TECHNICAL PROGRAMME | Energy Fuels and Molecules – Future Pathways
Pathways to Net-Zero Refining and Petrochemical Facilities
Forum 16 | Hall 5 Digital Poster Plaza 3
30
April
10:00
12:00
UTC+3
Work towards achieving net-zero emissions at assets by discovering leading-edge technologies and processes. As the refining and petrochemical sector responds to emerging carbon policies and regulations around the world, learn how to integrate renewable energy, carbon capture and storage (CCS), and process optimisations to reduce environmental impacts. Conversations will also highlight successful case studies, opportunities and challenges to enhancing operations, and balancing both economic and environmental interests.
Fossil energy (coal, natural gas, oil) is the main energy composition, accounting for 64%. In the IEA energy structure forecast for 2040, with sustainable development policies, (Solar、Wind、Hydro) Non-fossil energy will be the main energy component, accounting for 68%. Even under a stated policy, fossil energy accounting for 48%, Non-fossil energy accounting for 44%. It is an inevitable choice to adapt to energy transformation.
In order to reduce carbon emissions during natural gas development, the research and application of low-carbon technologies based on the production and construction characteristics of gas field were proposed.
Clarified “Low-carbon transformation path” in SSOC. Combined with the characteristics of natural gas development. Define carbon emission boundaries. Analyze emission factors. Identify 5 types of emission sources. Calculate and predict the comprehensive carbon emission over the past 12 years .
Promote “Energy saving and emission reduction” of gas fields from multiple angles. Continuously improve the efficiency of flareless. Optimize energy consumption management of process equipment. Strengthen VOCs detection and recovery.
Accelerate the “Renewable energy using” in gas fields. Efficient completion of wind, solar, land resources survey. Optimize Solar PV component and array selection design. 1.5MW distributed solar power station with 700kWh battery was completed and put into production.
Overall planning of gas field energy strategic replacement and “Fuel switch”. Optimize electric drive drilling lines. Improve the electric drive fracturing power system. Plan compressor selection and transformation in advance. Research energy storage application technology.
And based on the energy saving and emission reduction, energy using structure optimization, renewable energy efficiency promotion in the process of natural gas development, systematically put forward low carbon technology, carbon reduction technology, carbon negative technology and emission reduction strategy with the reduction and elimination of carbon emissions as the basic characteristics, thus effectively reduce the carbon emissions in SSOC gas field, the region has reduced its carbon emissions by 105,300 tons, a decrease of nearly 70%, provides reference for green low carbon natural gas development.
Co-author/s:
MA Qian,South Sulige Operating Company of CNPC Changqing Oilfield (SSOC).
LI Ze-liang,South Sulige Operating Company of CNPC Changqing Oilfield (SSOC).
LI Xiao-hui, South Sulige Operating Company of CNPC Changqing Oilfield (SSOC).
DONG Yi-fan, South Sulige Operating Company of CNPC Changqing Oilfield (SSOC).
ZHANG Hua-tao, South Sulige Operating Company of CNPC Changqing Oilfield (SSOC).
LEI Yu, South Sulige Operating Company of CNPC Changqing Oilfield (SSOC).
WANG-Long, South Sulige Operating Company of CNPC Changqing Oilfield (SSOC).
YE Ye, South Sulige Operating Company of CNPC Changqing Oilfield (SSOC).
QIAO Peng, South Sulige Operating Company of CNPC Changqing Oilfield (SSOC).
Zhu Min, South Sulige Operating Company of CNPC Changqing Oilfield (SSOC).
In order to reduce carbon emissions during natural gas development, the research and application of low-carbon technologies based on the production and construction characteristics of gas field were proposed.
Clarified “Low-carbon transformation path” in SSOC. Combined with the characteristics of natural gas development. Define carbon emission boundaries. Analyze emission factors. Identify 5 types of emission sources. Calculate and predict the comprehensive carbon emission over the past 12 years .
Promote “Energy saving and emission reduction” of gas fields from multiple angles. Continuously improve the efficiency of flareless. Optimize energy consumption management of process equipment. Strengthen VOCs detection and recovery.
Accelerate the “Renewable energy using” in gas fields. Efficient completion of wind, solar, land resources survey. Optimize Solar PV component and array selection design. 1.5MW distributed solar power station with 700kWh battery was completed and put into production.
Overall planning of gas field energy strategic replacement and “Fuel switch”. Optimize electric drive drilling lines. Improve the electric drive fracturing power system. Plan compressor selection and transformation in advance. Research energy storage application technology.
And based on the energy saving and emission reduction, energy using structure optimization, renewable energy efficiency promotion in the process of natural gas development, systematically put forward low carbon technology, carbon reduction technology, carbon negative technology and emission reduction strategy with the reduction and elimination of carbon emissions as the basic characteristics, thus effectively reduce the carbon emissions in SSOC gas field, the region has reduced its carbon emissions by 105,300 tons, a decrease of nearly 70%, provides reference for green low carbon natural gas development.
Co-author/s:
MA Qian,South Sulige Operating Company of CNPC Changqing Oilfield (SSOC).
LI Ze-liang,South Sulige Operating Company of CNPC Changqing Oilfield (SSOC).
LI Xiao-hui, South Sulige Operating Company of CNPC Changqing Oilfield (SSOC).
DONG Yi-fan, South Sulige Operating Company of CNPC Changqing Oilfield (SSOC).
ZHANG Hua-tao, South Sulige Operating Company of CNPC Changqing Oilfield (SSOC).
LEI Yu, South Sulige Operating Company of CNPC Changqing Oilfield (SSOC).
WANG-Long, South Sulige Operating Company of CNPC Changqing Oilfield (SSOC).
YE Ye, South Sulige Operating Company of CNPC Changqing Oilfield (SSOC).
QIAO Peng, South Sulige Operating Company of CNPC Changqing Oilfield (SSOC).
Zhu Min, South Sulige Operating Company of CNPC Changqing Oilfield (SSOC).
Hindustan Petroleum Corporation Limited (HPCL) has successfully demonstrated the co-processing of Plastic Pyrolysis Oil (PPO) in its New Fluidized Catalytic Cracking Unit (NFCCU) at Mumbai Refinery, marking a major step towards establishing circular economy practices in the Indian downstream sector. This initiative, jointly driven by Mumbai Refinery and HP Green R&D Centre (HPGRDC), showcases the refinery’s ability to recycle waste plastic into valuable fuels, thereby reducing environmental impact and contributing to national sustainability goals.
The project began with detailed laboratory characterization of PPO, including physio-chemical analyses and micro-reactor studies. These experiments confirmed that co-processing PPO in the range of 0.5–5 wt% with conventional FCC feedstock is technically feasible, enhancing conversion, LPG yield, reducing resid and light cycle oil yields. Field implementation was enabled through a Management of Change (MOC) framework, involving skid modifications, safety reviews, and operational trials. One of the main challenges addressed was the higher chlorine (50 ppm) and diene content (2.8) in untreated PPO, which can lead to corrosion and coke formation. Treated PPO, however, demonstrated chlorine and diene levels comparable to FCC feed, ensuring smooth operations and long-term reliability.
Between 10–21 March 2025, HPCL processed 16 MT of PPO at 0.5–5 wt% blend ratios with NFCC feed. The processing was completed without adverse operational impact and confirmed stable yields. Importantly, this initiative resulted in a net reduction of approximately 154.6 tCO₂e emissions during the processing period, underscoring its environmental benefits. Furthermore, yield improvements were observed, with higher PPO content correlating with increased production, demonstrating both ecological and economic value.
The successful completion of this initiative also earned HPCL’s Mumbai Refinery an International Sustainability and Carbon Certification (ISCC PLUS), making it the first Indian public sector refinery to achieve such recognition for PPO processing. Beyond immediate results, the case establishes replicability across other FCC units, positioning HPCL as a leader in advancing plastic waste valorization in refinery operations.
