Revolutionizing plastic recycling with pyrolysis

Plastics are still an essential part of our everyday life, and recycling them is key to meeting global sustainability and circular economy targets. With efficient recycling, we can significantly reduce the use of fossil oil and release less carbon into the atmosphere.

Traditionally, plastics have been recycled using mechanical recycling, which efficiently handles the types of plastics required to make products like shopping bags, buckets, and garden tools. However, it doesn’t meet the strict quality requirements for certain uses such as food packaging. In contrast, chemical recycling significantly expands the usability of recycled plastic.

Valmet has introduced a new plastic chemical recycling technology based on fast pyrolysis. Pyrolysis is a thermochemical conversion process in which feedstock such as recycled plastic is decomposed into gases, liquids, and solid residues in the absence of oxygen. The liquid fraction, known as pyrolysis oil, is a virgin-quality material that can re-enter the plastic manufacturing process.

Valmet’s innovative in-house testing facility and pilot plant is located in Tampere, Finland. Its new industrial-scale pyrolysis plant will be ready in 2027.

“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,” summarizes 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.

With Valmet Pyrolyzer, mixed plastic streams can be converted into high-quality raw material.

“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,” says Arttu Tolvanen, Product Engineer, Pyrolysis at Valmet.

Tolvanen and Marjomaa say that chemical recycling significantly expands the usability of recycled plastic.

Arttu Tolvanen and Pekko Marjomaa say that chemical recycling significantly expands the usability of recycled plastic.

Valmet’s technology can be scaled to large industrial capacities above 100 kta 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,” Marjomaa 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.

Valmet Pyrolyzer offers flexibility, allowing both thermal and catalytic process configurations.

“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,” says Jaakko Martikainen, Director, Circularity Growth, Energy and Circularity, Valmet.

To summarize: 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.