El Map of chemical recycling in Europe It has become a key tool for understanding what is happening with the most complex plastic waste on the continent. There is increasing talk of pyrolysis, solvolysis, and gasification, but it is often difficult to visualize where these plants are actually located, what their capacity is, and what stage the projects are at. The work of the German Fraunhofer Institute UMSICHT brings order to this entire landscape and allows us to see, almost at a glance, how this new industry is developing.
This interactive map not only shows operational facilities and projects under developmentbut also provides data on capabilities, technologies used and steam cracking plants which serve as a benchmark for the European petrochemical system. Furthermore, it comes at a delicate time: low fossil fuel prices, high energy costs, and significant regulatory uncertainty in the European Union, which complicates long-term investment decisions.
What is chemical recycling and why does it matter in Europe?
When talking about advanced chemical recycling (or advanced recycling) refers to a set of processes that allow to break down the polymers of plastics into simpler molecules, either by returning them to their original monomers or by transforming them into usable hydrocarbon mixtures. Unlike mechanical recycling, which is based on shredding, washing, and reprocessing, this method uses heat, chemical reagents, or catalysts to break down the polymer chains.
This family of technologies is particularly interesting because It can treat mixed, dirty, or highly degraded plastics.which do not perform well in traditional mechanical processes. Furthermore, in many cases the resulting material is of similar quality to virgin plastic, allowing its use in demanding applications, such as food packaging, where regulatory requirements are very high.
In the European context, where plastic waste management remains a challenge, chemical recycling is seen as a way to Increase recycling rates and reduce dependence on virgin fossil resourcesIt is not intended to replace mechanical recycling, but to complement it: each technology is better suited to certain waste flows and material qualities.
The European Environment Agency estimates that in the EU alone the plastic value chain generates around 193 million tons of CO₂ per year, considering production, processing, and waste management. A large part of these emissions is linked to manufacturing using fossil fuels, so closing the loop through recycling—both mechanical and chemical—is one of the clearest ways to reduce this climate footprint.
The Fraunhofer UMSICHT interactive map on chemical recycling
The Fraunhofer UMSICHT institute has developed a Interactive map compiling chemical recycling activities in EuropeUpdated to October 2025. This tool includes both plants in operation and projects in different stages of processing, indicating the technology applied, the nominal treatment capacity and the progress status.
The map's scope is broad and focuses on six major families of chemical or advanced recycling technologiesPyrolysis, gasification, solvent-based processes, solvolysis, enzymatic technologies, and hydrothermal processes are all represented. Additionally, a separate layer shows the location and capabilities of European steam crackers, which is key to understanding how chemical recycling products can be integrated into the petrochemical industry.
According to the data collected, the map identifies 65 projects in the pipeline (excluding steam cracking units), spread across the continent. These projects have a planned chemical recycling capacity of 2.799 kt/a (thousands of tons per year), considering only initiatives under development and excluding both facilities already in operation and cancelled projects.
In addition, the following are collected 18 plants currently in operationwith a combined capacity of 289 kt/a. Of this capacity, 262 kt/a correspond to pyrolysis technologies, 19 kt/a to solvolysis processes, and 8 kt/a to solvent-based solutions. Currently, the map does not show any operational gasification plants, indicating that this technology is still in its early stages, at least on a commercial scale.
Looking at the overall capabilities—those already in operation and those planned—the technological distribution is quite uneven: pyrolysis concentrates 1.938 kt/a, gasification 860 kt/a, solvent-based processes 68 kt/a, the solvolysis 102 kt/a, the enzymatic routes 50 kt/a and the hydrothermal technologies 70 kt/a. That is to say, the economics of chemical recycling in Europe, today, is very much oriented towards pyrolysis and, secondarily, towards gasification.
The map also shows that Not all projects come to fruition.Nine chemical recycling initiatives, totaling 819 kt/a of capacity, have been officially cancelled, including seven pyrolysis projects with a combined capacity of 791 kt/a. These figures reflect the ongoing economic, regulatory, and technical challenges facing this sector.