This work highlights the innovation, scalability, and impact of PPO co-processing, proving that waste plastics can be transformed into high-value fuels while supporting global decarbonization and circularity objectives.
Co-author/s:
Kukude Somanath, Chief Manager, Hindustan Petroleum Corporation Limited.
The project began with detailed laboratory characterization of PPO, including physio-chemical analyses and micro-reactor studies. These experiments confirmed that co-processing PPO in the range of 0.5–5 wt% with conventional FCC feedstock is technically feasible, enhancing conversion, LPG yield, reducing resid and light cycle oil yields. Field implementation was enabled through a Management of Change (MOC) framework, involving skid modifications, safety reviews, and operational trials. One of the main challenges addressed was the higher chlorine (50 ppm) and diene content (2.8) in untreated PPO, which can lead to corrosion and coke formation. Treated PPO, however, demonstrated chlorine and diene levels comparable to FCC feed, ensuring smooth operations and long-term reliability.
Between 10–21 March 2025, HPCL processed 16 MT of PPO at 0.5–5 wt% blend ratios with NFCC feed. The processing was completed without adverse operational impact and confirmed stable yields. Importantly, this initiative resulted in a net reduction of approximately 154.6 tCO₂e emissions during the processing period, underscoring its environmental benefits. Furthermore, yield improvements were observed, with higher PPO content correlating with increased production, demonstrating both ecological and economic value.
The successful completion of this initiative also earned HPCL’s Mumbai Refinery an International Sustainability and Carbon Certification (ISCC PLUS), making it the first Indian public sector refinery to achieve such recognition for PPO processing. Beyond immediate results, the case establishes replicability across other FCC units, positioning HPCL as a leader in advancing plastic waste valorization in refinery operations.
This work highlights the innovation, scalability, and impact of PPO co-processing, proving that waste plastics can be transformed into high-value fuels while supporting global decarbonization and circularity objectives.
Co-author/s:
Kukude Somanath, Chief Manager, Hindustan Petroleum Corporation Limited.
A key part of achieving net zero emission is decarbonization. SASREF’s efforts on decarbonization started back in 2021 when we successfully captured CO2 from our Hydrogen Manufacturing Plant and exported the CO2 to our neighboring company as their feedstock, which also mark a major milestone in our efforts to develop clean energy solutions. The testament for this achievement was when SASREF proudly obtained the world’s first independent certification on “blue hydrogen” production which was granted by TUV Rheindland in August 2022, certifying SASREF for producing 8,075 tons of blue hydrogen in 2021.
In year 2024, 221750 tons of Carbon Capture was achieved by SASREF and exported to a neighboring company as feedstock
In line with the Kingdom of Saudi Arabia’s target to achieve net zero carbon emission by year 2060, SASREF in turn has an ambition to achieve net-zero Scope 1 and Scope 2 GHG emissions by 2050, which is also in line with our Shareholder, Saudi Aramco.
Moving forward, SASREF embarked on an Energy Optimization Study in 2024, in order to identify current consumption and losses across the refinery’s processes and equipment, and explore potential overall energy efficiency improvement.
Upon completion of the study at the end of 2024, we have identified several projects and initiatives to be executed in near future. To mitigate the 0.11 MMtCO2e from our current business and operations by 2035, we will execute several initiatives as listed below
In year 2024, 221750 tons of Carbon Capture was achieved by SASREF and exported to a neighboring company as feedstock
In line with the Kingdom of Saudi Arabia’s target to achieve net zero carbon emission by year 2060, SASREF in turn has an ambition to achieve net-zero Scope 1 and Scope 2 GHG emissions by 2050, which is also in line with our Shareholder, Saudi Aramco.
Moving forward, SASREF embarked on an Energy Optimization Study in 2024, in order to identify current consumption and losses across the refinery’s processes and equipment, and explore potential overall energy efficiency improvement.
Upon completion of the study at the end of 2024, we have identified several projects and initiatives to be executed in near future. To mitigate the 0.11 MMtCO2e from our current business and operations by 2035, we will execute several initiatives as listed below
- Low Pressure Steam (LPS) Header Excess Steam Elimination
- Recovery of Medium Pressure Steam (MPS) Gen in Ultra Low Sulphur Diesel (ULSD) Unit
- Seven (7) Major Heaters Efficiency Improvement
- Multi-stage Steam Turbine Generator (STG) to Balance MP and LP Steam Headers
Emissions of CO2 globally has been brought into attention in recent years through declarations by international leaders, and also by industrialists committing themselves to substantial reductions.
Owing to its role as a provider of transport fuels and chemicals, the refining sector produces an estimated 478,000 metric tons of CO2 every year, second only to power plants as a producer in CO2 emissions.
A refinery is generally a joint production process system. Nearly all of the energy consumed is fossil fuel for combustion; thus the petroleum refining industry is a significant source of GHG emissions (CO2, CH4, etc).
Due to the complex nature of the process involved, while it converts heavier oils into high quality oil products, fuels and other high value products, it also provides a way to curb CO2 emissions.
The study uses linear programming (LP) model to assess the impact of CO2 emissions on a refinery’s operational configuration, and energy using strategies. In the case of refineries, which usually operate on complex energy systems, CO2 emissions introduce an additional factor to the complexity of the energy costs reduction challenge.
Some of the areas in which a charge for CO2 emissions can drive changes in
refinery operation, and even in the actual configuration selected for the refinery, may involve the following:
Where potential schemes for reducing CO2 are being considered, the LP model can be used in an investment-modelling mode to look at the viability of these schemes and how that viability varies with emissions pricing. Where a number of potential schemes have been developed, the LP can be used to identify the best scheme to produce a given reduction on CO2, or it can be used to identify the optimum level of reduction at a given CO2 price.
The evaluation has been done for a typical existing refinery, with cracking and hydrotreating units. The refinery undergoes an increase in crude throughput and thus new secondary processing and residue upgradation units are planned to be installed.
The impact of carbon emission cost is then studied on the expansion refining scheme. It is envisaged that the optimization of the capacities of existing process units, fuel switching, crude substitution, relaxation in product specifications can lead to low CO2 emissions.
This paper concludes that with high dependence on the use of crude oil, suitable optimization of oil refineries during their planning stage must be done in order to mitigate their contribution to global warming.
Owing to its role as a provider of transport fuels and chemicals, the refining sector produces an estimated 478,000 metric tons of CO2 every year, second only to power plants as a producer in CO2 emissions.
A refinery is generally a joint production process system. Nearly all of the energy consumed is fossil fuel for combustion; thus the petroleum refining industry is a significant source of GHG emissions (CO2, CH4, etc).
Due to the complex nature of the process involved, while it converts heavier oils into high quality oil products, fuels and other high value products, it also provides a way to curb CO2 emissions.
The study uses linear programming (LP) model to assess the impact of CO2 emissions on a refinery’s operational configuration, and energy using strategies. In the case of refineries, which usually operate on complex energy systems, CO2 emissions introduce an additional factor to the complexity of the energy costs reduction challenge.
Some of the areas in which a charge for CO2 emissions can drive changes in
refinery operation, and even in the actual configuration selected for the refinery, may involve the following:
- Fuel substitution
- Crude substitution
- Hydrogen production
- Residue upgrading
Where potential schemes for reducing CO2 are being considered, the LP model can be used in an investment-modelling mode to look at the viability of these schemes and how that viability varies with emissions pricing. Where a number of potential schemes have been developed, the LP can be used to identify the best scheme to produce a given reduction on CO2, or it can be used to identify the optimum level of reduction at a given CO2 price.
The evaluation has been done for a typical existing refinery, with cracking and hydrotreating units. The refinery undergoes an increase in crude throughput and thus new secondary processing and residue upgradation units are planned to be installed.
