Clariant, a sustainability-focused specialty chemicals company, successfully completed a pilot-scale project to advance circular plastics recycling. The initiative was carried out in collaboration with Borealis AG, a leading provider of advanced and circular polyolefin solutions, and SINTEF, one of Europe’s largest independent research organizations.
Through this partnership, the companies demonstrated the effectiveness of Clariant’s pyrolysis oil (pyoil) upgrading technology, marking an important step toward scaling circular economy solutions for the plastics industry. The project highlights how collaborative innovation can accelerate the development of sustainable recycling technologies.
Turning Plastic Waste into High-Quality Feedstock
At the center of the project was the challenge of upgrading pyrolysis oil derived from plastic waste into feedstock compatible with steam crackers. Such feedstock must meet strict quality standards before it can be used to produce virgin-grade polymers.
To address this, the partners conducted pilot-scale testing at SINTEF’s advanced research facility in Norway. Using Clariant’s proprietary HDMax catalysts, the team successfully converted plastic waste-derived pyoil into high-quality feedstock suitable for producing virgin polyolefins.
Importantly, the catalyst achieved full conversion across all critical parameters. It completely saturated reactive dienes without causing gum formation—an essential requirement for downstream processing. In addition, the system removed contaminants such as oxygenates, nitrogenates, and halogenides. As a result, the upgraded feedstock fully met cracker-grade specifications, confirming the technology’s readiness for industrial applications.
Catalyst Technology Enables Closed-Loop Plastic Recycling
According to Gene Mueller, Vice President and Head of Ethylene at Clariant Catalysts, the project demonstrates the feasibility of closed-loop plastic recycling at industrial scale. He explained that the HDMax catalyst technology enables plastic waste to be converted back into feedstock that meets the strict quality standards of steam crackers. Consequently, manufacturers can produce new plastics from recycled material without compromising performance or product quality.
Single-Step Processing Improves Efficiency
One of the most important advantages of Clariant’s HDMax technology is its single-step processing capability. Unlike alternative upgrading solutions that require three to four reactors, HDMax achieves all required product specifications in a single multi-layer hydrotreating reactor.
The streamlined approach significantly reduces capital investment, operational complexity, and energy consumption. Furthermore, the process supports additional hydrocracking, which converts the upgraded oil into naphtha-like hydrocarbon fractions. This added step increases both operational efficiency and product flexibility.
Combined Expertise Drives Innovation
The success of the project reflects the complementary strengths of the three organizations involved. Clariant designed the tailored catalyst system and supplied commercial samples of its specialized catalysts, including HDMax for pyrolysis oil upgrading and HYDEX™ for hydrocracking applications.
Borealis defined the required quality specifications for the upgraded pyrolysis oil and contributed its extensive expertise as a leading polyolefin producer. The company also supports chemically recycled polyolefin solutions through its Borcycle™ C portfolio. SINTEF conducted comprehensive pilot-scale testing and validation at its advanced research facility in Norway, ensuring the reliability of the process and performance results. By combining expertise in specialty chemicals, polymer production, and research capabilities, the partners successfully validated a practical pathway for circular plastic recycling.
Supporting the Transition to a Circular Economy
The successful demonstration represents a major step toward integrating recycled plastics into industrial production. By converting plastic waste back into high-quality feedstock, the technology helps create a closed-loop system for plastics where materials can be reused without sacrificing performance.
Moreover, the project shows how strategic collaboration can accelerate innovation in sustainable materials and recycling technologies. As the industry seeks solutions to reduce plastic waste and lower carbon footprints, such technologies will play a crucial role in enabling a truly circular plastics economy.
As per the press release, the partners plan to build on this pilot-scale success and explore opportunities for commercial implementation, further strengthening the transition toward sustainable plastic production.