Spain's position on the map of European chemical recycling
Spain appears in Fraunhofer's work with a significant presence, with several facilities in operation and projects under developmentAccording to the various sources referenced, the country has a set of pyrolysis plants, steam crackers and a large gasification project in the planning phase.
Regarding operational pyrolysis plants, the map identifies facilities in Ascó (Tarragona), Seville and AlmeríaThe Ascó plant, managed by 2G Chemical Plastic Recycling, has an approximate capacity of 9 kt/a; the Seville plant, operated by Plastic Energy, reaches 33 kt/a; and the Almería facility, also of Plastic Energy, has a capacity of around 5,5 kt/a.
In the area of steam cracking, the map indicates the following as assets: Cracker in Tarragona operated by Dowwith a capacity of 675 kt/a, and another in Puertollano (Ciudad Real). These facilities are part of the petrochemical context in which chemical recycling products, such as pyrolysis oils or synthesis gases, could be integrated to manufacture new monomers and polymers.
Regarding projects in the pipeline, two initiatives stand out: on the one hand, a pyrolysis plant in Jerez de la Frontera (Cadiz), associated with Valoriza, with pyrolytic technology and an announced capacity of around 20 kt/a; on the other hand, the Eco-gasification plant promoted by Repsol in El Morell (Tarragona), developed with Enerkem technology, with a planned capacity of around 400 kt/a, which would place it as one of the reference facilities in Europe in this field.
Some sources also mention the existence of five or six plants in operationThis varies depending on whether only chemical recycling technologies are considered or if steam crackers are also included. In any case, the overall picture indicates that Spain already has a small but significant chemical recycling ecosystem and aims to expand its capacity, especially through larger-scale gasification and pyrolysis projects.
Regulatory context and competitiveness challenges in the EU
The deployment of chemical recycling in Europe depends not only on technology or investment willingness; it is also heavily conditioned by a regulatory framework still under constructionAs Professor Matthias Franke of Fraunhofer UMSICHT points out, the specific regulations at the European level are still not fully defined and their transposition into national legislation is still pending.
In parallel, economic factors such as the relatively low prices of fossil raw materialsHigh energy costs in Europe and the influx of low-cost recycled materials from Asia are putting pressure on the competitiveness of both mechanical and chemical recycling. This increases the perceived risk for investors and has contributed to the suspension or cancellation of some projects.
One of the most important debates in Brussels revolves around the methodology for calculating the performance of chemical recyclingIn particular, the approach known as “Fuel Use Exempt.” How this methodology is defined will determine, for example, whether pyrolysis oil used to produce new plastics can be counted as recycled content, which is crucial for the industry to meet mandatory recycled content targets in packaging and other products.
This discussion has a direct impact on the business model of many plants: if the pyrolysis oil used as a raw material for new polymers is not recognized as recycled, Regulatory demand for this material could fallaffecting the profitability of the facilities. Conversely, a clear and favorable regulatory framework could become the definitive push needed to consolidate the industry.
In addition to the regulatory aspect, many advanced technologies still face problems with operational stability, performance, and product qualityIn some cases, these are processes that have only been in operation at an industrial scale for a few years and are still in the optimization phase. This results in frequent shutdowns, high maintenance costs, or variability in the properties of the resulting products.
Overview of plastics recycling in Europe and the role of chemical recycling
Across the European Union, the most common option for treating plastic waste is recycling, at around 40,7% of the managed volume. Energy recovery, through incineration with generation of heat, electricity or fuel, represents about 35%. The rest ends up mostly in landfills or as unwanted outputs from the system.
The recycling rate of plastic packaging waste has gradually increased, going from from around 25,2% in 2005 to 40,7% in 2022Even so, millions of tons of plastic waste are still not being properly utilized. A significant portion—around 1,3 million tons in 2023—was exported outside the EU, sometimes to countries with weaker environmental or traceability standards.
For years, a considerable fraction of this waste was sent to China for recycling, but the restrictions imposed by this country on the import of waste have forced Europe to seek internal solutions, intensifying the debate on new recycling capabilities and emerging technologies such as chemical recycling.