The impact of carbon emission cost is then studied on the expansion refining scheme. It is envisaged that the optimization of the capacities of existing process units, fuel switching, crude substitution, relaxation in product specifications can lead to low CO2 emissions.
This paper concludes that with high dependence on the use of crude oil, suitable optimization of oil refineries during their planning stage must be done in order to mitigate their contribution to global warming.
Decarbonization policies and circular economy imperatives are reshaping the role of heavy fuel oil (HFO), long considered a high-carbon by-product, and plastic waste, a rapidly growing environmental challenge across the Gulf region. This study presents an innovative co-gasification pathway that simultaneously valorizes refinery residues and polyethylene (PE) waste into competitive, low-carbon hydrogen. By addressing two hard-to-abate streams within one integrated design, the process contributes to regional ambitions of carbon neutrality, waste minimization, and clean energy leadership.
A process simulation was developed in Aspen Plus V14, benchmarking conventional HFO gasification against HFO–PE co-gasification (1:1 ratio). Feed decomposition was modeled through RYield reactors, while gasification was performed in an entrained-flow RGibbs reactor at 900 °C and 1 atm. Downstream units included water-gas shift for H₂/CO tuning, and CO₂ capture at 99% recovery. Performance indicators comprised hydrogen yield, H₂/CO ratio, stoichiometric number, process efficiencies, and CO₂ intensity. Technoeconomic assessment was carried out for a 100 kg/h feed plant using standard cost correlations.
The blended feedstock achieved significant advantages over HFO-only gasification: a 76% improvement in H₂/CO ratio, a 30% reduction in CO₂ emissions per unit of hydrogen, and a 16% rise in overall efficiency. Hydrogen yield increased by 19%, while the levelized cost of hydrogen decreased from $2.29/kg to $1.92/kg—competitive with steam methane reforming. Profitability projections showed a 51% higher net present value and a shorter payback period (12 vs. 14 years). These findings demonstrate that HFO–PE co-gasification offers a replicable and scalable pathway for sustainable hydrogen production. By transforming waste and low-value residues into clean energy, the design exemplifies how technological integration can advance both emissions reduction and economic competitiveness. This work highlights a practical solution for GCC economies and beyond, reinforcing the Congress theme of building inclusive and actionable pathways to an energy future for all.
Co-author/s:
Usama Ahmed, Associate Professor, King Fahd University of Petroleum and Minerals.
A process simulation was developed in Aspen Plus V14, benchmarking conventional HFO gasification against HFO–PE co-gasification (1:1 ratio). Feed decomposition was modeled through RYield reactors, while gasification was performed in an entrained-flow RGibbs reactor at 900 °C and 1 atm. Downstream units included water-gas shift for H₂/CO tuning, and CO₂ capture at 99% recovery. Performance indicators comprised hydrogen yield, H₂/CO ratio, stoichiometric number, process efficiencies, and CO₂ intensity. Technoeconomic assessment was carried out for a 100 kg/h feed plant using standard cost correlations.
The blended feedstock achieved significant advantages over HFO-only gasification: a 76% improvement in H₂/CO ratio, a 30% reduction in CO₂ emissions per unit of hydrogen, and a 16% rise in overall efficiency. Hydrogen yield increased by 19%, while the levelized cost of hydrogen decreased from $2.29/kg to $1.92/kg—competitive with steam methane reforming. Profitability projections showed a 51% higher net present value and a shorter payback period (12 vs. 14 years). These findings demonstrate that HFO–PE co-gasification offers a replicable and scalable pathway for sustainable hydrogen production. By transforming waste and low-value residues into clean energy, the design exemplifies how technological integration can advance both emissions reduction and economic competitiveness. This work highlights a practical solution for GCC economies and beyond, reinforcing the Congress theme of building inclusive and actionable pathways to an energy future for all.
Co-author/s:
Usama Ahmed, Associate Professor, King Fahd University of Petroleum and Minerals.
Saudi Arabia has set a national target of achieving net-zero carbon emissions by 2060, an ambition that requires transformative changes across the industrial sector. In alignment with Saudi Vision 2030 and the Saudi Green Initiative, TASNEE has developed a comprehensive and phased decarbonization roadmap to guide its contribution to this national commitment. The roadmap quantifies Scope 1 and Scope 2 emissions across TASNEE’s operations, which systematically identifies the major emission sources, and evaluates multiple abatement options on a techno-economic basis to establish a flexible yet actionable pathway toward carbon neutrality.
The short-term phase of this pathway emphasizes efficiency improvements, energy optimization, and near-term fuel-switching measures. For example, the replacement of liquid fuel firing with natural gas (C2+ substitution) is projected to reduce carbon emissions by approximately 60,000 tCO₂ annually. Between 2022 and 2023, these efforts collectively contributed to a 4% reduction in CO₂ intensity across all operations. Mid- to long-term measures focus on adoption of emerging technologies such as hydrogen refueling, large-scale electrification, carbon capture, utilization, and storage (CCUS), and integration of renewable energy systems. TASNEE also maintains close engagement with licensors and technology providers to evaluate low-carbon catalysts and energy-efficient process technologies.
Complementing these decarbonization measures are renewable and green initiatives, including installation of solar power that offsets 24% of TASNEE’s R&D center electricity demand and a tree-planting program that has already added 2,000 trees, with planned expansion across company sites. Additionally, circular economy initiatives play a central role. TASNEE’s downstream operations produce over one million lightweight polypropylene pallets annually from mechanically recycled battery cases (13 KTA capacity) and manufacture car batteries through a closed-loop lead recycling process (67 KTA capacity). To further strengthen resource recovery, pilot-scale chemical recycling of polyolefins has been initiated, which will enable the conversion of used polymers into valuable monomers and chemicals.
Taken together, TASNEE’s decarbonization roadmap demonstrates how a phased, technology-driven, and circular approach can support both national and corporate climate goals. The combination of immediate efficiency gains, mid-term technology adoption, and long-term renewable and recycling strategies highlights a scalable framework for advancing industrial sustainability while reducing carbon intensity in line with Saudi Arabia’s 2060 net-zero target.
The short-term phase of this pathway emphasizes efficiency improvements, energy optimization, and near-term fuel-switching measures. For example, the replacement of liquid fuel firing with natural gas (C2+ substitution) is projected to reduce carbon emissions by approximately 60,000 tCO₂ annually. Between 2022 and 2023, these efforts collectively contributed to a 4% reduction in CO₂ intensity across all operations. Mid- to long-term measures focus on adoption of emerging technologies such as hydrogen refueling, large-scale electrification, carbon capture, utilization, and storage (CCUS), and integration of renewable energy systems. TASNEE also maintains close engagement with licensors and technology providers to evaluate low-carbon catalysts and energy-efficient process technologies.
Complementing these decarbonization measures are renewable and green initiatives, including installation of solar power that offsets 24% of TASNEE’s R&D center electricity demand and a tree-planting program that has already added 2,000 trees, with planned expansion across company sites. Additionally, circular economy initiatives play a central role. TASNEE’s downstream operations produce over one million lightweight polypropylene pallets annually from mechanically recycled battery cases (13 KTA capacity) and manufacture car batteries through a closed-loop lead recycling process (67 KTA capacity). To further strengthen resource recovery, pilot-scale chemical recycling of polyolefins has been initiated, which will enable the conversion of used polymers into valuable monomers and chemicals.
Taken together, TASNEE’s decarbonization roadmap demonstrates how a phased, technology-driven, and circular approach can support both national and corporate climate goals. The combination of immediate efficiency gains, mid-term technology adoption, and long-term renewable and recycling strategies highlights a scalable framework for advancing industrial sustainability while reducing carbon intensity in line with Saudi Arabia’s 2060 net-zero target.
