Development of a novel microwave-assisted process that converts waste polyethylene plastic to ethylene

This study proposes a novel microwave-assisted process for converting waste low-density polyethylene into polymer-grade ethylene at an industrial scale, producing approximately 77 tons per hour. Experimental data from a laboratory-scale microwave reactor were utilized to design and evaluate the process through a detailed technoeconomic analysis. The results indicate that the microwave-assisted system exhibits a lower capital expenditure and a comparable operating expenditure relative to conventional ethane steam cracking, while generating additional valuable co-products such as propylene and aromatic hydrocarbons, leading to a higher net present value potential. Sensitivity analyses reveal that electricity price has the most significant impact on both net present value and levelized cost of production, followed by low-density polyethylene feedstock cost, whereas microwave reactor investment shows only a minor effect. Furthermore, when renewable electricity is used, the novel microwave process has the potential to substantially reduce the global warming potential. Overall, the proposed process demonstrates economic robustness and strong potential for sustainable, circular production of ethylene from waste plastics.