Emerson Partners with ReNew ELP to Automate First‑of‑Its‑Kind Hydrothermal Plastics Recycling Plant

Emerson (NYSE:EMR) has been selected as the digital automation partner for ReNew ELP’s new plastics recycling facility in Teesside, north‑east England. The collaboration will deliver advanced control and safety systems that enable the safe, efficient operation of HydroPRS™, a hydrothermal process that transforms end‑of‑life plastics into the original feedstock for new plastic products.

ReNew ELP’s HydroPRS™ uses supercritical steam to break down waste plastics into valuable chemicals and oils, providing a cleaner alternative to conventional mechanical recycling. The process is designed to handle flexible and multi‑layer packaging—films, pots, tubs and trays—that are typically deemed “unrecyclable” and end up in landfill or incineration. According to the World Economic Forum, 95% of the value of plastic packaging is lost after a single use, costing the global economy $80–120 billion each year.

Richard Daley, Managing Director of ReNew ELP, explains, “By converting end‑of‑life plastics into fossil‑replacement feedstocks, we can eliminate unnecessary single‑use plastic and create the raw ingredients for a circular economy, turning waste into value.” He adds, “Emerson’s advanced automation model will be crucial for the first commercial‑scale plant and for future sites across Europe.”

To assess environmental performance, the HydroPRS™ process is undergoing a Life Cycle Assessment by the Warwick Manufacturing Group. Early results show a substantially lower Global Warming Potential compared to energy‑from‑waste incineration and fossil naphtha, supporting a viable pathway to net‑zero emissions.

As the main automation contractor, Emerson will design a comprehensive control and safety architecture that minimizes operator intervention while maximizing safety and efficiency. The solution will include:

• DeltaV™ Distributed Control System and DeltaV Safety Instrumented System for process control, emergency shutdown, and fire‑and‑gas detection.
• Plantweb™ digital ecosystem with wired and wireless networks to provide real‑time visibility into process performance and equipment health.
• A range of severe‑service and general‑purpose valves, on/off valves, and pressure control technology to support reliable operation.
• Asset‑management tools that enhance equipment reliability, increase throughput, and reduce field inspections.

Emerson’s Project Certainty methodology digitalises project execution, ensuring the plant is delivered on budget and on schedule. Operational Certainty tools will help ReNew ELP achieve peak performance and profitability over the facility’s lifecycle.

Roel Van Doren, Group President of Global Sales at Emerson, states, “Our digital solutions empower industrial companies to achieve environmental sustainability through greater efficiency, cleaner energy, emissions capture, and improved waste management.”

The Teesside plant is slated to commence operations in late 2022. The first phase will feature one of four recycling lines, each capable of processing 20,000 tonnes of plastic waste annually, a significant step toward a scalable circular plastics economy.