The problem goes beyond mere waste management: each year it is estimated that between Between 19 and 23 million tons of plastic end up in soils, rivers, and oceans. Globally, this not only damages ecosystems but also affects food production, tourism, fishing, and numerous other economic activities. Added to this is the climate impact: in 2019, plastics generated around 1.800 billion tons of greenhouse gas emissions, approximately 3,4% of global emissions.
If the way plastic is produced, used, and managed is not changed, projections indicate that Emissions associated with its life cycle could triple by 2060In this context, any way that allows for more and better recycling – from mechanical to chemical recycling – is strategic for the EU, for environmental, economic and resource security reasons.
Chemical recycling technologies: thermal depolymerization and pyrolysis
Multiple technologies are grouped under the umbrella of chemical recycling. One major category is the thermal depolymerizationThis group includes processes where the polymer is broken down into monomers or oligomers by the application of heat, without the use of a specific chemical reagent to break the chains. Examples include the pyrolysis of certain plastics, microwave treatments, and very high-temperature processes.
La pyrolysis It is normally carried out at temperatures above 450 °C and with relatively long residence times, since a lot of energy is needed to break the carbon-carbon bonds of the polymer chains. During the process, primary reactions occur, which give rise to the desired products, but also less selective secondary reactions, with the formation of radicals that complicate process control and can reduce yields.
Under suitable conditions, pyrolysis can generate monomers such as ethylene or propyleneHowever, this process often yields low results and produces numerous byproducts. For this reason, significant R&D efforts are being dedicated to incorporating catalysts that allow operation at lower temperatures, improve selectivity, and increase the fraction of high-value products. If conditions are not optimal, the plastics are transformed into petrochemical mixtures such as synthesis gas or paraffins.
Another variant is the hydrogenation or hydrocrackingIn this process, plastic waste is thermally treated in the presence of hydrogen, generally at temperatures of 400–500 °C and high pressures (between 10 and 100 kPa). Bifunctional catalysts, which combine cracking and hydrogenation functions, are used here. These are typically transition metals supported in acidic matrices to promote chain breaking and saturation of the resulting fragments.
Hydrocracking results in highly saturated products that can be used directly as fuels or raw materials in refinerieswith liquid hydrocarbon yields close to 85%. The downside is that the use of hydrogen at high pressure and temperature increases the cost of the process and requires very strict safety measures, which may limit its large-scale implementation unless the price of hydrogen is reduced or these plants are integrated into existing industrial complexes.
This family also includes the thermal cracking Classical hydrocarbon production involves breaking polymer chains solely through the application of heat in the absence of oxygen, typically between 500 and 800 °C. The result is usually a mixture of liquid, gaseous, and solid hydrocarbons with a very broad molecular weight distribution. The ratio between these fractions depends heavily on the operating temperature and other process parameters.
Dissolution, solvolysis, and other chemical recycling routes
Beyond thermal depolymerization, chemical recycling includes other methods, including processes such as selective dissolution of plasticsThese techniques aim to dissolve the polymer in a suitable solvent to separate it from fillers, additives, inks, or other contaminants, obtaining a purified polymeric material that can then be reprocessed. The polymer molecules are not modified, so these techniques do not fully fit the definition of mechanical recycling or energy recovery.
La solvolysis This is another fundamental building block. Here, the solvent also acts as a reactant, breaking the polymer chains. Depending on the solvent, different types of chemolysis are distinguished, such as glycolysis, hydrolysis, or methanolysis, often operating with fluids under supercritical conditions. This approach is particularly suitable for condensation polymers, such as PET or polyamides.
At hydrolysis For PET, for example, the process is usually carried out in a basic medium (saponification), which facilitates the reaction but requires a subsequent treatment stage to convert the product into usable monomers. Its main advantage is that it allows the treatment of colored and mixed waste that cause problems in other processes.
La methanolysis It involves applying methanol to PET to break it down into its basic molecules—dimethyl terephthalate and ethylene glycol—which can then be repolymerized to produce virgin-quality resin. It is an advanced and technologically demanding process, but very interesting for waste streams where the goal is to obtain high-performance material.
