FURI | Spring 2025

Energy-Efficient Recycling of Cross-Linked Polyethylene (XLPE) Using Electricity-Based Pyrolysis

Cross-linked polyethylene (XLPE) is widely used in electrical insulation due to its durability and thermal stability. However, its chemically cross-linked structure makes conventional recycling methods ineffective, leading to significant environmental challenges. Salt River Project (SRP) alone disposes of 540 tons of XLPE waste annually, with similar utility companies contributing much larger amounts to landfills and incineration. This research explores an energy-efficient and scalable approach to recycling XLPE using electricity-based pyrolysis. By incorporating conductive carbon fillers, localized joule heating can be induced to rapidly decompose XLPE at temperatures of 550–690°C, converting it into high-value carbon composite materials such as graphene and carbon black. This method improves heat transfer efficiency, significantly reducing energy consumption compared to traditional furnace-based pyrolysis. In collaboration with SRP, this research aims to develop a practical recycling strategy that can be adopted industry-wide, potentially diverting thousands of tons of plastic waste from landfills while promoting environmental sustainability.