CaviFlow® Cavitation Technology
Chemical Recycling

Chemical Recycling with Cavitation

With the increasing complexity of modern recycling streams, there is a growing need for innovative methods that make processes more efficient, adaptable and environmentally friendly. Hydrodynamic Cavitation offers a promising solution in the field of chemical recycling.

Energy efficiency and ecological benefits
Hydrodynamic cavitation is becoming increasingly established as a resource-saving and environmentally friendly process technology. Its key strengths include:

Less waste
Less secondary environmental pollution
Better ecological assessment of recycling processes

The hydrodynamic CaviFlow® Inline Modules are designed as plug & play systems and simultaneously take on the function of a highly effective mixer and a variably adjustable reactor. This enables them to optimize chemical recycling processes across different materials, process phases and liquid-solid-gas systems in a targeted manner. In addition, greater energy efficiency helps to meet the requirements of the circular economy and industrial decarbonization.

Recycling Application with CaviFlow® Inline Module

Chemical Recycling of Plastics

Plastic Pyrolysis Oil Upgrading

Biofuel Production from Waste Feedstocks

Artificial Bitumen from End-of-Life Tires

Industrial Processing and Material Homogenization

CaviFlow® Implementation in Recycling Processes

To the CaviFlow® Module

Tapping into Chemical Recycling Potential with Cavitation

Rely on hydrodynamic cavitation with CaviFlow® Inline Modules to process complex recycling streams with higher energy efficiency, lower environmental impact and optimized process conditions.

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Synergy Effects

Chemical Recycling of Plastics

Chemical plastics recycling is a particularly promising field of application for Hydrodynamic Cavitation with the CaviFlow® Inline Module. Especially in combination with depolymerization and solvolysis processes, it opens up considerable synergy effects.

Interaction and reaction rate
The intensive micro-mixing generated by cavitation improves the interaction between polymer material and solvent, while locally occurring high-energy zones increase the reaction rate of depolymerization.
Optimized processes
This allows processes to be carried out at lower temperatures and pressures and at the same time shortened in time.
Increased selectivity
Selectivity is also increased, which promotes cleaner recovery of monomers and reduces the formation of undesirable by-products such as coke residues or oligomers.

Homogeneity and Cold Flow Behavior

Upgrading of Plastic Pyrolysis Oil

Hydrodynamic Cavitation - such as with the CaviFlow® Inline Module - is increasingly being used in the industrial processing of plastic pyrolysis oil (PPO). Although pyrolysis has established itself as a proven method for converting mixed plastic waste into liquid hydrocarbons, the resulting oils often show deficits in their homogeneity and cold flow behavior. The reasons for this include waxes, heavy components and phase separations, which can make storage, transportation and further use more difficult.

Uniformity and quality specification
A practical industrial application showing that hydrodynamic cavitation can be used specifically as a conditioning step to improve both the uniformity and quality specification of PPO.
More uniform liquid phase
The intensive micro-mixing as well as the separation and distribution of heavy fractions and waxy agglomerates results in a more stable and uniform liquid phase.

Process combination without chemicals
In addition, hydrodynamic cavitation can be easily combined with thermal and catalytic recycling processes without the need for additional chemicals. This facilitates the integration of pyrolysis oils into existing fuel and refinery processes.

Process Technology for Pre-Treatment

Production of Biofuels from Waste Feedstocks

Hydrodynamic Cavitation is increasingly establishing itself as a powerful process technology for the production of biofuels from waste streams - like the CaviFlow® Inline Module. It is particularly frequently used as pre-treatment to make downstream conversion processes more efficient.

Homogenization and desulphurization

It improves the homogenization of the raw materials used and supports desulphurization processes in combination with oxidative or extractive processes.

Promotion of reactions

Hydrodynamic cavitation promotes both chemical and enzymatic reactions through more intensive mass transfer and faster reaction processes.

Less need for catalysts

In numerous applications, the need for catalysts and other chemicals can be reduced, while at the same time demanding input materials such as waste fractions or pyrolysis oils can be better processed.

Physical Intensification

Artificial Bitumen from End-of-Life Tires

Another new application with the CaviFlow® Inline Module is the production of artificial bitumen from used tires. Hydrodynamic Cavitation promotes the degradation and uniform distribution of tire components and additives, improving mixing, softening and integration into bitumen formulations. This physical intensification reduces processing time, improves product consistency and enables used tires to be recycled into construction and paving materials.

Highly Viscous or Multiphase Systems

Industrial Processing and Material Homogenization

In addition to specific recycling processes, Hydrodynamic Cavitation using the CaviFlow® Inline Module improves reactivity, homogenization and dispersion in highly viscous or multiphase systems.

Composites and secondary raw materials

It facilitates efficient emulsification and slurry processing, which is important for composite materials and the processing of secondary raw materials.

Metal and mineral recycling

In metal and mineral recycling, cavitation-assisted leaching and washing improve extraction efficiency and surface cleaning.

Organic and wastewater-related processes

In organic and wastewater-related processes, hydrodynamic cavitation accelerates particle disintegration, improves biodegradability and speeds up the subsequent treatment stage.

Intensification Unit

General integration of CaviFlow® in Recycling Processes

The CaviFlow® Inline Module, which is based on Hydrodynamic Cavitation, can be integrated as a process intensification unit in all areas of the recycling process. Including pre-treatment, conversion and post-treatment. It functions both as a high-performance mixer and as an adjustable reactor for liquid-solid-gas systems.

As a plug & play system, the CaviFlow® Inline Modules can be quickly integrated into existing recycling plants - without high investments. Direct integration and a quick start of operation is possible via flange or threaded connections. The modules work reliably and efficiently, even with contaminated recycling streams. A key reason for this is the design with no moving parts inside the module.

Through the controlled formation and collapse of cavitation bubbles, CaviFlow® generates controlled, localized high-energy conditions (e.g. microjets, shear forces and turbulence), resulting in:

Improved mass and heat transfer

Improved mixing and interface renewal increase phase contact and support the efficient processing of heterogeneous and multiphase flows.

Acceleration of chemical and physical reactions

Cavitation effects promote reaction kinetics and enable faster conversion and potentially milder operating conditions.

Reduction of particle size and agglomerates

Mechanical forces generated by cavitation allow agglomerates to be broken up and particle size to be reduced, typically from millimeter size to finer dispersions, depending on the system configuration and process conditions.

Reduced need for additives and catalysts

Improved process efficiency and intensified reaction environments can reduce the need for chemical additives and catalytic systems in many applications.

As a result, CaviFlow® improves overall process efficiency, facilitates the handling of complex or contaminated feedstocks and can be integrated into existing plants with high flexibility, supporting more sustainable recycling processes.

Technical Sketch

CaviFlow® Implementation

Physical Intensification

Recycling as an Economic and Ecological Necessity

With increasingly stringent regulatory frameworks and more ambitious sustainability targets, recycling is no longer optional, but an integral part of industrial strategy. In all areas of recycling, there is an obvious need for:

Improved mass transfer
Increased reaction performance
More effective handling of mixed or contaminated streams
Reduced environmental impact.

This has led to a growing interest in process intensification technologies that can improve existing recycling processes without the need to fundamentally redesign entire plants. One such technology is Hydrodynamic Cavitation with the CaviFlow® Inline Module.

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