Clariant, a sustainability-focused specialty chemicals company, today announced the successful completion of a collaborative pilot project with Borealis, a global leading provider of advanced and circular polyolefin solutions, and SINTEF, one of Europe’s top independent research organizations. The partnership marks a pivotal step forward in advancing circular economy solutions for the plastics industry by validating cutting-edge plastic pyrolysis oil upgrading technology.
In this collaboration, Clariant’s proprietary HDMax™ catalyst achieved full conversion of plastic waste-derived pyrolysis oil into high-quality cracker-grade feedstock that meets all quality specifications during pilot plant testing. The technology proves viable to transform plastic waste into virgin-grade polyolefin feedstock, establishing a true closed-loop recycling pathway. Unlike conventional technologies that require multiple reactors for hydrotreating, this solution completes the entire process in a single reactor, significantly reducing capital investment and operational complexity.
Breakthrough in Plastic Waste Recycling Technology
The core objective of the collaboration was to upgrade plastic waste-derived pyrolysis oil into compatible feedstock fully compliant with steam cracker quality standards. Conducted at SINTEF’s state-of-the-art research facility in Norway, the pilot-scale testing utilized Clariant’s patented HDMax™ catalyst to successfully convert plastic waste pyrolysis oil into high-quality feedstock suitable for virgin polyolefin production.
The HDMax™ catalyst delivered full conversion across all critical parameters: it fully saturates dienes without gum formation — a core requirement for downstream processing — and completely converts contaminants including oxygenates, nitrogenates, and halogenides. All product quality specifications were satisfied, confirming the technology’s readiness for industrial-scale application.
“The results of this collaboration prove that closed-loop plastic recycling can operate efficiently at industrial scale,” said Gene Mueller, Vice President and Head of Ethylene at Clariant Catalysts. “Our HDMax™ catalyst technology enables plastic waste to be converted into feedstock that meets the stringent quality requirements of steam crackers, creating a genuine circular pathway for the plastics industry.”
Single-Step Process Sets Industry Benchmark for Efficiency
The key competitive advantage of Clariant’s HDMax™ technology lies in its ability to meet all quality requirements in a single multi-layer hydrotreating reactor, whereas competing alternative technologies typically require three to four reactors to achieve equivalent results. This streamlined process drastically cuts capital expenditure, lowers operational complexity, and reduces energy consumption. Coupled with subsequent hydrocracking, it produces naphtha-like hydrocarbon fractions, further enhancing process efficiency and product flexibility.
The tripartite partnership leverages the core strengths of each party to build a high-efficiency R&D model:
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Clariant: Provides customized catalyst design and commercial samples of its specialty catalysts, including HDMax™ for pyrolysis oil upgrading and HYDEX™ for hydrocracking, drawing on its expertise in specialty catalyst development.
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Borealis: Defines target quality specifications for pyrolysis oil and contributes industrial expertise as a leading European polyolefin producer, leveraging its Borcycle™ C portfolio of chemically recycled polyolefin solutions.
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SINTEF: Conducts comprehensive pilot-scale testing and technical validation at its world-class research facility in Norway.
Advancing Circular Economy and Accelerating Industrial Transformation
This successful validation establishes a feasible pathway to reintroduce plastic waste-derived materials back into the high-quality industrial production chain. By converting plastic waste into premium feedstock, the technology supports the industry’s transition to a circular economy, enabling plastic recycling without compromising material quality. The pilot-scale results also confirm that strategic cross-sector collaboration accelerates the deployment of innovative circular plastics solutions. The combined strengths of the three partners in specialty chemicals, R&D capabilities, and industrial production lay a solid foundation for subsequent scale-up and potential commercialization.
Learn more about Clariant’s catalysts for plastic recycling solutions and Clariant’s catalytic innovations for the energy transition by visiting official resources.
HDMax™ and HYDEX™ are trademarks of Clariant. Borcycle™ is a trademark of Borealis.