Energy efficiency is a cornerstone of sustainable industrial practices, playing a pivotal role in reducing operational costs, minimizing environmental impact, and enhancing competitiveness. As sustainable energy practices reshape operational efficiency, oil and gas industries increasingly adopt innovative strategies to optimize energy use and reduce their Energy Intensity Index (EII). This Abstract shows the efforts exerted at Saudi Aramco Base Oil Company - Luberef refinery and highlights key interventions that contributed to improve energy efficiency and utilization. Luberef’s EII moved from Quartile 3 into Quartile 2 in Solomon’s Association rating. This improvement resulting in energy saving around 2*106 MMBTU per year and avoiding greenhouse gas (GHG) emission releasing of 110*106 kg.CO2e per year. This energy saving resulted from many improvement actions include but not limited to:
Additionally, maximizing heat recovery through increased refinery utilization. These measures not only reduced energy intensity but also demonstrated how sustainable energy practices can drive operational excellence and streamline logistics. The findings underscore the importance of continuous monitoring, process optimization, and strategic planning in achieving energy efficiency goals while supporting global sustainability initiatives.
- Enhance steam condensate recovery system,
- Improve fired heaters and boilers efficiencies,
- Optimize Hydrogen Manufacturing Unit (HMU) operating strategy,
- Reduce flaring gases and reuse it through new installed flare gas recovery system.
Additionally, maximizing heat recovery through increased refinery utilization. These measures not only reduced energy intensity but also demonstrated how sustainable energy practices can drive operational excellence and streamline logistics. The findings underscore the importance of continuous monitoring, process optimization, and strategic planning in achieving energy efficiency goals while supporting global sustainability initiatives.
The Gulf Cooperation Council (GCC) countries—Saudi Arabia, UAE, Kuwait, Qatar, Oman, and Bahrain—are prominent producers and consumers of plastics due to their robust petrochemical sectors. However, their plastic recycling rates remain low (~10%), with landfilling still dominant. As plastic waste surges globally—projected to exceed 1,200 million metric tons (MMT) by 2060—the GCC faces mounting pressure to enhance its waste management systems.
The report benchmarks the GCC's performance against global trends, noting that leading regions like the EU and South Korea already exceed 35–40% recycling rates due to cohesive regulations, infrastructure, and public engagement. By contrast, the GCC suffers from fragmented policies, limited public awareness, and underdeveloped recycling markets.
Two core recycling methods are highlighted: mechanical recycling, suited for clean and uniform plastic waste, and chemical recycling (e.g., pyrolysis, gasification, depolymerization), which is more versatile but costlier. The GCC’s low energy costs and industrial expertise make it strategically positioned to scale chemical recycling technologies. Case studies of regional initiatives—such as SABIC’s TRUCIRCLE in Saudi Arabia and DGrade in the UAE—show growing momentum in the plastic sector engagement.
Economically, the potential is significant. Achieving a 40% recycling rate could yield over USD 6 billion annually, create 50,000 jobs, and eliminate up to 12 million tons of CO₂ emissions per year. However, this would require USD 12–25 billion in investments by 2045 in infrastructure like sorting centers and recycling plants.
Policy recommendations include adopting region-wide policy schemes, harmonizing recycling standards, and fostering public-private partnerships. Investments in AI-powered sorting, innovation hubs, and public education are also crucial to close the implementation gap.
Ultimately, the report urges a shift from the current disposal-centric model to a circular plastic economy that integrates recycling into national economic and environmental strategies. With the right coordination and investment, the GCC can emerge as a global leader in sustainable plastic waste management.
The report benchmarks the GCC's performance against global trends, noting that leading regions like the EU and South Korea already exceed 35–40% recycling rates due to cohesive regulations, infrastructure, and public engagement. By contrast, the GCC suffers from fragmented policies, limited public awareness, and underdeveloped recycling markets.
Two core recycling methods are highlighted: mechanical recycling, suited for clean and uniform plastic waste, and chemical recycling (e.g., pyrolysis, gasification, depolymerization), which is more versatile but costlier. The GCC’s low energy costs and industrial expertise make it strategically positioned to scale chemical recycling technologies. Case studies of regional initiatives—such as SABIC’s TRUCIRCLE in Saudi Arabia and DGrade in the UAE—show growing momentum in the plastic sector engagement.
Economically, the potential is significant. Achieving a 40% recycling rate could yield over USD 6 billion annually, create 50,000 jobs, and eliminate up to 12 million tons of CO₂ emissions per year. However, this would require USD 12–25 billion in investments by 2045 in infrastructure like sorting centers and recycling plants.
Policy recommendations include adopting region-wide policy schemes, harmonizing recycling standards, and fostering public-private partnerships. Investments in AI-powered sorting, innovation hubs, and public education are also crucial to close the implementation gap.
Ultimately, the report urges a shift from the current disposal-centric model to a circular plastic economy that integrates recycling into national economic and environmental strategies. With the right coordination and investment, the GCC can emerge as a global leader in sustainable plastic waste management.
The global plastic crisis has emerged as one of the most urgent environmental challenges of the 21st century, with annual production exceeding 390 million tons and recycling rates falling below 10%. In Saudi Arabia alone, over 3.4 million tons of plastic waste are generated annually, yet less than 15% is recovered. This widening gap between consumption and recycling capacity underscores the need for innovative waste-to-chemicals pathways that reduce environmental burdens while supporting the transition to a circular carbon economy.
This study investigates thermochemical conversion routes for transforming mixed plastic waste into high-value light olefins, specifically ethylene and propylene, which serve as essential building blocks for the petrochemical industry. Two distinct pathways were designed and rigorously modeled using Aspen Plus® process simulation. At a proposed scale of 40,000 kg/hr (equivalent to diverting over 350,000 tons of plastic waste per year), these routes demonstrate both environmental and economic potential, contributing directly to decarbonization strategies in the Gulf region.
The first pathway integrates pyrolysis, hydrotreating, and steam cracking. Mixed plastic waste undergoes pyrolysis to yield pyro-oil, gases, and char. Subsequent hydrotreating upgrades pyro-oil into lighter hydrocarbons, which are then cracked to maximize olefin production. Simulation results indicate overall olefin yields of up to 70 wt.% with approximately 30 wt.% as light olefins, alongside a 40–60% reduction in CO₂ emissions compared to conventional fossil-based naphtha cracking. Process efficiency exceeds 90% with minimal char formation, enabling effective resource recovery.
The second pathway employs steam gasification followed by a methanol-to-olefins (MTO) process. Gasification converts plastic feedstock into high-quality syngas, with sensitivity analyses performed to optimize temperature and steam-to-plastic ratio. The syngas is subsequently synthesized into methanol, which is upgraded to light olefins via MTO. Although more complex, this route offers flexibility for integration with existing petrochemical infrastructure and can diversify product streams while enabling future syngas-based energy systems.
Both pathways demonstrate substantial decarbonization potential, with estimated reductions of 0.6–1.0 million tons of CO₂ annually at the proposed scale. While pyrolysis delivers higher olefin yields and simpler operation, the gasification–MTO route provides strategic advantages for infrastructure integration and syngas valorization. Together, these findings highlight the role of advanced thermochemical technologies in addressing plastic waste, reducing emissions, and reinforcing the circular carbon economy.
By linking waste management with petrochemical innovation, this work presents a viable pathway to produce sustainable olefins at scale. The outcomes align with global energy transition goals and Saudi Arabia’s Vision 2030 strategy, offering practical contributions toward cleaner production, carbon reduction, and sustainable growth in the energy and chemicals sector.
Co-author/s:
Umer Zahid, Associate Professor, King Fahd University of Petroleum & Minerals.
