Project ReCarbon uses pyrolysis to destroy PFAS in workwear

Overview

High-visibility workwear is essential for site safety across the construction, mining, and infrastructure sectors, but the water-resistant coatings applied to these garments frequently contain per- and polyfluoroalkyl substances (PFAS). This creates a significant waste management challenge: when these heavily treated industrial textiles reach end of life, they cannot be recycled through conventional streams and typically end up in landfill, where persistent fluorinated compounds can leach into surrounding soil and groundwater. Project ReCarbon, an Australian industry collaboration, has developed a continuous pyrolysis process that destroys PFAS in contaminated workwear while converting the textile waste into beneficial biochar for use in soil rehabilitation.

Key details

The Project ReCarbon pilot represents a notable advance in onshore PFAS destruction capability. The key technical details include:

• Pyrolysis process: The technology uses continuous pyrolysis, a thermal decomposition process conducted in a low-oxygen environment. The operating temperatures are sufficient to break carbon-fluorine bonds, which are among the strongest in organic chemistry. The low-oxygen conditions prevent the formation of hazardous byproducts, such as dioxins and furans, that are often associated with conventional high-temperature incineration of fluorinated materials.
• PFAS destruction efficiency: The process achieves destruction of PFAS compounds present in the textile coatings. This aligns with the regulatory preference for destruction and irreversible transformation over containment or disposal to landfill.
• Biochar output: The solid residue from pyrolysis is a carbon-rich biochar product. This material has beneficial properties for soil amendment, including improved moisture retention, nutrient stability, and soil structure. It can be used in site rehabilitation and land remediation applications.
• Industry partners: The project is led by Vital Chemical, Earth Systems, and Georgiou Group, with support from partners across Australia. This collaboration links waste generators (construction and infrastructure companies) directly with technology providers and end users of the biochar product.

Australian context

The management of PFAS-containing waste is a significant and growing challenge for Australian industry. The PFAS National Environmental Management Plan (PFAS NEMP 3.0) establishes the waste management hierarchy for PFAS materials, which prioritises:

1. Avoidance and reduction of PFAS use
2. Reuse and recycling where safe to do so
3. Destruction and irreversible transformation
4. Containment and disposal as a last resort

Historically, the limited availability of onshore destruction technologies has meant that many PFAS-containing waste streams, including contaminated soils, stockpiled AFFF, and industrial textiles, have been directed to lined landfills or held in temporary storage. This approach is increasingly problematic as landfill operators face tighter acceptance criteria and community concerns about PFAS in landfill leachate grow.

State-level waste regulations are also evolving. In Queensland, the Environmental Protection Regulation includes specific provisions for the handling and disposal of PFAS-containing wastes. Victoria’s EPA has published guidance on PFAS in waste, and NSW’s waste classification system is being updated to better address PFAS contamination. The development of proven onshore destruction technologies such as Project ReCarbon’s pyrolysis process provides the industry with practical alternatives to landfill disposal.

For civil contractors managing major infrastructure projects, such as road corridors, tunnel excavations, and rail upgrades, the generation of PFAS-contaminated PPE and workwear is an ongoing waste management issue. Having access to a destruction pathway that also produces a useful soil amendment product creates a circular economy opportunity that aligns with both environmental regulations and sustainability commitments.

Practical implications

For environmental consultants, waste management professionals, and site managers, the implications include:

• Waste management plans: Consultants should update client waste management plans to include emerging onshore PFAS destruction technologies as viable options. This is particularly relevant for projects generating significant quantities of PFAS-contaminated PPE and textiles.
• Cost-benefit analysis: While destruction technologies may carry higher per-unit costs than landfill disposal, the long-term liability reduction and regulatory alignment can make them more cost-effective over the project lifecycle.
• Rehabilitation opportunities: The biochar output from the pyrolysis process can be incorporated into site rehabilitation strategies, potentially reducing the need for imported soil amendments.
• Supply chain engagement: Construction and infrastructure companies should engage with their PPE suppliers to understand the PFAS content of workwear products and plan for end-of-life management from procurement onwards.

References and related sources

• Original source article – Seamless Australia
• PFAS National Environmental Management Plan (PFAS NEMP 3.0)
• Vital Chemical

How iEnvi can help

iEnvi’s contaminated land and remediation specialists provide advice on PFAS waste management, contaminated site assessment, and remediation strategy development. We assist clients across the construction, infrastructure, and resources sectors with waste classification, disposal pathway assessment, and regulatory compliance for PFAS-affected materials. Our team can help you integrate emerging destruction technologies into your project waste management plans and site rehabilitation strategies. Contact iEnvi to discuss your PFAS waste management requirements.

This is an iEnvi Machete news summary. Prepared by iEnvi to summarise the source article for contaminated land, groundwater, remediation, approvals and site risk professionals.

Need advice on this topic? Speak to an iEnvi expert at hello@ienvi.com.au or 1300 043 684, or contact us online.