Exxon Mobil says advanced recycling can solve plastic waste

When California Atty. Gen. Rob Bonta filed suit against Exxon Mobil and accused the oil giant of misleading the public about the effectiveness of plastic recycling, many of the allegations surrounded the company’s marketing of a process called “advanced recycling.”

In recent years — as longstanding efforts to recycle plastics have faltered — Exxon Mobil has touted advanced recycling as a groundbreaking technology that will turn the tide on the plastic crisis. Company officials and petrochemical trade organizations have used the phrase in radio spots, TV interviews and a variety of marketing material online. In a 2021 blog post, Exxon Mobil president of product solutions Karen McKee painted a particularly promising picture.

“Imagine your discarded yogurt containers being transformed into medical equipment for your next doctor’s appointment, and then into the dashboard of your next fuel-efficient car.”

But despite its seemingly eco-friendly name, the attorney general’s lawsuit denounced advanced recycling as a “public relations stunt” that largely involves superheating plastics to convert them into fuel. At Exxon Mobil’s only “advanced recycling” facility in Baytown, Texas, only 8% of plastic is remade into new material, while the remaining 92% is processed into fuel that is later burned.

Bonta’s lawsuit seeks a court order to prohibit the company from describing the practice as “advanced recycling,” arguing the vast majority of plastic is destroyed. Many environmental advocates and policy experts lauded the legal action as a major step toward ending greenwashing by Exxon Mobil — the world’s largest producer of single-use plastic polymer.

“There’s nothing ‘advanced’ about it,” said Jane Williams, executive director of California Communities Against Toxics. “It’s a deception. It’s been a deception for half a century. If they were going to be able to recycle plastic polymer back into virgin resin, they would have done it already. But they are using the same technology we’ve had since the Industrial Revolution. It’s a coke oven, a blast furnace.”

As more research has emerged on the limitations of plastics recycling, the revelations have shaken the public’s confidence about what to put in their blue, curbside recycling bins.

“The public perception of what’s recyclable with respect to plastic doesn’t match reality,” said Daniel Coffee, a UCLA researcher who studied plastic waste in Los Angeles County. “Recycling, for so long, was thought of as this perfectly crafted solution to single-use plastics. And the clearest answer as to why, is that the public was told so. They were told so, in large part, by an industry-backed misinformation campaign.”

Advanced recycling, which is also called chemical recycling, is an umbrella term that typically involves heating or dissolving plastic waste to create fuel, chemicals and waxes — a fraction of which can be used to remake plastic. The most common techniques yield only 1% to 14% of the plastic waste, according to a 2023 study by the National Renewable Energy Laboratory. Exxon Mobil has largely used reclaimed plastic for fuel production while ramping up its virgin plastic production, according to Bonta.

“You’re essentially drawing oil up, turning it into plastic, and then having to burn more oil to turn that plastic back into oil, which you then burn,” Coffee said.

Bonta alleges Exxon Mobil has had a patent for this technology since 1978, and the company is falsely rebranding it as “new” and “advanced.” The practice was tested in the 1990s, but did not continue beyond the trial phase. It recently reemerged after the company learned that the term “advanced recycling” resonated with members of the public at a time of increasing concern over increasing amounts of plastic waste.

In December 2022, it announced the start of an advanced recycling program. In a 2023 interview with a Houston television station, an Exxon Mobil representative touted the Baytown facility.

“When [customers] buy a plastic product off the shelf, they want to know that it’s sustainable,” the Exxon Mobil employee said. “This is a huge game change for the industry — but I would say society in general.”

In response to Bonta’s lawsuit, Exxon Mobil said its Baytown facility has processed 60 million pounds of plastic into “usable raw materials” that otherwise would go to landfills. Experts say that figure pales in comparison with the company’s 31.9 billion-pound annual production capacity.

Nationwide, the Baytown plant is one of about five facilities that break plastics down by exposing them to high heat, according to the Last Beach Cleanup, a nonprofit working on plastic pollution.

California has adopted some of the nation’s most strict laws to reduce single-use plastics. Perhaps the most consequential, SB 54, requires the state to sell 25% less single-use plastic packaging and foodware. It also prohibits waste incineration and similar practices from being counted as recycling.

Because most plastics cannot be recycled, state officials have struggled to figure out how to dispose of this material. California had previously exported much of its plastic waste to China. But China has banned the import of most foreign plastics, nearly eliminating the market for used plastic.

In 2021, about 5.4 million tons of plastic waste was taken to California landfills, according to the latest state disposal data. That same year, more than 625,000 tons of trash was sent to so-called “transformation” facilities, where waste is incinerated, or burned in the absence of oxygen (a process called pyrolysis).

California does not track data on how much of this incinerated waste was plastic, according to CalRecycle, the state agency that oversees waste management. The state also doesn’t keep detailed information on how much plastic waste is exported to other states and how they process it.

“California’s vision for a waste-free future is focused on reducing waste, reuse, and intentionally designing products that flow back into the system for efficient collection and remanufacturing into new products,” said Maria West, a spokesperson for CalRecycle.

If the state is earnest in its pledge to eliminate waste, environmental advocates say the state needs to phase out single-use plastics.

“You can’t do anything with plastic but landfill it or burn it,” said Williams. “You can try to repurpose it, but you’ll never compete with virgin stock. And even then, you have to shred it, make it into pellets and feed it into a blast furnace. How is that good for the climate? How is that better than coal?”