This study investigates thermochemical conversion routes for transforming mixed plastic waste into high-value light olefins, specifically ethylene and propylene, which serve as essential building blocks for the petrochemical industry. Two distinct pathways were designed and rigorously modeled using Aspen Plus® process simulation. At a proposed scale of 40,000 kg/hr (equivalent to diverting over 350,000 tons of plastic waste per year), these routes demonstrate both environmental and economic potential, contributing directly to decarbonization strategies in the Gulf region.
The first pathway integrates pyrolysis, hydrotreating, and steam cracking. Mixed plastic waste undergoes pyrolysis to yield pyro-oil, gases, and char. Subsequent hydrotreating upgrades pyro-oil into lighter hydrocarbons, which are then cracked to maximize olefin production. Simulation results indicate overall olefin yields of up to 70 wt.% with approximately 30 wt.% as light olefins, alongside a 40–60% reduction in CO₂ emissions compared to conventional fossil-based naphtha cracking. Process efficiency exceeds 90% with minimal char formation, enabling effective resource recovery.
The second pathway employs steam gasification followed by a methanol-to-olefins (MTO) process. Gasification converts plastic feedstock into high-quality syngas, with sensitivity analyses performed to optimize temperature and steam-to-plastic ratio. The syngas is subsequently synthesized into methanol, which is upgraded to light olefins via MTO. Although more complex, this route offers flexibility for integration with existing petrochemical infrastructure and can diversify product streams while enabling future syngas-based energy systems.
Both pathways demonstrate substantial decarbonization potential, with estimated reductions of 0.6–1.0 million tons of CO₂ annually at the proposed scale. While pyrolysis delivers higher olefin yields and simpler operation, the gasification–MTO route provides strategic advantages for infrastructure integration and syngas valorization. Together, these findings highlight the role of advanced thermochemical technologies in addressing plastic waste, reducing emissions, and reinforcing the circular carbon economy.
By linking waste management with petrochemical innovation, this work presents a viable pathway to produce sustainable olefins at scale. The outcomes align with global energy transition goals and Saudi Arabia’s Vision 2030 strategy, offering practical contributions toward cleaner production, carbon reduction, and sustainable growth in the energy and chemicals sector.
Co-author/s:
Umer Zahid, Associate Professor, King Fahd University of Petroleum & Minerals.
In recent years, the pressure of environmental regulations and the global goal of reducing carbon emissions have led refineries to change and rethink their operating practices. This research focuses on practical and implementable improvements to existing refineries rather than designing new and costly infrastructure. We introduce a set of simple but effective solutions that, by combining process optimization and the use of clean technologies, can lead to a significant reduction in pollutant emissions.
In this regard, measures such as upgrading heat recovery systems, improving catalyst performance, and simplifying chemical reaction pathways in units such as hydrocrackers and desulfurization units have been investigated. It is also proposed to replace part of the energy required with solar steam systems and green electricity, and to use CO₂ absorption units (including amine solutions and solid adsorbents) without the need for long-term shutdowns of operations.To test how realistic these measures are, we worked with engineers and planners from the energy sector to look at costs, timelines, and possible operational limits. The framework was built to stay flexible, so each refinery can adjust it according to its size, location, and specific needs. Our estimates suggest that, with the right incentives and supportive policies, emissions could be cut by 40–45%, and the required investment may be recovered within only a few years.
This design goes beyond a theoretical idea and is capable of being piloted on a real scale. Combining academic research results with field experience, this approach makes it a valuable starting point for moving towards low-carbon and sustainable refineries.
Co-author/s:
Mehrzad Lamuchi Deli, Engineer, National Iranian South Oil Company (NISOC).
In this regard, measures such as upgrading heat recovery systems, improving catalyst performance, and simplifying chemical reaction pathways in units such as hydrocrackers and desulfurization units have been investigated. It is also proposed to replace part of the energy required with solar steam systems and green electricity, and to use CO₂ absorption units (including amine solutions and solid adsorbents) without the need for long-term shutdowns of operations.To test how realistic these measures are, we worked with engineers and planners from the energy sector to look at costs, timelines, and possible operational limits. The framework was built to stay flexible, so each refinery can adjust it according to its size, location, and specific needs. Our estimates suggest that, with the right incentives and supportive policies, emissions could be cut by 40–45%, and the required investment may be recovered within only a few years.
This design goes beyond a theoretical idea and is capable of being piloted on a real scale. Combining academic research results with field experience, this approach makes it a valuable starting point for moving towards low-carbon and sustainable refineries.
Co-author/s:
Mehrzad Lamuchi Deli, Engineer, National Iranian South Oil Company (NISOC).
Ivan Soucek
Chair
Director
Association of the Chemical Industry of the Czech Republic
Czech Republic
Mohamed Abdo
Speaker
Senior Process Specialist
SAUDI ARAMCO BASE OIL COMPANY (LUBEREF)
Saudi Arabia
Energy efficiency is a cornerstone of sustainable industrial practices, playing a pivotal role in reducing operational costs, minimizing environmental impact, and enhancing competitiveness. As sustainable energy practices reshape operational efficiency, oil and gas industries increasingly adopt innovative strategies to optimize energy use and reduce their Energy Intensity Index (EII). This Abstract shows the efforts exerted at Saudi Aramco Base Oil Company - Luberef refinery and highlights key interventions that contributed to improve energy efficiency and utilization. Luberef’s EII moved from Quartile 3 into Quartile 2 in Solomon’s Association rating. This improvement resulting in energy saving around 2*106 MMBTU per year and avoiding greenhouse gas (GHG) emission releasing of 110*106 kg.CO2e per year. This energy saving resulted from many improvement actions include but not limited to:
Additionally, maximizing heat recovery through increased refinery utilization. These measures not only reduced energy intensity but also demonstrated how sustainable energy practices can drive operational excellence and streamline logistics. The findings underscore the importance of continuous monitoring, process optimization, and strategic planning in achieving energy efficiency goals while supporting global sustainability initiatives.
- Enhance steam condensate recovery system,
- Improve fired heaters and boilers efficiencies,
- Optimize Hydrogen Manufacturing Unit (HMU) operating strategy,
- Reduce flaring gases and reuse it through new installed flare gas recovery system.
Additionally, maximizing heat recovery through increased refinery utilization. These measures not only reduced energy intensity but also demonstrated how sustainable energy practices can drive operational excellence and streamline logistics. The findings underscore the importance of continuous monitoring, process optimization, and strategic planning in achieving energy efficiency goals while supporting global sustainability initiatives.
Ali Abdullah Al Qadri
Speaker
Ph.D Candidate
King Fahd University of Petroleum and Minerals
Saudi Arabia
Decarbonization policies and circular economy imperatives are reshaping the role of heavy fuel oil (HFO), long considered a high-carbon by-product, and plastic waste, a rapidly growing environmental challenge across the Gulf region. This study presents an innovative co-gasification pathway that simultaneously valorizes refinery residues and polyethylene (PE) waste into competitive, low-carbon hydrogen. By addressing two hard-to-abate streams within one integrated design, the process contributes to regional ambitions of carbon neutrality, waste minimization, and clean energy leadership.
A process simulation was developed in Aspen Plus V14, benchmarking conventional HFO gasification against HFO–PE co-gasification (1:1 ratio). Feed decomposition was modeled through RYield reactors, while gasification was performed in an entrained-flow RGibbs reactor at 900 °C and 1 atm. Downstream units included water-gas shift for H₂/CO tuning, and CO₂ capture at 99% recovery. Performance indicators comprised hydrogen yield, H₂/CO ratio, stoichiometric number, process efficiencies, and CO₂ intensity. Technoeconomic assessment was carried out for a 100 kg/h feed plant using standard cost correlations.
