Gate-to-Gate Life Cycle Study and Techno-Economic Analysis of an Industrial Process for Producing Densified Polystyrene from Recycled Expanded Polystyrene

In this study, material and energy losses were systematically assessed, together with a comprehensive economic and environmental evaluation, for an industrial expanded polystyrene (EPS) recycling process implemented under a circular economy framework at a company located in Medellín, Colombia. The system boundaries were clearly defined, and detailed mass and energy balances were performed using operational data collected over a six-month period. The process achieved a yield of 78.09 percent in the production of densified polystyrene from post-consumer EPS, with the main material losses attributed to solid residues and water losses during processing. The total energy consumption was 7350.34 kWh, of which 55.46 percent corresponded to energy losses, predominantly thermal losses associated with the EPS melting stage. Techno-economic evaluation indicated that the process is financially viable over a twelve-year operational horizon. Furthermore, the environmental assessment demonstrated a 68.44 percent reduction in carbon footprint, underscoring the strong potential of this recycling route as a sustainable and effective alternative for the management of recyclable solid waste.