Coolbrook successfully cracks 100% plastic-waste pyrolysis oil using RDR technology, advancing circular plastics, sustainable olefin production, and EU decarbonisation goals.
Coolbrook, a technology and engineering pioneer, has reached a landmark achievement in the field of circular materials by successfully cracking 100% plastic-waste-derived pyrolysis oil at its large-scale pilot facility. This milestone was achieved using the company’s proprietary RotoDynamic Reactor™ (RDR), marking a world first in demonstrating the direct cracking of plastic-waste-based pyrolysis oil while maintaining high yields and stable operations.
The accomplishment highlights the robustness and flexibility of Coolbrook’s electrified cracking technology, designed to handle non-traditional, circular feedstocks without compromising efficiency or output. By proving that plastic-waste pyrolysis oil can be processed directly in the RDR, the company has opened the door to sustainable olefin production, offering a potential breakthrough in closing the loop on plastics recycling.
Pyrolysis oil, derived from end-of-life plastic waste, is a crucial intermediate in enabling circularity in the plastics sector. Traditionally, processing such feedstocks has required blending with fossil-based materials to ensure stable operations. Coolbrook’s achievement removes that barrier, proving that 100% pyrolysis oil can be handled independently. This development not only simplifies operations but also strengthens the traceability of recycled materials in the value chain—an important consideration for both regulators and customers seeking transparency in sustainability practices.
The new success builds on earlier pilot plant milestones at Brightlands in the Netherlands, where Coolbrook demonstrated its RDR’s ability to heat gases—including air, steam, nitrogen, and methane—to temperatures exceeding 1000°C using renewable electricity. In addition, the company previously cracked naphtha with the RDR, recording significantly higher yields than conventional steam crackers. With the pyrolysis oil breakthrough, Coolbrook has now shown that its turbomachinery-based electrified process is capable of handling both fossil and alternative circular feedstocks, reinforcing its potential as a game-changing technology for the petrochemical sector.
Commenting on the achievement, Dr. Tuomas Ouni, Head of Process Development at Coolbrook, emphasized the operational and sustainability benefits: “Cracking 100% pyrolysis oil directly without dilution simplifies operations, enhances the traceability of circular materials, and delivers superior yields compared to conventional furnaces. Importantly, this was achieved without any noticeable increase in coking, proving the stability of the process.” He added that the results confirm RDR’s potential role in driving both decarbonisation and circularity in petrochemicals.
The tests were conducted under the EU-funded eLECTRO project, supported by Horizon Europe. The project integrates advanced waste pre-treatment, electrified pyrolysis, and Coolbrook’s RDR-based electrified cracking to develop a sustainable, circular, and scalable pathway for converting mixed plastic waste into light olefins such as ethylene and propylene. Through this initiative, Coolbrook is helping to redefine the future of plastics and petrochemicals, aligning industrial innovation with global sustainability goals.
