The escalating levels
of plastic waste have created an urgent need
for sustainable recycling methods aligned with the circular economy
(CE) goals. Leveraging process systems engineering (PSE) models, which
facilitate sustainability-driven problem-solving, this work proposes
a comprehensive mathematical framework optimizing diverse recycling
technologiespyrolysis, gasification, mechanical recycling,
and incinerationbalancing economic feasibility and CE contributions.
Recognizing the versatility of chemical recycling derivatives, this
model explores their applications in methanol and ammonia synthesis,
hydrogen production, and more, emphasizing plastic waste’s
potential to yield energy and valuable products through open- and
closed-loop pathways. A novel CE metric was introduced to assess recycling
pathways across critical indicators. An illustrative case study of
20 scenarios highlights pyrolysis refinery technology as promising
sustainable fuel and olefin production, tripling profitability, and
improving circularity by over 25%. Combining methanol synthesis and
pyrolysis refinery maximizes circularity to 44% enhancement. The flexible
weight allocation for the individual circularity metrics during optimization
highlights the emphasis on tailored solutions aligned with system-specific
needs. Comparative analyses between plastic waste and conventional
feedstocks unveil a cost-effective landscape that is dependent on
the product. Capacity-level sensitivity analysis consistently demonstrates
the superior performance of optimal solutions compared with the base
case regarding circularity and profitability.