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Measure chemical plastic recycling as a life-cycle inventory and assessment, not with one standalone energy or emissions figure. Define what is being compared, map the process boundary, gather facility-specific energy and material flows, apply documented emissions factors, and show how co-products and substitution are handled. A result is meaningful only when its technology, feedstock, location, reporting period, boundary, and accounting choices are clear.
What should the measurement answer?
Start by stating the decision the study will inform. A facility improvement study, a product footprint, a comparison between technologies, and a waste-policy assessment may need different boundaries and functional units.
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Choose a functional unit that matches that decision. For a treatment comparison, it could describe a stated mass and composition of incoming plastic waste treated. For a product comparison, it could describe a stated quantity and quality of usable recycled output. Record the feedstock composition and condition, the process technology, the location and operating year, and the product specification. Do not treat results based on different functions as directly interchangeable.
Also say whether the result concerns energy demand, greenhouse-gas emissions, or broader environmental impacts. Energy use and climate impact are related but distinct results; a CO2-equivalent figure is not an energy total.
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Which process stages belong in the boundary?
Draw a process map and mark every included stage and exclusion. Depending on the study goal, relevant stages may include feedstock receipt and preparation; sorting, shredding, drying or washing; chemical conversion; gas handling and treatment; condensation and product recovery; upgrading or refining; residue treatment; transport; and downstream use or disposal. Upstream feedstock collection, capital goods, utility supply and displaced virgin production may also matter.
A gate-to-gate inventory can answer what energy is used at a facility, but by itself it does not establish a full life-cycle comparison. Keep measured direct plant emissions distinct from emissions modelled for purchased electricity, fuels, feedstock supply or other background processes. State the boundary diagram, assumptions, omissions and cut-offs. The European Commission’s Product Environmental Footprint guidance calls for these choices to be explicit; the JRC’s plastic-waste pathways assessment also considers factors such as electricity, transport, capital goods, background activities and displacement scenarios.
How should facility activity data be collected?
Make an inventory by process stage and reporting period. Prefer direct facility-specific data where accessible, using sources such as calibrated meters, utility bills, batch records, mass-flow meters and production logs. For each value, record its unit, period, source or instrument, uncertainty, and whether it was measured, estimated or modelled. If background datasets are needed, assess and disclose how well they represent the facility’s place, time and technology.
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| Inventory flow | What to record |
|---|---|
| Electricity | Consumption by process and period, with imports and exports distinguished; report in kWh or MWh. |
| Fuel, steam and heat | Type and quantity of on-site fuels and purchased steam or heat; identify the calorific-value basis where relevant. |
| Feedstock and preparation | Mass, polymer mix or other composition, moisture and contamination, plus pre-treatment inputs within scope. |
| Process inputs | Process aids, catalysts, water and relevant consumables when included in the boundary. |
| Outputs and residues | Product streams, off-gases, char, tar, non-condensable gases, aqueous streams and residues, with treatment flows and measurement uncertainty. |
| Transport and background processes | Distances and modes, and relevant infrastructure or background activities when included. |
Check whether the measured inputs and outputs form a credible mass balance, and report any unresolved gap and its uncertainty rather than silently treating the balance as complete. Keep energy reported by carrier and process stage before calculating any normalized total.
How do activity data become emissions results?
For each activity, select an emissions factor that matches its carrier, geography, year and technology as closely as the available data allow. Record the factor’s unit, source, year and representativeness. Calculate the contribution as activity multiplied by the matched factor. Use measured stack emissions for direct sources where suitable measurements exist; otherwise document the calculation method and assumptions.
Keep direct facility emissions, purchased-energy emissions and upstream supply-chain contributions identifiable in the inventory. Retain greenhouse-gas data by gas and document the characterization method used to aggregate them. Report climate impact in a stated CO2-equivalent unit and name the characterization method and time horizon. A CO2-equivalent result may include gases other than carbon dioxide and modelled upstream emissions, so it should not be described as measured CO2.
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The cited European Commission and JRC guidance supports life-cycle inventory and impact assessment, but it does not establish one emissions-factor dataset that is suitable for every plant and location. Select and explain factors for the specific study rather than presenting them as universal.
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Chemical routes can yield several streams. Chemical Recycling Europe’s industry-authored LCA guideline uses pyrolysis to illustrate outputs such as product gas, tars, chars and non-condensable gases. First determine which streams are wastes and which are products or co-products; that classification affects the accounting.
- Subdivide where possible. Assign inputs to separate outputs if the process can be divided in a way that reflects how it operates.
- Consider system expansion or substitution. Model the additional function and the product actually displaced only when the displaced product, its market and quality, and the substitution are supported by evidence.
- Allocate shared flows if the earlier approaches are unsuitable. State and justify the relationship used, such as mass, energy content or carbon content, show the shared flows and calculation, and test alternative choices when they could materially change the result.
The European Commission’s Environmental Footprint method describes subdivision or system expansion before allocation and identifies physical relationships as an allocation basis. Do not award recycled output a full virgin-material displacement credit by default: explain what it is assumed to replace and why that assumption fits its quality and use.
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How can results be compared fairly?
Align the functional unit, geography, reporting period, feedstock, output quality, process boundary and counterfactual before comparing routes or studies. For technology comparisons, specify the process route—such as pyrolysis, gasification or depolymerization—and whether preparation, upgrading and residue handling are included. Also compare yields, contamination, moisture, utility supply and the treatment of co-products.
A facility’s gate-to-gate energy total cannot be ranked fairly against a life-cycle result that includes upstream energy and supply chains. Nor does a plant-specific result automatically represent every facility using the same technology. State whether the comparison is about energy demand, climate impact or a broader set of environmental impacts.
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What should the final report disclose?
- The study goal, functional unit, feedstock description, technology, location, operating or reporting year, and product specifications.
- A boundary diagram, included life-cycle stages, exclusions, assumptions and cut-offs.
- Activity data by carrier and process stage, with units, sources, measurement period, uncertainty, and measured, estimated or modelled status.
- Emissions factors with source, unit, year, geography and technology relevance; the characterization method and time horizon for CO2-equivalent results.
- The treatment of each output, allocation calculations or substitution assumptions, and sensitivity tests for choices that could change the result.
- Data quality and uncertainty, including the distinction between foreground facility measurements and secondary background data.
Test sensitivity to factors that may materially affect the outcome, including electricity mix, feedstock composition, process yield, product quality and co-product allocation or substitution. The European Commission’s Environmental Footprint guidance emphasizes representativeness, sources, assumptions and exclusions; the JRC’s plastic-waste pathways assessment provides context for modelling background processes and displaced products. The JRC ILCD handbook and waste-management guidance offer broader life-cycle methods based on ISO 14040/14044.
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