Polymer Recycling Pilot Plant: FEED and Detailed Design
ReVentas is a recycling technology company that set out to prove a scalable, commercially viable way to recycle mixed waste polymers into new products. IDEA acted as ReVentas's end-to-end engineering partner, covering FEED, detailed design across process, mechanical, electrical, control and instrumentation (EC&I), process safety and compliance, and support through procurement, installation and commissioning, to turn that concept into an operating pilot plant.
At a glance
- Sector: Chemicals
- Scope: FEED, detailed multi-discipline design, process safety and compliance support, procurement, installation and commissioning support
- Disciplines: Process, mechanical, EC&I, process safety
- Outcome: A flexible pilot plant proving a new polymer recycling route, with data and documentation supporting future scale-up.
Client Overview
ReVentas is an innovative recycling technology company focused on unlocking more value from mixed waste polymers. Rather than treating mixed plastics as a problem stream, ReVentas set out to prove a scalable, commercially viable way to recycle them into new products.
To do that, ReVentas needed an operating pilot plant that could turn their concept into real data, real product and real investor confidence.
The challenge: turning a recycling concept into a buildable, operable pilot plant
The core challenge was converting an innovative recycling concept into a pilot plant that could be built, operated safely, and produce reliable, repeatable data across a range of feedstocks.
- Demonstrating a new recycling route for mixed polymers under realistic operating conditions.
- Building in flexibility so different feedstocks, blends and operating modes could be trialled without major rework.
- Embedding safety and environmental performance in line with UK regulations and the expectations of future full scale facilities.
IDEA's role
IDEA acted as an end to end engineering partner, delivering FEED and detailed multi-discipline design alongside process safety and compliance support, and remained involved through procurement, installation and commissioning.
- FEED and Basis of Design, defining feedstock ranges, unit operations, utilities and the design envelope.
- Operating and control philosophy covering start-up, shutdown, upset response and protective interlocks.
- Verified mass and energy balances to underpin equipment and utility sizing.
- Coordinated process, mechanical and EC&I design, supported by a 3D model.
- HAZOP and LOPA facilitation, DSEAR support and hazardous area classification.
What we delivered
The delivered package covered FEED, detailed multi-discipline design, and the process safety documentation needed to support safe pilot operation.
- FEED package, including Basis of Design and developed P&IDs.
- Verified mass and energy balances.
- Detailed process, mechanical and EC&I design deliverables.
- Equipment datasheets and technical specifications.
- Coordinated 3D plant model.
- HAZOP and LOPA facilitation with tracked actions.
- DSEAR support and hazardous area classification deliverables.
Results and outcome
The project delivered a pilot plant designed to trial different mixed polymer feedstocks and operating strategies, with safety and compliance requirements embedded into the design.
- Supports iterative development across different feedstocks and operating strategies.
- Embeds safety and regulatory compliance requirements into the design.
- Provides a clear set of process and control deliverables to support operator confidence and repeatable trial outcomes.
- Establishes a traceable engineering basis, including mass and energy balance data, for future scale-up decisions.
Why IDEA for pilot plant and process safety engineering
IDEA combines FEED and detailed design capability with process safety leadership, supporting clients from concept through to commissioning.
- Delivery from FEED through to commissioning support.
- HAZOP, LOPA and DSEAR experience across process industries.
- Integrated process, mechanical and EC&I design capability.
- Vendor-neutral, client-focused engineering advice.
Frequently Asked Questions
A pilot plant FEED (Front End Engineering Design) study defines the Basis of Design, feedstock ranges, unit operations and utilities for a pilot scale facility, establishing the engineering basis before detailed design begins.
A recycling pilot plant is typically used to trial different feedstocks, blends and operating modes. Building flexibility into the design from FEED stage avoids major rework later and supports faster, lower-risk trials.
Detailed design typically produces finalised P&IDs, equipment and instrument datasheets, a coordinated 3D model, mechanical and EC&I design packages, and the documentation needed to support procurement and construction.
A HAZOP (Hazard and Operability study) systematically reviews a design to identify hazards and operability issues. LOPA (Layer of Protection Analysis) then assesses the adequacy of the safeguards identified, helping confirm whether additional protection layers are required.
DSEAR (Dangerous Substances and Explosive Atmospheres Regulations) applies where flammable or explosive substances are handled or created. It requires hazardous area classification and appropriate equipment selection to manage explosion risk.
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Planning a pilot plant or process scale-up project?
IDEA supports pilot plant and process scale-up projects from FEED through to commissioning, with process safety and compliance built in from the start.