Pyrolyzer Solution from Valmet: Converting plastic waste into pyrolysis oil

Plastic Waste: From an Environmental Burden to a Circular Economy Resource

 

Plastic is a material widely used in daily life. However, its overconsumption is generating a massive amount of waste globally. Managing plastic waste has long been a major challenge for policymakers and scientists, as plastic is highly durable, extremely difficult to fully decompose, and can persist in the environment for hundreds of years.

 

However, despite its negative impacts, plastic is still considered a valuable resource if properly collected, sorted, and processed. Instead of becoming an environmental burden, plastic waste can be recycled and reused, contributing to the promotion of a circular economy and sustainable development on a global scale. Recycling not only reduces reliance on fossil fuel resources but also significantly cuts carbon emissions.

 

Traditionally, plastic is recycled mechanically. This method effectively processes plastics used in products such as plastic bags, buckets, and gardening tools. However, mechanical recycling fails to meet strict quality requirements for specialized applications like food packaging. Outstandingly, chemical recycling technology significantly expands the application potential of recycled plastics.

 

Mechanical Recycling

Plastic bags

Lower quality output

Limited food-contact use


Chemical Recycling

Mixed plastic waste

Virgin-quality output

Suitable for demanding applications

 

Pyrolysis Technology: A Breakthrough in Chemical Recycling

 

Valmet has introduced a new plastic chemical recycling technology based on fast pyrolysis. Pyrolysis is a thermochemical conversion process in which feedstocks such as mixed plastic waste are decomposed into gases, liquids, and solid residues in the absence of oxygen. The liquid fraction, known as pyrolysis oil, can be further upgraded for use in downstream petrochemical processes, where it serves as a feedstock for producing virgin-quality plastics. These recycled plastics are suitable for demanding applications, including contact-sensitive and other quality-critical uses.

“In other words, through pyrolysis, even multilayer packaging, contaminated materials, and mixed plastic streams that have traditionally been difficult to handle can be converted into high-quality raw material for new plastic products.”
Mr. Pekko Marjomaa
Product Sales Manager, Pyrolysis at Valmet
Decades of pyrolysis expertise

Valmet has a long history in pyrolysis technology development, and extending the technology’s use to chemical recycling supports Valmet’s goal of transforming industries for a regenerative tomorrow.

Valmet’s pyrolysis technology journey began in the 2000s with foundational research. In 2011, the company officially completed its first pilot facility to conduct tests on the pyrolysis system. A major breakthrough occurred in 2013 with the establishment of the Catalytic Pyrolysis Consortium, alongside the commercial startup of a 50,000 tonnes-per-year fast pyrolysis plant in Joensuu.

 

“In a nutshell, our pyrolysis technology leads to improved recycling efficiency, meets stringent plastic recycling targets, and recycles various plastic types such as polyethylene (PE), polypropylene (PP), and polystyrene (PS) effectively. Valmet Pyrolyzer is based on fluidized bed technology, which we know by heart. It’s highly reliable and scalable, offering exceptional flexibility and allowing both thermal and catalytic process configurations for different operational setups.”
Mr. Arttu Tolvanen
Product Engineer, Pyrolysis at Valmet

Valmet’s technology can be scaled to large industrial capacities above 100 kt/a in a single unit, thanks to the excellent heat transfer inherent in fluid bed systems. This scalability reduces both capital and operating costs, enabling economically viable industrial-scale chemical recycling.

“Moreover, we’ve adopted a comprehensive lifecycle approach, offering everything from key technology and automation systems to maintenance and spare parts – helping our customers achieve their circularity targets easily.”
Mr. Marjomaa
Product Sales Manager, Pyrolysis adds
Industrial-scale piloting aids investment decisions

Valmet operates an innovative in-house testing facility and pilot plant in Tampere, Finland. At the heart of this R&D Center is the world’s largest catalytic bio pyrolysis pilot plant, commissioned in 2023. Valmet is currently expanding its facility with a new industrial-scale pyrolysis plant, offering infrastructure that bridges the gap between lab-scale trials and commercial deployment of plastic recycling—supporting customers’ investment decisions with real-life data. The new industrial-scale pyrolysis plant is scheduled to be ready in 2027.

 

Image: Valmet

“The new pyrolysis plant enables different feedstocks, optimizing catalysts, and validating energy and emission metrics to be explored before full-scale investments. By combining our cutting-edge technology with true customer process parameters, we will enhance safe, efficient, and scalable chemical recycling solutions for our customers, accelerating the transition to a true circular economy.”
Mr. Jaakko Martikainen
Director, Circularity Growth, Energy and Circularity, Valmet

With scalable technology, real‑world testing capabilities, and comprehensive lifecycle support, Valmet is ready to help its customers turn today’s plastic waste challenges into tomorrow’s competitive advantage. Valmet Pyrolyzer brings chemical recycling within reach, enabling companies to meet stricter regulatory demands while building a more circular and sustainable business.

 

Learn more about the Valmet Pyrolyzer system in the video below.

 

Source: YouTube, video “Valmet Pyrolyzer: Revolutionizing Plastic Recycling with Pyrolysis”

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