds of plastic waste, even mixed. 

2. Produces low and zero-sulfur fuels. 

3.  Has lower CAPEX because our carbon based nano elements achieve high-quality products in a single step.  

4. Delivers high calorific value of 11.250 Kcal/Kg in Diesel tests (comparable and higher than fossil fuels).

Our innovative and disruptive technology is a proprietary chemical recycling process for mixed plastic waste, leveraging on nano element use for high yields and quality. 

It is a process that turns plastic waste into petrochemical products by a catalyst-free advanced pyrolysis. 

A core aspect of our technology is the ability to used different types of plastic waste, even mixed, including high & low density polyethylene (HDPE & LDPE), polystyrene (PS), polyethylene (PET), polypropylene (PP), among others.  

In general terms, our process is a thermochemical decomposition carried out at low temperature and at a controlled pressure, cost efficient, and with no need to pre-treat plastic waste.

These optimized reaction conditions allow a controlled polymer degradation and a control in the size of final compounds, via a re-arrangement of carbons bonding. All this is possible by using carbon-based reagents that are integrated into the reaction products without generating additional residues. 

The use of catalysts is avoided, and this is also an innovation.  It reduces the cost of the process, and avoids environmental pollution.  Our process can create petrochemical products such as pyrolysis oil, fuels, paraffins or naphtha, and further process to obtain other valuable compounds. 

We think the only way to effectively help solve the plastic waste crisis is to create tangible value in plastic waste.  "Tangible" means financial and economic value.  

To effectively make a long term impact, we must work with lower-income families that depend on waste recycling, to create value in waste.

Our idea was born while managing a plastic recycling firm that had direct contact with hundreds of very low income families living from waste and landfills.

Our activities will include building relationships with local waste management facilities, local governments, plastic recyclers, plastic manufacturers, and Oil & Gas companies.  

Impact will be driven by households, though targeted marketing and product placement campaigns, but where the "product" is plastic waste.

Outputs include: better recollection and sorting, because at origin (households) plastic is not mixed or polluted; this in turn leads to higher recycling rates, and in turn leads to processes like ours where up cycling of plastic waste can occur. 

We have proven our technology to use nano-elements and produce high quality low & zero-sulfur fuels and chemical compounds from mixed plastic waste.  This in turn drives investor interest & product demand; an innovative technology is a sought after solution.  

There is a positive environmental impact, by reducing greenhouse emissions from fossil fuels (essential in addressing global warming concerns), and allowing landfills to make better use of their facilities and produce bio fuels, achievable when plastic waste is out of the equation.

Our company is Pre-revenue and in Pilot Plant stage.  Production has not yet begun.  The pilot plant will rollout in 2020.

The pilot plant is expected to serve a population of 2.1 million.  This is the population of the Basque Country region, north of Spain.  This region has an estimated 500.000 tons of plastic waste going to landfills or incinerator facilities each year.  We chose this region as a launch strategy given the high recycling targets, overall stable regulation, access to top tier engineering firms and specialized research labs.  

When we expand Latin America & the Caribbean, we expect to partner up with local recycling and waste management firms, local governments, and positively impact waste recollection and plastic waste treatment.

Our first target market will be Argentina, Gran Buenos Aires area.  This is a +12 million population.   As mentioned earlier, Ceamse is a waste management facility that attends this community, and has a very low plastic waste recycling status.  Argentina is chosen because of existing relationships, and market potential.  

Our process can scale and expand.  It is a modular solution replicable anywhere where plastic waste is a problem.

In a five year period outcome will depend on how our solution is implemented and accepted.  It is too soon to determine if we will be operating in multiple countries.   However, our focus is to be a definite solution for mixed plastic waste.

Our technology and business model have a "Triple bottom line":

• Social: Our process can transform the way plastic is disposed of and/or collected, significantly improving the lives of low-income families involved in waste recollection and recycling.  The broad scope of people who work in waste recollection and waste treatment is mostly unknown or not fully understood.  This is especially true when considering developing countries; there, a municipal landfill may employ hundreds of workers that literally sort through tons of garbage to collect small amounts of recyclable products (plastics, cans, metals, etc.) in order to survive. The general perception is that recycling “occurs” when we dispose our plastic waste to a plastic specific waste bin or container.  However, this is just the beginning of the cycle.

• Environmental: Plastic waste that goes to incineration plants, or that reaches landfills contributes to greenhouse gas emissions; so reducing the amount of plastic that reaches both will have a positive impact.  Plus, our zero-sulfur fuels burn cleaner, contributing to lowering emissions. 

• Financial: Our process yields a high conversion rate of plastic waste to high quality low & zero-sulfur fuels and chemical compounds.  We produce a wide range of usable fuels, have exceptional global scalability, and a healthy projected EBIDTA. 

