Shell Chemicals Park Moerdijk takes a big step towards plastic circularity

The Market Development Upgrader at Shell Chemicals Park Moerdijk © Shell plc

Shell Chemicals Park Moerdijk started up a new unit that allows difficult to recycle plastics to be reused. With the Market Development Upgrader (MDU), the chemical complex can process circular raw materials at scale. The opening marks a significant milestone for Shell and is essential for the development of plastic circularity in the Netherlands.

Until now, plastic has mainly been recycled mechanically

This is not possible for all plastics. For example, food packaging cannot be mechanically recycled for hygiene reasons. With chemical recycling, food packaging can be given a second life. The MDU, which opened today, plays a key role in advancing circularity for hard to recycle plastic waste.

From plastic waste to new ingredients

How does this process work? First, plastic waste is heated until the oxygen has been completely extracted. What remains is called pyrolysis oil. The MDU purifies this oil so that it can serve as feedstock for the cracking plant at Moerdijk. This cracker cuts and separates larger and smaller molecule chains, making the base chemicals for everyday products we all use.

“The industry plays a major role in the transition to a sustainable, circular economy. Shell’s new plant will improve plastic recycling capabilities, reduce dependence on fossil “feedstock” and stimulate innovation and green growth. This is a good example of how the Netherlands can excel internationally in a future-proof industry.” – Dutch Minister Sophie Hermans of Climate and Green Growth.

“Moerdijk is the first location within Shell to upgrade pyrolysis oil at an industrial scale. Chemical recycling supports the development of a truly circular system for plastic, similar to how societies collect and reuse empty glass bottles and wastepaper.”- Richard Zwinkels, General Manager of Shell Chemicals Park Moerdijk.

“Today I saw another great example of how innovative the Netherlands is. We need these kinds of innovations for the transition to a circular plastic value chain. In addition to the existing recycling routes, there is a need to scale up new recycling routes, such as this plant. It’s great to see the sector is taking another step today.”- Dutch Environment Minister Chris Jansen.

The new way of recycling

Currently in the Netherlands, a maximum of 46% of plastic waste is (mechanically) recycled, which means it is shredded, washed, sorted and reused to a limited extent. The rest of the plastic waste is incinerated. The MDU installation at Shell Chemicals Park Moerdijk is helping to change that. Eventually, the MDU will be scaled up to full capacity and will handle up to 50 kilotons of pyrolysis oil per year. The amount is equal to what 2.5 million Dutch people produce in plastic waste annually.

Chemistry for today and tomorrow

Shell Chemicals Park Moerdijk [[link to shell.nl/moerdijk]] does much more in the chemicals sector for the chemicals needed today and tomorrow. Last month, the electrification of two existing steam turbines on the cracker was announced, and, together with the replacement of old furnaces in the same installation, will result in roughly a 20% reduction of CO2 emissions at Moerdijk.