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Purpose <p>Beverage cartons (BCs) are multi-material, multilayer packaging composed of paper, low-density polyethylene (LDPE), and aluminium. While the paper fraction is commonly recycled, the LDPE–aluminium fraction (PolyAl) is partially recycled, with most still incinerated with energy recovery (IwER). Chemical recycling (CR) is emerging as a promising solution for PolyAl. As a medium-TRL technology, its environmental performance remains uncertain. This study assesses the potential environmental impacts of PolyAl CR and how methodological choices influence impact outcomes.</p> Methods <p>Material Flow Analysis (MFA) and Life Cycle Assessment (LCA) were applied using SimaPro v9.5.0 and e! Sankey v5, respectively. The management of one ton of PolyAl fraction after paper separation was the functional unit (F.U). The Environmental Footprint method (v3.1) was used. IwER was the reference scenario. Mainly primary data obtained from pilot plant design specifications informed the foreground system. Secondary data from ecoinvent v3.9.1 supported the background system and filled foreground data gaps. Methodological choices included a waste perspective F.U., substitution for co-product modelling, and substitution plus a cut-off for end-of-life modelling. Data sensitivity was assessed through scenario analysis. Three methodological variants, combining F.U. perspectives (waste/product) and co-product modelling approaches (substitution/basket of products) were applied to evaluate the influence of modelling choices on results.</p> Results <p>CR achieved a material yield of 31% per ton of PolyAl (129&#xa0;kg of ethylene and 180&#xa0;kg of other hydrocarbon products), increasing to 50% when considering only the LDPE portion (61.5%) of the feedstock. Yields may vary with feedstock composition and scale-up. CR outperformed IwER in four impact categories, including climate change, fossil resource use, and particulate matter. IwER performed better in 12 categories, largely due to Belgium’s electricity mix and the incineration of CR residues. Scenario analysis showed that assumptions, particularly on transport distances and alumina recovery, strongly influenced outcomes. When full substitutability of recovered alumina was assumed, CR outperformed IwER in all categories. Methodological choices substantially impacted conclusions, with the same CR system appearing more or less favourable depending on these choices.</p> Conclusions <p>This study highlights the importance of electricity sourcing and facility location in determining CR’s environmental performance. Substitutability assumptions significantly influenced results. Methodological transparency in LCA is essential, as modelling choices can lead to contrasting conclusions. By addressing both environmental performance and modelling sensitivity, this study provides a sound basis for evaluating CR as a potential treatment pathway for the PolyAl fraction in beverage cartons.</p>

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Material flow analysis and life cycle assessment of chemical recycling of the polyethylene-aluminium fraction from used beverage cartons: effects of methodological choices in LCA

  • 期刊论文

  • 发表日期：

    2026年3月9日

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  • Estefania Sanabria-Garcia,
  • Pieter Nachtergaele,
  • T. Trang Nhu,
  • Jo Dewulf,
  • Sophie Huysveld

摘要

Purpose

Beverage cartons (BCs) are multi-material, multilayer packaging composed of paper, low-density polyethylene (LDPE), and aluminium. While the paper fraction is commonly recycled, the LDPE–aluminium fraction (PolyAl) is partially recycled, with most still incinerated with energy recovery (IwER). Chemical recycling (CR) is emerging as a promising solution for PolyAl. As a medium-TRL technology, its environmental performance remains uncertain. This study assesses the potential environmental impacts of PolyAl CR and how methodological choices influence impact outcomes.

Methods

Material Flow Analysis (MFA) and Life Cycle Assessment (LCA) were applied using SimaPro v9.5.0 and e! Sankey v5, respectively. The management of one ton of PolyAl fraction after paper separation was the functional unit (F.U). The Environmental Footprint method (v3.1) was used. IwER was the reference scenario. Mainly primary data obtained from pilot plant design specifications informed the foreground system. Secondary data from ecoinvent v3.9.1 supported the background system and filled foreground data gaps. Methodological choices included a waste perspective F.U., substitution for co-product modelling, and substitution plus a cut-off for end-of-life modelling. Data sensitivity was assessed through scenario analysis. Three methodological variants, combining F.U. perspectives (waste/product) and co-product modelling approaches (substitution/basket of products) were applied to evaluate the influence of modelling choices on results.

Results

CR achieved a material yield of 31% per ton of PolyAl (129 kg of ethylene and 180 kg of other hydrocarbon products), increasing to 50% when considering only the LDPE portion (61.5%) of the feedstock. Yields may vary with feedstock composition and scale-up. CR outperformed IwER in four impact categories, including climate change, fossil resource use, and particulate matter. IwER performed better in 12 categories, largely due to Belgium’s electricity mix and the incineration of CR residues. Scenario analysis showed that assumptions, particularly on transport distances and alumina recovery, strongly influenced outcomes. When full substitutability of recovered alumina was assumed, CR outperformed IwER in all categories. Methodological choices substantially impacted conclusions, with the same CR system appearing more or less favourable depending on these choices.

Conclusions

This study highlights the importance of electricity sourcing and facility location in determining CR’s environmental performance. Substitutability assumptions significantly influenced results. Methodological transparency in LCA is essential, as modelling choices can lead to contrasting conclusions. By addressing both environmental performance and modelling sensitivity, this study provides a sound basis for evaluating CR as a potential treatment pathway for the PolyAl fraction in beverage cartons.