Our one year goal is to build and operate a 10 ton/day processing capacity pilot plant for mixed plastic waste.   

This is the necessary first step to have proof of concept at an industrial scale.  It will help us validate technology, work on permits, product validation and testing, further R&D concerns, and implement our long term strategy.

The five year goal is to reach +200 ton/day processing capacity, distributed in three plants and in three countries, Spain, United States and Argentina.  This will allow us to process plastic waste in different locations, work with local landfills, waste managers and recycling facilities.  

We intend to have a global impact, grow steady with a comprehensive analysis and long term strategy.

This focus will allow us to change the way plastic waste is collected and processed, and help positively impact large communities.

For the one year plan the barriers are: 1. Obtaining commissioning and site permits for the pilot plant; 2. Positive carbon credits valuation via process certification; 3. Fuel testing and certifications via local independent labs; 4. Engine validations with test banks; 5. Emission control and certification; 6. Power generation testing and emissions control; 7. Complying with fuel specific taxation requirements.

We have conducted testing in a semi-industrial scale prototype, so key assumptions to overcome these barriers are aligned with our findings and previous R&D.   

Plastic availability is no concern, but plastic logistics is important for strategic planning of plant location.  

We expect technical challenges as we scale, however all within our teams´ field of expertise.

We have analyzed our scaling opportunities with a critical view on real go-to-market situations.  

On the mid term, five year plan, we expect regulatory and zoning barriers, specially considering we will expand internationally.

Recycling culture in different countries will be a barrier.  

Related to end products (diesel, paraffin, naphtha, others): We see a favorable plastic related regulation of sulfur reduction and overall “greener” fuels is in place.

These regulatory barriers depend on local regulation, but in general, selling to general public or industry players, all products must comply with similar criteria.

One year - same order as above: 

1. An environmental specific engineering firm has been hired to conduct permits.  We have also built a relationship with local government as they are eager to find solutions for mixed plastic waste.

2. A full process emission balance to be conducted by a CO2 specialized firm.

3. All fuel compounds and products are sent to Intertek, a world-class quality assurance lab. 

4. To be tested in specific engine banks.

5. The equipment manufacturer will be required to comply with local regulation. 

6. To be conducted with a 300kW gas powered turbine.  

7. Taxation will require specific accounting practices in line with local regulation.

Five year plan:

A successful launch is replicable throughout the world, and capturing a readily available supply of plastic waste is a key aspect that builds on operational excellence and cost efficiency.  The economies of scale for plastic waste supply translate to competitive pricing.

We will work with local firms to overcome zoning approvals.  Usual permits are required both at local government level and at central government level; Environmental and safety regulations/compliance apply depending on each location.

Recycling culture will require working with local recycling firms, waste management firms and local governments.   

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We plan to Build & Operate mixed plastic waste Up cycling facilities.

Latin America has readily and easily available streams of plastic waste, however with lesser quality of plastic waste due to lack of proper recycling and landfilling infrastructure.  

The market opportunity is to up-cycle mixed plastic waste to higher value end products.

Our strategic analysis includes: Financial requirements to scale, commissioning processes to build reactor units and plant facilities.

We have determined and analyzed some key factors:

·      Product(s) for each region/country: type, quality, quantity, customer validation, packaging, pricing. 

• Identify Product for each market: Diesel Grade A, B and Marine, Paraffin, Naphtha.
• Flexibility →locally adaptive response in marketing and sales.

• Marketing and sales are B2B.  
• Focus on Oil & Gas, Heating Solutions, and later to Marine Fuels and Power Generation.
• PR efforts will be in place to have visibility and work with local public administrations, NOGs, trade associations, and such.
• Legal and regulatory concerns to comply with in each country/region.
• Location: Economies of Scale upstream →Aggregate feedstock of plastic waste.

• Have Feedstock Supply Agreements with waste management facilities. 

• We will test all the plastic waste streams that work best and confirm volume.
• Team: Recruiting and hiring global teams plus local talent.
• Distribution strategy: direct to end-user, distributors, off-take, and franchise.
• Feedstock supplier network: local & international.  
• Offtake agreements with Oil & Gas, heating solutions and other target buyers.
• Franchise (or License) for growth opportunities.

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Full time staff: 6.

Part time staff: 1.

Contractors: Specialized EU top tier labs CIC nanoGune, CEIT-IK4, and Intertek.

Advisor: 1.

Our team has the unique combination of entrepreneurial & management skills, ability to build long-term relationships, technical in-depth knowledge of nano-elements, engineering expertise, combined with extensive experience in the Oil refinery industry, as well as hands-on plastic recycling experience.

Full time Team members:

CEO - Carlos U. - Engineering degree & entrepreneur. +10 yr experience in product placement of new technologies.

Corp Business Development: Humberto K. - MBA degree. +20 years of combined experience in plastic recycling and financial services.

