Asahi Kasei and Microwave Chemical launched a joint demonstration project in April 2023 with the objective of commercializing a chemical recycling process for polyamide 661 (PA66, also called nylon 66) using microwave technology.

The process utilizes microwaves to depolymerize2 PA66 and directly obtain the monomers hexamethylenediamine (HMD) and adipic acid (ADA), which is expected to be accomplished at high yield with low energy consumption.

The monomers obtained can then be used to manufacture new PA66. In the demonstration, scraps from manufacturing and post-use waste material of PA66 for airbags and automobile parts are depolymerized.

Asahi Kasei currently produces fossil fuel–derived HMD and ADA as intermediates to manufacture Leona PA663, an engineering plastic featuring outstanding heat resistance and rigidity. PA66 is used in various applications, including plastic parts for automotive and electronic products, and yarn for airbag fabric, and its demand is expected to increase worldwide.

Laboratory-scale studies that began in fiscal 2021 have confirmed the high-yield depolymerization of PA66 using microwaves, as well as the principle of the separation and purification process after depolymerization. Bench-scale equipment will now be assembled at Microwave Chemical’s Osaka Factory by the end of fiscal 2023, and a small-scale demonstration trial using this equipment will be performed in fiscal 2024 to collect basic process data for commercialization.

Microwave Chemical’s PlaWave technology platform for decomposing plastic using microwaves can depolymerize PA66 with low energy and obtain HMD and ADA monomers in high yield. The manufacturing process for PA66 using HMD and ADA obtained by depolymerization with this technology is expected to reduce GHG emissions compared to the conventional PA66 manufacturing process, while further reduction of GHG emissions may be achieved by the use of renewable energy for the power required to generate the microwaves.

By verifying the process from depolymerization to separation and purification in an integrated manner, this demonstration project aims to enable resource circulation of PA66 for further reduction of GHG emissions.

Moving forward, based on the results of the small-scale demonstration trial, a decision on the possibility of commercialization will be made by fiscal 2025 following detailed analysis. Concurrently with the small-scale demonstration trial, construction of a business model that involves the entire value chain in the chemical recycling of PA66 will be advanced, aiming to achieve a circular economy together with stakeholders in the PA66 value chain.