US-based Resynergi and Lummus Technology announced they have started commercialising Resynergi's Continuous Microwave Assisted Pyrolysis (CMAP) modules.
The chemical recyclers started their partnership in 2024, when Lummus participated in a $6.4 million funding round to scale up Resynergi’s technology.
CMAP converts HDPE, LDPE, PP, and PS waste plastics into pyrolysis oil at a rate 20 times fast than standard pyrolysis methods. The technology’s modular design allows for rapid deployment and scalability, reportedly making chemical recycling more affordable and versatile.
Lummus will fabricate and supply the modules, leveraging its global fabrication network and long history of supplying modular and proprietary equipment.
"The world can't wait for large factories and recycling facilities to come online to process our mounting plastic waste crisis," said Resynergi CEO Brian Bauer. "The commercial offering of our modules is a crucial milestone in the viability, speed and impact of a circular future for plastic. We're proud to have Lummus Technology as our trusted partner to bring our technology to market and make advanced recycling not only possible and profitable but friendly, safe and clean for local municipalities."
The modules are placed on a skid and can be scaled horizontally, purportedly shortening the plant’s deployment and start-up to weeks rather than years. The pyrolysis reactor is said to have a 10 times smaller footprint than standard reactors, where polymer molecules are broken down 100 times faster with the use of microwave energy. Microwave assisted technology reportedly leads to carbon emission reduction of up to 68% compared with standard pyrolysis.
Resynergi operates a demo plant in Santa Rosa, California, with a 1-ton CMAP reactor unit which converts 1.25 tons of both post-industrial and post-consumer plastic waste per day. By placing four CMAP reactor units on a skid, Resynergi plans to convert 5 tons per day and scale production of its reactor units-on-a-skid model across the US. Four CMAP reactors easily fit into a single 40 ft x 8 ft (12 m x 2 m) shipping container skid, according to the company.
The Resynergi modules can also leverage digital capabilities from Lummus Digital. The available capabilities can integrate data collection, machine learning and artificial intelligence. They can also monitor module installations offering real-time data for improved decision-making allowing operators to access expert advice and remote support.
"This milestone demonstrates how Lummus and Resynergi are advancing the circular economy with their decentralized solution which makes it easier and faster to transform plastic waste into valuable resources," said Leon de Bruyn, President and Chief Executive Officer of Lummus Technology. "Now that the technology is available, we can work with customers to integrate this advanced solution into existing infrastructure, helping close the loop on plastic waste and drive sustainability in our industry."