The CEO of Versalis, in an interview with Repubblica, retraces the company's activities from a circular economy perspective

We gladly welcome on r NEWS Giacomo Talignani 's interview with the CEO of Versalis, Daniele Ferrari , in which the issues of the present and future of the circular economy are addressed, regarding the processing and disposal of plastic waste. The article addresses the still open problems of the waste cycle: landfills, waste-to-energy, pyrolysis, disposable products and the creation of sustainable packaging.

Chemistry and its processes as the key to designing a world based on greater recycling capacity, packaging and leaner and more environmentally friendly products, but also plastic recovered and made "virgin" again and new recipes for the long road towards decarbonisation . Products designed under the lens of circularity, the recovery of materials and the search for alternative ones are today at the center of the mission of Versalis, Eni's chemical company. Daniele Ferrari, CEO of Versalis, talks about the importance of chemistry for the sustainability of today and the future.

How can chemistry help recycling today and be at the center of the circular economy?

"As producers of plastic materials and chemical products, it is very important for us today not only to produce but also to provide new solutions which will then be used on the markets. This is why for Versalis circularity must be 360 degrees.

We move along three fundamental lines: eco design, that is, producing and thinking about our products also from an end-of-life perspective, maximizing resources and thinking, for example, about how to make products easier to recycle; then the use of alternative feedstocks with the right transition mix between fossil and renewable raw materials, which we are increasingly focusing on in our production; and finally, particular development and attention to recycling technologies.

We have a strong sense of social responsibility, with ever greater attention to sustainability in the company: therefore we as the chemical industry must commit to contributing with the aim of recycling both mechanically and chemically the products."

The plastic you deal with is a complex material to recycle. How are you moving to recover it?

"The rate of plastic recycling in the world is still low. In Europe, with a market of around 50 million tonnes of virgin plastic, over 30% of the plastic waste collected is sent to recycling processes, over 40% is waste-to-energy and the remainder ends up in landfills, and the latter is a big problem.

We need to be able to recycle more. During the pandemic linked to Covid we realized the importance of some applications of plastic: from those used in the healthcare sector to those in food packaging, the importance of plastic came to our attention precisely due to its versatility, because without this material it would have been difficult to do many of the things we did, from swabs to masks.

It is therefore necessary to think more and more about the reuse of plastic: today in Europe mechanical recycling can satisfy the need up to a certain point. We will probably increase the percentage of mechanically recycled plastic, but it is unlikely that we will go further because there are mixed plastics and multi-layer materials on the markets.

That's why, to go further and achieve greater recovery possibilities, we are developing molecular recycling. An example is what we do with the Hoop project, we plan to build a first 6 thousand tons per year plant in Mantua".

What does this project consist of?

"In very simple words, Hoop is based on the pyrolysis process to transform mixed plastics into raw material that can give life to new "virgin" plastics, in order to have a circular economy cycle.

The recovered plastic is heated in the reactor to 400-500 degrees with low pressures: essentially we break it down to be able to reuse it. Beyond the energy production to heat the reactor there are no direct emissions and this process ensures that this plastic returns to being a primary good.

With molecular recycling you are less limited than mechanical recycling. In the future we hope that this cycle will also include the possibility that the energy necessary for this process comes entirely from renewable sources, in order to close the cycle completely"

Is it difficult to apply the concept of circularity to plastic recovery?

"We are part of the Circular Plastics Alliance and have made important commitments for the recycling of plastic, trying to demonstrate that this material can be recovered.

Plastic is not a problem, but poor end-of-life management is. This can be achieved with the technologies we are developing. In fact, we believe that for the future it is better to commit to better managing plastic waste, rather than eliminating this material, in a slogan it is better to be "plastic waste free" than "plastic free".

What other challenges involve plastic waste?

"For example, one of the first challenges undertaken is the Versalis Revive project. We create new products with up to 75% virgin plastic and recycled plastic.

We can do this both in polystyrene and in polyethylene, for example to obtain products for the agricultural sector for packaging such as films and films.

Then there are initiatives like RiVending, in which we collect coffee cups and stirrers and from disposables we give life to the production of expandable polystyrene for insulating sheets for condominiums or homes and protective packaging for household appliances and furniture.

I believe that RiVending also demonstrates that in the great rush to ban single-use plastic we could think differently, that is, on how to recycle them and capture their value without damaging an industry already under pressure. We have demonstrated in a practical way what can be done with disposable items, an example of recycling that can also be applied in other situations."

An example of reconversion instead comes from Crescentino (Vercelli), where you now produce disinfectant.

"Yes, with the experience we have in chemistry from renewable sources at the Crescentino site in Piedmont we have adapted the production plants to produce a range of disinfectants (called Invix, ed.) using ethanol from vegetable raw materials as the active ingredient.

A necessary reconversion for the particular and difficult moment we are experiencing. We will continue to produce and expand our product range soon."

What other transformations will be necessary to guarantee the energy transition?

"We will need a complete transformation of our industry, but it cannot be done in a single stage. Integrating traditional chemical plants with new and technological structures that allow us to be increasingly renewable and circular is the objective.

To do this we use a strategy that I would define as phased, modular, a path that chemistry is already following and must follow to be at the forefront, stimulated by environmental sensitivity, by the New Green Deal and by all the support systems that will come for the change".

What role does chemistry play in this match?

"Within Eni each business does its part towards decarbonisation. We as the chemical part have the possibility of integrating and being able to make a technological contribution towards this change.

We feel strongly motivated and responsible: the chemical industry affects approximately 95% of each industrial sector, many of the products that surround us are made thanks to chemistry and for this reason we know we have an important role towards the future.

We hope that people also understand how chemistry, sometimes incorrectly framed or perhaps associated with pollution, actually has a decisive and precious role, as a resource, for the development of a more sustainable society".

Giacomo Talignani, la Repubblica