Cryogenic separation of CO2 is a potential technology that can benefit from energy efficiency improvements. However, the current conventional and emerging cryogenic technologies face challenges in terms of high utility consumption. The high utility requirement leads to increasing operational costs and emissions due to the production of required utilities from external energy sources. This issue can be solved if the heat recovery potential of the technology can be realized. Heat recovery enables further improvement in energy efficiency that is required to elevate the feasibility of cryogenic separation. This paper explores heat recovery opportunities between hot and cold streams in a novel cryogenic CO2 capture technology known as Turbo-Expander-based Cryogenic Distillation (CryoDT). This is achieved using P-HENS, a P-graph-based heat exchanger network synthesis tool where multiple feasible heat exchanger network configurations are generated to determine the options that effectively recover process heat to reduce utility consumption. Moreover, the solutions generated by P-HENS are benchmarked with other tools like Aspen Energy Analyzer, by comparing the number of required heat exchangers, along with the associated capital and operating costs. For the predefined hot and cold process streams of the novel technology, the total number of heat exchangers present in the network was lower in the recommended design using P-HENS (i.e., 9 heat exchangers) as opposed to Aspen Energy Analyzer (16 heat exchangers) while maintaining similar energy consumption levels. This indicates that there is a further opportunity to reduce capital costs as a result of less heat exchangers. The CryoDT configuration that is integrated with a heat exchanger network offers significant economic advantages as opposed to other existing cryogenic processes in the market such as the Ryan Holmes and Controlled Freeze Zone (CFZ) processes. Despite its high capital cost, the CryoDT process demonstrates significantly lower operating cost relative to the other two processes. Hence, while the initial investment is substantial, the CryoDT process is much more cost efficient to operate. The low operating cost is attributed to its higher energy efficiency and minimal energy penalties, with only 0.26 GJ/tonne of CO2 compared with 0.82 GJ/tonne of CO2 for the CFZ process and 2.33 GJ/tonne of CO2 for Ryan Holmes. In contrast, the Ryan Holmes process, despite its low capital cost, incurs extremely high annual operational costs, rendering it less economic in the long term. The CFZ process, with its moderate operating cost, presents a balance between capital cost and operational efficiency.

Plastic waste conversion has been widely recognized as a promising strategy to address growing waste management challenges. However, the feasibility of its integration into existing industrial systems remains uncertain. This paper explores a plastic waste-to-X strategy aimed at reintegrating plastic waste into its original supply chain, in alignment with circular economy principles. A graph-theoretic optimization model is developed using P-graph to identify the optimal and near-optimal pathway configurations under multiple scenarios. Under a cost minimization scenario, the optimal solution achieves a 0.013–0.19% lower cost compared with alternative pathways; however, related to the higher opportunity cost of up to 24,364 USD/y from forgone utility savings and carbon tax reductions. Incorporating carbon credits shifts the focus toward balancing cost efficiency and emission reduction. Under budget constraints, the benefit-cost analysis reveals that emission reduction does not increase linearly with budget expansion. These findings guide decision-makers in setting realistic emission reduction targets and allocating budget efficiently, while helping policymakers to develop a financial scheme that promotes greater emission reductions without excessive expenditure.