The blended feedstock achieved significant advantages over HFO-only gasification: a 76% improvement in H₂/CO ratio, a 30% reduction in CO₂ emissions per unit of hydrogen, and a 16% rise in overall efficiency. Hydrogen yield increased by 19%, while the levelized cost of hydrogen decreased from $2.29/kg to $1.92/kg—competitive with steam methane reforming. Profitability projections showed a 51% higher net present value and a shorter payback period (12 vs. 14 years). These findings demonstrate that HFO–PE co-gasification offers a replicable and scalable pathway for sustainable hydrogen production. By transforming waste and low-value residues into clean energy, the design exemplifies how technological integration can advance both emissions reduction and economic competitiveness. This work highlights a practical solution for GCC economies and beyond, reinforcing the Congress theme of building inclusive and actionable pathways to an energy future for all.
Co-author/s:
Usama Ahmed, Associate Professor, King Fahd University of Petroleum and Minerals.
A process simulation was developed in Aspen Plus V14, benchmarking conventional HFO gasification against HFO–PE co-gasification (1:1 ratio). Feed decomposition was modeled through RYield reactors, while gasification was performed in an entrained-flow RGibbs reactor at 900 °C and 1 atm. Downstream units included water-gas shift for H₂/CO tuning, and CO₂ capture at 99% recovery. Performance indicators comprised hydrogen yield, H₂/CO ratio, stoichiometric number, process efficiencies, and CO₂ intensity. Technoeconomic assessment was carried out for a 100 kg/h feed plant using standard cost correlations.
The blended feedstock achieved significant advantages over HFO-only gasification: a 76% improvement in H₂/CO ratio, a 30% reduction in CO₂ emissions per unit of hydrogen, and a 16% rise in overall efficiency. Hydrogen yield increased by 19%, while the levelized cost of hydrogen decreased from $2.29/kg to $1.92/kg—competitive with steam methane reforming. Profitability projections showed a 51% higher net present value and a shorter payback period (12 vs. 14 years). These findings demonstrate that HFO–PE co-gasification offers a replicable and scalable pathway for sustainable hydrogen production. By transforming waste and low-value residues into clean energy, the design exemplifies how technological integration can advance both emissions reduction and economic competitiveness. This work highlights a practical solution for GCC economies and beyond, reinforcing the Congress theme of building inclusive and actionable pathways to an energy future for all.
Co-author/s:
Usama Ahmed, Associate Professor, King Fahd University of Petroleum and Minerals.
Saudi Arabia has set a national target of achieving net-zero carbon emissions by 2060, an ambition that requires transformative changes across the industrial sector. In alignment with Saudi Vision 2030 and the Saudi Green Initiative, TASNEE has developed a comprehensive and phased decarbonization roadmap to guide its contribution to this national commitment. The roadmap quantifies Scope 1 and Scope 2 emissions across TASNEE’s operations, which systematically identifies the major emission sources, and evaluates multiple abatement options on a techno-economic basis to establish a flexible yet actionable pathway toward carbon neutrality.
The short-term phase of this pathway emphasizes efficiency improvements, energy optimization, and near-term fuel-switching measures. For example, the replacement of liquid fuel firing with natural gas (C2+ substitution) is projected to reduce carbon emissions by approximately 60,000 tCO₂ annually. Between 2022 and 2023, these efforts collectively contributed to a 4% reduction in CO₂ intensity across all operations. Mid- to long-term measures focus on adoption of emerging technologies such as hydrogen refueling, large-scale electrification, carbon capture, utilization, and storage (CCUS), and integration of renewable energy systems. TASNEE also maintains close engagement with licensors and technology providers to evaluate low-carbon catalysts and energy-efficient process technologies.
Complementing these decarbonization measures are renewable and green initiatives, including installation of solar power that offsets 24% of TASNEE’s R&D center electricity demand and a tree-planting program that has already added 2,000 trees, with planned expansion across company sites. Additionally, circular economy initiatives play a central role. TASNEE’s downstream operations produce over one million lightweight polypropylene pallets annually from mechanically recycled battery cases (13 KTA capacity) and manufacture car batteries through a closed-loop lead recycling process (67 KTA capacity). To further strengthen resource recovery, pilot-scale chemical recycling of polyolefins has been initiated, which will enable the conversion of used polymers into valuable monomers and chemicals.
Taken together, TASNEE’s decarbonization roadmap demonstrates how a phased, technology-driven, and circular approach can support both national and corporate climate goals. The combination of immediate efficiency gains, mid-term technology adoption, and long-term renewable and recycling strategies highlights a scalable framework for advancing industrial sustainability while reducing carbon intensity in line with Saudi Arabia’s 2060 net-zero target.
The short-term phase of this pathway emphasizes efficiency improvements, energy optimization, and near-term fuel-switching measures. For example, the replacement of liquid fuel firing with natural gas (C2+ substitution) is projected to reduce carbon emissions by approximately 60,000 tCO₂ annually. Between 2022 and 2023, these efforts collectively contributed to a 4% reduction in CO₂ intensity across all operations. Mid- to long-term measures focus on adoption of emerging technologies such as hydrogen refueling, large-scale electrification, carbon capture, utilization, and storage (CCUS), and integration of renewable energy systems. TASNEE also maintains close engagement with licensors and technology providers to evaluate low-carbon catalysts and energy-efficient process technologies.
Complementing these decarbonization measures are renewable and green initiatives, including installation of solar power that offsets 24% of TASNEE’s R&D center electricity demand and a tree-planting program that has already added 2,000 trees, with planned expansion across company sites. Additionally, circular economy initiatives play a central role. TASNEE’s downstream operations produce over one million lightweight polypropylene pallets annually from mechanically recycled battery cases (13 KTA capacity) and manufacture car batteries through a closed-loop lead recycling process (67 KTA capacity). To further strengthen resource recovery, pilot-scale chemical recycling of polyolefins has been initiated, which will enable the conversion of used polymers into valuable monomers and chemicals.
Taken together, TASNEE’s decarbonization roadmap demonstrates how a phased, technology-driven, and circular approach can support both national and corporate climate goals. The combination of immediate efficiency gains, mid-term technology adoption, and long-term renewable and recycling strategies highlights a scalable framework for advancing industrial sustainability while reducing carbon intensity in line with Saudi Arabia’s 2060 net-zero target.
Abdulrahman Nasser Alhatlani
Speaker
Advanced Process Control Engineer
Saudi Aramco Jubail Refinery (SASREF)
A key part of achieving net zero emission is decarbonization. SASREF’s efforts on decarbonization started back in 2021 when we successfully captured CO2 from our Hydrogen Manufacturing Plant and exported the CO2 to our neighboring company as their feedstock, which also mark a major milestone in our efforts to develop clean energy solutions. The testament for this achievement was when SASREF proudly obtained the world’s first independent certification on “blue hydrogen” production which was granted by TUV Rheindland in August 2022, certifying SASREF for producing 8,075 tons of blue hydrogen in 2021.
In year 2024, 221750 tons of Carbon Capture was achieved by SASREF and exported to a neighboring company as feedstock
In line with the Kingdom of Saudi Arabia’s target to achieve net zero carbon emission by year 2060, SASREF in turn has an ambition to achieve net-zero Scope 1 and Scope 2 GHG emissions by 2050, which is also in line with our Shareholder, Saudi Aramco.
Moving forward, SASREF embarked on an Energy Optimization Study in 2024, in order to identify current consumption and losses across the refinery’s processes and equipment, and explore potential overall energy efficiency improvement.
Upon completion of the study at the end of 2024, we have identified several projects and initiatives to be executed in near future. To mitigate the 0.11 MMtCO2e from our current business and operations by 2035, we will execute several initiatives as listed below
In year 2024, 221750 tons of Carbon Capture was achieved by SASREF and exported to a neighboring company as feedstock
In line with the Kingdom of Saudi Arabia’s target to achieve net zero carbon emission by year 2060, SASREF in turn has an ambition to achieve net-zero Scope 1 and Scope 2 GHG emissions by 2050, which is also in line with our Shareholder, Saudi Aramco.
