This pilot project is an innovative research initiative by Grace scientists to study a new technology for plastics recycling. The project aims to develop a more efficient and environmentally friendly solution. To study this potential new solution, we submitted an application to the Maryland Department of the Environment (MDE) to build a small pilot in an existing building on our Columbia, Maryland campus, where we routinely conduct Research and Development (R&D).

By “pilot plant,” we simply mean a testing space for our new technology. After we study a new innovation in a laboratory setting, our next step is to set up a small-scale model of the process to perform controlled tests and validations. It is not a manufacturing facility.

It will measure 24 feet high, 32 feet long, and 12 feet wide—roughly the size of a one-car garage.​ It will be housed within an existing building.

The pilot is designed for us to test and refine a new plastics recycling process. It operates on a small scale, using research-scale reactors, chillers, separators, feeders, and samplers to study the chemical processes involved in our plastics recycling solution. Our MDE application includes science and evidence demonstrating the safety and exciting potential benefits of this project.

The project aims to contribute to the development of sustainable plastic recycling solutions, while minimizing the environmental impact. It has the potential to reduce emissions, save energy, and lower costs compared to other plastic recycling methods that exist today.

MDE's process evaluates the air quality impacts associated with the project. As part of its evaluation, MDE reviews the technical information contained in the permit application and will only approve the application if it determines the estimated emissions from the project will not cause a violation of any applicable air quality standard and will not have an adverse effect on public health.

Moreover, in all our research activity, Grace follows industry best practices and the guidelines of the American Chemical Council (ACC) Responsible Care program. We have well-established safety processes and protocols at our site and work closely with our employees, contractors and appropriate local authorities – including MDE and Howard County Fire & Rescue – to ensure the safety of our 600 on-site employees and the surrounding community.

The pilot plant project will have no impact on the health or wellbeing of our local community or the employees who work at the facility every day.

No.

No.

No.

No.

Because this project will produce modest air emissions, we have closely followed the MDE process to disclose them and obtain the proper permit. Potential daily emissions from this pilot, as disclosed in the permit application, include:

• 73 lbs of Carbon Dioxide (CO₂),
• .002 lbs of Carbon Monoxide (CO),
• .011 lbs of Nitrogen Oxides (NOx) and
• 218 lbs of Volatile Organic Compounds (VOC).
• Additionally, the application discloses essentially no Particulate Matter (PM) (we say “essentially” because the PM will be less than a pound a year, which amounts to two ten-thousandths of a pound of PM a day (.0002) or half a pound per year based on our operating hours)

See the permit application for details.

To put the emissions in context, here are some comparisons:

• Less CO₂ in a day than an average passenger vehicle using 4 gallons of gasoline*.
• CO in a day equal to an average US vehicle driving 2 tenths of a mile**.
• NOx in a day equal to an average US vehicle driving about 10 miles – so driving from Cedar Creek to the Columbia Town Center and back emits as much NOx as this plant could in a day**.
• VOCs in a day equal to using about ¼ to ½ gallon of paint***.
• And essentially no Particulate Matter****.

*Based on US EPA data for CO₂ emissions per gallon of fuel for an average passenger vehicle

**Based on 2024 Bureau of Transportation Statistics data for average vehicle emissions

***Maryland Law limits VOC content of flat coatings (e.g. paints) to 50 g/l, and non-flat coatings to 100 g/l. (Maryland Register Reference: 26.11.39.00-26.11.39.9999).

****We say “essentially” because the PM will be less than a pound a year, which amounts to two ten-thousandths of a pound of PM a day (.0002) or half a pound per year based on our operating hours

Grace followed the appropriate process with the Maryland Department of the Environment, which includes a public notice period. Based on the public notice, a public hearing was requested, and we participated fully.

We have been operating Research and Development (R&D) at our Columbia, MD site since 1959, and have the talent, experience and infrastructure to run the project at our Columbia facility.

Our Columbia headquarters is a research facility, not a factory. When we look to scale this process up for production, it will not be at our Columbia site.

No. We follow industry and regulatory requirements and best practices for safety in all our R&D. Additionally, this project will have safety interlocks built in as an added measure. Finally, we work closely with the Howard County Fire Department on a regular basis as a responsible business practice.

No trash will be used in this project. Grace will study well-controlled plastic samples sourced from manufacturers and established recycling facilities.

Should the MDE permit be issued, we expect it will take 4 months to build and begin pilot operations.

Contact Community@grace.com for questions.