Head of Engineering: Koldo M. - Engineering degree & +10 yr specialized in commissioning plants. 

Head of Lab: Mikel A. - Chemistry PhD, + 10 yr experience with nano elements. 

Sales: Angel A. - Business degree and +10 yr experience in International sales. 

IT & Logistics: Javier E. - Business and IT degrees.  +12 yr experience in international logistics and IT solutions.

Part-time: Nagore A. - Biochemistry PhD, lab researcher. 

Contractors: Specialized EU top tier labs CIC nanoGune, CEIT-IK4, and Intertek.

Advisor: Pablo O. + 20 years relevant experience in Oil refinery industries.  Has held several key roles in large Oil & Gas companies as Country Manager, Planning Advisor, Transition Manager, for USA, Latam and Chile operations.  Holds a Civil Engineer degree, specialized in Hydraulics.

We have established relationships with: 

1. Top tier research centers: Gaiker, Tecnalia, CIC-Nanogune, UPV-EHU; to conduct R&D on nano elements, fuel compounds, and plastic characterization, among others.

2. Industry engineering firms (confidential); for basic and detailed tailor-made engineering pilot plant design.

3. Quality assurance fuel-specific lab: Intertek. For fuel testing and certifications.

4. A CO2 emissions certification firm to evaluate our carbon footprint.

5. Potential customers in the Oil & Gas industry (confidential).  Working towards an offtake agreement. 

6. Potential strategic industrial partners (confidential). To secure location, pilot plant commissioning, and financing.

On the supply side, we are currently working on a Feedstock Supply Agreement for the pilot plant.  This is a key element for growth.  

On the demand side, we are building relationships with our target Oil & Gas companies to sign an Offtake Agreement.

Our business model is to build and operate mixed plastic waste chemical upcycling plants. Revenue is driven by fuel and upcycled chemical compound sales.

Our impact will be to reduce plastic waste going to landfills, incinerator facilities, or left in the environment.    

Key partners will be local recycling firms, waste management operators, local governments, Oil & Gas firms, and plastic producers.

With key customers, the plan is to lock in long-term agreements.  After fuels are tested and certified, we will leverage on success of previous relationships to build further capacity and product lines/uses, always identifying and securing availability of plastic waste, while considering end-buyer location.

Once volume increases, we can transition to applying a “gate fee” to collect plastic waste.  Plastic waste generated by a recycling firm is anywhere from 15% up to 40% of their total annual plastic intake.  By having our own collection site with a gate fee, we increase revenue and reduce direct costs.

There are many applications of our process, beyond paraffin and oil refinery markets.   Once we reach a 20ton/day capacity and can leverage off our built infrastructure, we aim to target the marine fuels market.

Once we reach +90ton/day capacity, we will capitalize on our experience to pursue power generation.  We will begin testing with a small 300 kW gas-powered turbine, and later with larger gas-powered turbines operating on-site, effectively using our synthetic fuels for power generation.

All made from plastic waste.

Revenue stream will be achieved by selling our products.

We are a pre-revenue company, at seed round stage raising investment capital.

We will deliver return and value to our investors and stakeholders through a clear and achievable Four-stage roadmap, based on three years of R&D, with a completed industrial scale prototype.  (Revenue figures are confidential)

Pilot plant is a ten-month setup and 12-months revenue stream.

Year 2 and 3: revenue grows as we increase the number of reactor units, production & sales accordingly. 

Year 4 onwards, we project to be at a 190 ton/day processing capability.  

We want to emphasize that there are multiple growth opportunities: by regions, by line of products, by expanding product uses, etc.  

In addition to local regulation, the growth dynamic will be driven by plastic logistics; simply put, how many trucks of plastic waste can we actually/effectively move per day to reach for example a +200 ton/day capacity, in one site or in multiple sites/regions/countries.

All financial considerations mentioned here are the result of a comprehensive 5 year cash flow analysis.  Details of this planning can be submitted upon request.

We are applying to the Rethink Plastics Challenge because we truly believe to have a proven solution to up cycle mixed plastic waste, and that this solution can be a game changer.   

We can achieve a positive impact in developing nations, given the lack of recycling infrastructure in these communities/countries. 

Our strategy includes expanding to Latin America and the Caribbean, and we feel it is the right time to start working on the next steps of this strategy.

This challenge allows for international recognition and visibility, for growth opportunities, for funding options, among others.  

Given the nature of the IDB Group, it also allows to positively impact communities that require recycling infrastructure, qualified job opportunities, and a positive social impact for lower income families throughout the region.

This challenge will also give us feedback on the strategy we intend to follow.  

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In the US: The American Chemical Council and The Recycling Partnership.

At a per/country level: 

Local waste management companies and recycling facilities.

Local government run waste collection facilities.

Local governments for recycling programs & campaigns.

Universities and plastic related research centers.