Moving forward, SASREF embarked on an Energy Optimization Study in 2024, in order to identify current consumption and losses across the refinery’s processes and equipment, and explore potential overall energy efficiency improvement.
Upon completion of the study at the end of 2024, we have identified several projects and initiatives to be executed in near future. To mitigate the 0.11 MMtCO2e from our current business and operations by 2035, we will execute several initiatives as listed below
- Low Pressure Steam (LPS) Header Excess Steam Elimination
- Recovery of Medium Pressure Steam (MPS) Gen in Ultra Low Sulphur Diesel (ULSD) Unit
- Seven (7) Major Heaters Efficiency Improvement
- Multi-stage Steam Turbine Generator (STG) to Balance MP and LP Steam Headers
Forouzan Arash Nezhad
Speaker
PhD Candidate, Department of Chemistry
Shahid Chamran University of Ahvaz
Iran
In recent years, the pressure of environmental regulations and the global goal of reducing carbon emissions have led refineries to change and rethink their operating practices. This research focuses on practical and implementable improvements to existing refineries rather than designing new and costly infrastructure. We introduce a set of simple but effective solutions that, by combining process optimization and the use of clean technologies, can lead to a significant reduction in pollutant emissions.
In this regard, measures such as upgrading heat recovery systems, improving catalyst performance, and simplifying chemical reaction pathways in units such as hydrocrackers and desulfurization units have been investigated. It is also proposed to replace part of the energy required with solar steam systems and green electricity, and to use CO₂ absorption units (including amine solutions and solid adsorbents) without the need for long-term shutdowns of operations.To test how realistic these measures are, we worked with engineers and planners from the energy sector to look at costs, timelines, and possible operational limits. The framework was built to stay flexible, so each refinery can adjust it according to its size, location, and specific needs. Our estimates suggest that, with the right incentives and supportive policies, emissions could be cut by 40–45%, and the required investment may be recovered within only a few years.
This design goes beyond a theoretical idea and is capable of being piloted on a real scale. Combining academic research results with field experience, this approach makes it a valuable starting point for moving towards low-carbon and sustainable refineries.
Co-author/s:
Mehrzad Lamuchi Deli, Engineer, National Iranian South Oil Company (NISOC).
In this regard, measures such as upgrading heat recovery systems, improving catalyst performance, and simplifying chemical reaction pathways in units such as hydrocrackers and desulfurization units have been investigated. It is also proposed to replace part of the energy required with solar steam systems and green electricity, and to use CO₂ absorption units (including amine solutions and solid adsorbents) without the need for long-term shutdowns of operations.To test how realistic these measures are, we worked with engineers and planners from the energy sector to look at costs, timelines, and possible operational limits. The framework was built to stay flexible, so each refinery can adjust it according to its size, location, and specific needs. Our estimates suggest that, with the right incentives and supportive policies, emissions could be cut by 40–45%, and the required investment may be recovered within only a few years.
This design goes beyond a theoretical idea and is capable of being piloted on a real scale. Combining academic research results with field experience, this approach makes it a valuable starting point for moving towards low-carbon and sustainable refineries.
Co-author/s:
Mehrzad Lamuchi Deli, Engineer, National Iranian South Oil Company (NISOC).
The Gulf Cooperation Council (GCC) countries—Saudi Arabia, UAE, Kuwait, Qatar, Oman, and Bahrain—are prominent producers and consumers of plastics due to their robust petrochemical sectors. However, their plastic recycling rates remain low (~10%), with landfilling still dominant. As plastic waste surges globally—projected to exceed 1,200 million metric tons (MMT) by 2060—the GCC faces mounting pressure to enhance its waste management systems.
The report benchmarks the GCC's performance against global trends, noting that leading regions like the EU and South Korea already exceed 35–40% recycling rates due to cohesive regulations, infrastructure, and public engagement. By contrast, the GCC suffers from fragmented policies, limited public awareness, and underdeveloped recycling markets.
Two core recycling methods are highlighted: mechanical recycling, suited for clean and uniform plastic waste, and chemical recycling (e.g., pyrolysis, gasification, depolymerization), which is more versatile but costlier. The GCC’s low energy costs and industrial expertise make it strategically positioned to scale chemical recycling technologies. Case studies of regional initiatives—such as SABIC’s TRUCIRCLE in Saudi Arabia and DGrade in the UAE—show growing momentum in the plastic sector engagement.
Economically, the potential is significant. Achieving a 40% recycling rate could yield over USD 6 billion annually, create 50,000 jobs, and eliminate up to 12 million tons of CO₂ emissions per year. However, this would require USD 12–25 billion in investments by 2045 in infrastructure like sorting centers and recycling plants.
Policy recommendations include adopting region-wide policy schemes, harmonizing recycling standards, and fostering public-private partnerships. Investments in AI-powered sorting, innovation hubs, and public education are also crucial to close the implementation gap.
Ultimately, the report urges a shift from the current disposal-centric model to a circular plastic economy that integrates recycling into national economic and environmental strategies. With the right coordination and investment, the GCC can emerge as a global leader in sustainable plastic waste management.
The report benchmarks the GCC's performance against global trends, noting that leading regions like the EU and South Korea already exceed 35–40% recycling rates due to cohesive regulations, infrastructure, and public engagement. By contrast, the GCC suffers from fragmented policies, limited public awareness, and underdeveloped recycling markets.
Two core recycling methods are highlighted: mechanical recycling, suited for clean and uniform plastic waste, and chemical recycling (e.g., pyrolysis, gasification, depolymerization), which is more versatile but costlier. The GCC’s low energy costs and industrial expertise make it strategically positioned to scale chemical recycling technologies. Case studies of regional initiatives—such as SABIC’s TRUCIRCLE in Saudi Arabia and DGrade in the UAE—show growing momentum in the plastic sector engagement.
Economically, the potential is significant. Achieving a 40% recycling rate could yield over USD 6 billion annually, create 50,000 jobs, and eliminate up to 12 million tons of CO₂ emissions per year. However, this would require USD 12–25 billion in investments by 2045 in infrastructure like sorting centers and recycling plants.
Policy recommendations include adopting region-wide policy schemes, harmonizing recycling standards, and fostering public-private partnerships. Investments in AI-powered sorting, innovation hubs, and public education are also crucial to close the implementation gap.
Ultimately, the report urges a shift from the current disposal-centric model to a circular plastic economy that integrates recycling into national economic and environmental strategies. With the right coordination and investment, the GCC can emerge as a global leader in sustainable plastic waste management.
Ramanathan Arunachalam
Speaker
Chief Manager - Technical
Hindustan Petroleum Corporation Limited
India
Hindustan Petroleum Corporation Limited (HPCL) has successfully demonstrated the co-processing of Plastic Pyrolysis Oil (PPO) in its New Fluidized Catalytic Cracking Unit (NFCCU) at Mumbai Refinery, marking a major step towards establishing circular economy practices in the Indian downstream sector. This initiative, jointly driven by Mumbai Refinery and HP Green R&D Centre (HPGRDC), showcases the refinery’s ability to recycle waste plastic into valuable fuels, thereby reducing environmental impact and contributing to national sustainability goals.
The project began with detailed laboratory characterization of PPO, including physio-chemical analyses and micro-reactor studies. These experiments confirmed that co-processing PPO in the range of 0.5–5 wt% with conventional FCC feedstock is technically feasible, enhancing conversion, LPG yield, reducing resid and light cycle oil yields. Field implementation was enabled through a Management of Change (MOC) framework, involving skid modifications, safety reviews, and operational trials. One of the main challenges addressed was the higher chlorine (50 ppm) and diene content (2.8) in untreated PPO, which can lead to corrosion and coke formation. Treated PPO, however, demonstrated chlorine and diene levels comparable to FCC feed, ensuring smooth operations and long-term reliability.