La glycolysis It uses ethylene glycol and is usually carried out under less severe conditions than methanolysis and hydrolysis, which reduces operating costs. However, it is less effective at treating colored or highly mixed waste. The reaction products can be reused to manufacture PET or as precursors for polyurethane foams and unsaturated polyestersopening the door to new value chains.
Chemical recycling also appears other chemical depolymerizations These methods employ specific reagents, such as strong acids or phenolic derivatives, as well as the catalytic cracking of plastic waste. The latter offers advantages over pure thermal cracking, allowing operation at lower temperatures (on the order of 300-400 °C) thanks to the catalyst and enabling better control of product distribution.
An interesting alternative is the catalytic reforming of the gases generated in thermal cracking of plastics, which can yield gasoline, diesel, kerosene, and other valuable products. These routes require significant optimization but offer great potential for integrating chemical recycling into existing refineries and petrochemical complexes.
Cross-referencing the different types of processes with the types of plastics that can be treated yields a fairly comprehensive array of options. Nine major polymer groups—such as PE, PP, PVC recyclingPS, PMMA, PET, PA, PC and PUR can undergo chemical recycling, although Not everyone responds the same way to each technology.Addition polymers (PE, PP, PVC, PS, PMMA) are better suited to thermal depolymerization, while condensation polymers (PET, PA, PC, PUR) accept most chemical treatments.
The dissolution process, for its part, is applicable to a wide variety of plastics, but from the point of view of the quality of the recycled material it is usually considered less satisfactory than thermal depolymerizationIn any case, all these routes are at different stages of technological maturity: solvolysis is the most industrially developed, followed by thermal depolymerization and, lastly, dissolution processes.
Synergies between mechanical and chemical recycling and the role of R&D
Mechanical recycling remains the most widespread form of plastic waste recovery in Europe today, thanks to its good performance in terms of energy and costespecially when dealing with clean and homogeneous waste streams. However, it has clear limitations: it requires well-separated streams, struggles with complex or heavily contaminated plastics, and materials can only be recycled a limited number of times before their properties degrade.
Chemical recycling arrives precisely to fill that gap, offering the possibility of to treat plastics that are not suitable for mechanical recycling and returning them to products that, in many cases, are virtually indistinguishable from virgin materials. This complementarity allows for increased global recycling rates and a move closer to true circularity, while simultaneously reducing the demand for fossil resources.
Technology centers like CIRCE have been working in this field for years, developing and scaling technologies such as microwave-assisted solvolysis, pyrolysis, or glycolysisThese lines of work are applied to waste products of increasing relevance, such as wind turbine blades, photovoltaic modules or technical textiles, which combine different materials and are difficult to recycle using conventional methods.
In addition to the technical aspect, these entities promote the collaboration between the different actors in the value chain Recycling involves waste managers, processors, raw material producers, consumer goods manufacturers, public administrations, and regulatory bodies. This collaborative approach is key to ensuring that each waste stream is directed to the most appropriate process and that the resulting products find a market.
The Aragonese technology center participates, for example, in several highly relevant European projects Projects like Plastice, Redol, Cubic, Digintrace, and Refresh explore traceability solutions, new recycling processes, circular business models, and digital tools to optimize the design of recyclable products. These initiatives aim to accelerate the transition from pilot projects to viable industrial plants.
Taken together, the map of chemical recycling in Europe, data on planned and operational capacities, and the research efforts of centers and companies show a sector in full swing. Although it still faces regulatory uncertainties, cost pressures, and technical challenges, Europe maintains a leading position in innovation in plastic waste management, as reflected in patent applications, even though countries like China, South Korea or Japan are closing the gap.
La future evolution It will depend on how the game rules In the EU, success depends on the speed at which key technologies mature and the ability to integrate chemical recycling with mechanical recycling and existing petrochemical infrastructure. If these elements align, Fraunhofer's interactive map could be just the first glimpse of a much denser network of plants, capable of transforming complex waste streams into valuable resources and truly strengthening the European circular economy.
