Karmactive Staff
Chemical recycling sounds promising—a technology that breaks down plastics into their molecular components to create new materials. But recent research reveals a different story. According to an NRDC report, what the plastics industry markets as an environmental solution is largely a form of incineration that creates new pollution problems while failing to address our growing plastic crisis.
The Pyrolysis Problem
Nearly 80% of so-called “chemical recycling” facilities in the United States use pyrolysis—a high-temperature process that breaks down plastics. Scientists from the Department of Energy’s National Renewable Energy Lab found that pyrolysis converts only 0.1% to 6% of plastic waste back into new plastic. Most of the remaining material becomes fuel or waste products.
“The public wants an end to the plastics crisis, not more toxic air pollution or hazardous waste,” said Renée Sharp, NRDC’s director of plastics and petrochemical advocacy.
These facilities generate significant toxic byproducts. EPA data shows that between 2021 and 2024, just three pyrolysis facilities produced over 2 million pounds of hazardous waste. If all 26 currently proposed or under construction pyrolysis facilities are built, they could generate between 624,000 and 10.8 million additional pounds of hazardous waste.
Environmental Justice Concerns
The impact extends beyond the facilities themselves. Hazardous waste from just three existing pyrolysis plants traveled through 13 states for disposal. These facilities tend to be located in low-income communities and communities of color, raising serious environmental justice concerns.
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Cancer Risks from Fuel Production
What pyrolysis primarily produces isn’t recycled plastic but fuel. In 2023, the EPA approved 18 new chemical mixtures from plastic waste for use as fuels. One jet fuel mixture was estimated to pose a one-in-four cancer risk—meaning one in every four people regularly exposed throughout their life would likely develop cancer. The EPA later rescinded these approvals for reassessment.
Industry Lobbying
Despite these concerns, the plastics industry continues aggressively marketing chemical recycling as a “clean” source of “sustainable” fuels. The chemical industry is lobbying Congress and the EPA to speed approval for these technologies while removing federal pollution controls on toxic air pollution and hazardous waste.
Real Solutions
While the U.S. plastic recycling rate remains at only about 5%, the industry’s focus on chemical recycling diverts attention from more effective approaches.
“The world is drowning in plastic and we need to stop the massive overproduction before it’s too late,” said Sharp. “Reducing plastics use and production, switching to more environmentally sound materials, and investing in a robust infrastructure for nontoxic reuse/return systems are the best solutions to the plastics crisis.”
FAQ
What is chemical recycling and how does it differ from traditional recycling?
Chemical recycling breaks down plastics at the molecular level, unlike traditional mechanical recycling which melts and reshapes plastics. However, the most common form (pyrolysis) is essentially a type of incineration that produces fuel rather than new plastic products. Scientists found that only 0.1% to 6% of plastic processed through pyrolysis actually becomes new plastic.
Is chemical recycling effective at solving our plastic waste problem?
No. Despite industry claims, chemical recycling facilities in the US are not recycling much plastic. Instead, they primarily produce fuels or create hazardous waste. The US plastic recycling rate remains at only about 5%, and chemical recycling technologies have not meaningfully improved this rate.
What environmental and health concerns are associated with chemical recycling?
Chemical recycling facilities generate significant hazardous waste and toxic air pollution. EPA data shows three facilities produced over 2 million pounds of hazardous waste in just three years. The fuels produced can pose serious health risks—one EPA-approved fuel mixture was estimated to create a one-in-four cancer risk for those regularly exposed over their lifetime. These facilities are also typically located in low-income communities and communities of color.
How many chemical recycling facilities exist in the United States?
While there are currently few operational chemical recycling facilities in the US, more than one-third of all states have at least one proposed or operating facility. Most (80%) use pyrolysis technology. There are 26 additional pyrolysis facilities currently proposed or under construction across the country.
Who regulates chemical recycling facilities?
Chemical recycling facilities are regulated under the federal Clean Air Act, as pyrolysis and gasification are forms of incineration. However, the industry is lobbying Congress and the EPA to remove federal pollution controls on toxic air pollution and hazardous waste generated by these facilities.
What are more effective alternatives to chemical recycling?
More effective solutions include reducing plastic production and use, switching to environmentally sound alternative materials, eliminating the most toxic plastics and chemical additives, and building infrastructure for reusable packaging systems. These approaches address the root cause of plastic pollution rather than creating new environmental problems through chemical recycling.