Between 10–21 March 2025, HPCL processed 16 MT of PPO at 0.5–5 wt% blend ratios with NFCC feed. The processing was completed without adverse operational impact and confirmed stable yields. Importantly, this initiative resulted in a net reduction of approximately 154.6 tCO₂e emissions during the processing period, underscoring its environmental benefits. Furthermore, yield improvements were observed, with higher PPO content correlating with increased production, demonstrating both ecological and economic value.
The successful completion of this initiative also earned HPCL’s Mumbai Refinery an International Sustainability and Carbon Certification (ISCC PLUS), making it the first Indian public sector refinery to achieve such recognition for PPO processing. Beyond immediate results, the case establishes replicability across other FCC units, positioning HPCL as a leader in advancing plastic waste valorization in refinery operations.
This work highlights the innovation, scalability, and impact of PPO co-processing, proving that waste plastics can be transformed into high-value fuels while supporting global decarbonization and circularity objectives.
Co-author/s:
Kukude Somanath, Chief Manager, Hindustan Petroleum Corporation Limited.
The project began with detailed laboratory characterization of PPO, including physio-chemical analyses and micro-reactor studies. These experiments confirmed that co-processing PPO in the range of 0.5–5 wt% with conventional FCC feedstock is technically feasible, enhancing conversion, LPG yield, reducing resid and light cycle oil yields. Field implementation was enabled through a Management of Change (MOC) framework, involving skid modifications, safety reviews, and operational trials. One of the main challenges addressed was the higher chlorine (50 ppm) and diene content (2.8) in untreated PPO, which can lead to corrosion and coke formation. Treated PPO, however, demonstrated chlorine and diene levels comparable to FCC feed, ensuring smooth operations and long-term reliability.
Between 10–21 March 2025, HPCL processed 16 MT of PPO at 0.5–5 wt% blend ratios with NFCC feed. The processing was completed without adverse operational impact and confirmed stable yields. Importantly, this initiative resulted in a net reduction of approximately 154.6 tCO₂e emissions during the processing period, underscoring its environmental benefits. Furthermore, yield improvements were observed, with higher PPO content correlating with increased production, demonstrating both ecological and economic value.
The successful completion of this initiative also earned HPCL’s Mumbai Refinery an International Sustainability and Carbon Certification (ISCC PLUS), making it the first Indian public sector refinery to achieve such recognition for PPO processing. Beyond immediate results, the case establishes replicability across other FCC units, positioning HPCL as a leader in advancing plastic waste valorization in refinery operations.
This work highlights the innovation, scalability, and impact of PPO co-processing, proving that waste plastics can be transformed into high-value fuels while supporting global decarbonization and circularity objectives.
Co-author/s:
Kukude Somanath, Chief Manager, Hindustan Petroleum Corporation Limited.
Ze liang Li
Speaker
Engineer
South Sulige Operating Company of CNPC Changqing Oilfield
China
Fossil energy (coal, natural gas, oil) is the main energy composition, accounting for 64%. In the IEA energy structure forecast for 2040, with sustainable development policies, (Solar、Wind、Hydro) Non-fossil energy will be the main energy component, accounting for 68%. Even under a stated policy, fossil energy accounting for 48%, Non-fossil energy accounting for 44%. It is an inevitable choice to adapt to energy transformation.
In order to reduce carbon emissions during natural gas development, the research and application of low-carbon technologies based on the production and construction characteristics of gas field were proposed.
Clarified “Low-carbon transformation path” in SSOC. Combined with the characteristics of natural gas development. Define carbon emission boundaries. Analyze emission factors. Identify 5 types of emission sources. Calculate and predict the comprehensive carbon emission over the past 12 years .
Promote “Energy saving and emission reduction” of gas fields from multiple angles. Continuously improve the efficiency of flareless. Optimize energy consumption management of process equipment. Strengthen VOCs detection and recovery.
Accelerate the “Renewable energy using” in gas fields. Efficient completion of wind, solar, land resources survey. Optimize Solar PV component and array selection design. 1.5MW distributed solar power station with 700kWh battery was completed and put into production.
Overall planning of gas field energy strategic replacement and “Fuel switch”. Optimize electric drive drilling lines. Improve the electric drive fracturing power system. Plan compressor selection and transformation in advance. Research energy storage application technology.
And based on the energy saving and emission reduction, energy using structure optimization, renewable energy efficiency promotion in the process of natural gas development, systematically put forward low carbon technology, carbon reduction technology, carbon negative technology and emission reduction strategy with the reduction and elimination of carbon emissions as the basic characteristics, thus effectively reduce the carbon emissions in SSOC gas field, the region has reduced its carbon emissions by 105,300 tons, a decrease of nearly 70%, provides reference for green low carbon natural gas development.
Co-author/s:
MA Qian,South Sulige Operating Company of CNPC Changqing Oilfield (SSOC).
LI Ze-liang,South Sulige Operating Company of CNPC Changqing Oilfield (SSOC).
LI Xiao-hui, South Sulige Operating Company of CNPC Changqing Oilfield (SSOC).
DONG Yi-fan, South Sulige Operating Company of CNPC Changqing Oilfield (SSOC).
ZHANG Hua-tao, South Sulige Operating Company of CNPC Changqing Oilfield (SSOC).
LEI Yu, South Sulige Operating Company of CNPC Changqing Oilfield (SSOC).
WANG-Long, South Sulige Operating Company of CNPC Changqing Oilfield (SSOC).
YE Ye, South Sulige Operating Company of CNPC Changqing Oilfield (SSOC).
QIAO Peng, South Sulige Operating Company of CNPC Changqing Oilfield (SSOC).
Zhu Min, South Sulige Operating Company of CNPC Changqing Oilfield (SSOC).
In order to reduce carbon emissions during natural gas development, the research and application of low-carbon technologies based on the production and construction characteristics of gas field were proposed.
Clarified “Low-carbon transformation path” in SSOC. Combined with the characteristics of natural gas development. Define carbon emission boundaries. Analyze emission factors. Identify 5 types of emission sources. Calculate and predict the comprehensive carbon emission over the past 12 years .
Promote “Energy saving and emission reduction” of gas fields from multiple angles. Continuously improve the efficiency of flareless. Optimize energy consumption management of process equipment. Strengthen VOCs detection and recovery.
Accelerate the “Renewable energy using” in gas fields. Efficient completion of wind, solar, land resources survey. Optimize Solar PV component and array selection design. 1.5MW distributed solar power station with 700kWh battery was completed and put into production.
Overall planning of gas field energy strategic replacement and “Fuel switch”. Optimize electric drive drilling lines. Improve the electric drive fracturing power system. Plan compressor selection and transformation in advance. Research energy storage application technology.
And based on the energy saving and emission reduction, energy using structure optimization, renewable energy efficiency promotion in the process of natural gas development, systematically put forward low carbon technology, carbon reduction technology, carbon negative technology and emission reduction strategy with the reduction and elimination of carbon emissions as the basic characteristics, thus effectively reduce the carbon emissions in SSOC gas field, the region has reduced its carbon emissions by 105,300 tons, a decrease of nearly 70%, provides reference for green low carbon natural gas development.
Co-author/s:
MA Qian,South Sulige Operating Company of CNPC Changqing Oilfield (SSOC).
LI Ze-liang,South Sulige Operating Company of CNPC Changqing Oilfield (SSOC).
LI Xiao-hui, South Sulige Operating Company of CNPC Changqing Oilfield (SSOC).
DONG Yi-fan, South Sulige Operating Company of CNPC Changqing Oilfield (SSOC).
ZHANG Hua-tao, South Sulige Operating Company of CNPC Changqing Oilfield (SSOC).
LEI Yu, South Sulige Operating Company of CNPC Changqing Oilfield (SSOC).
WANG-Long, South Sulige Operating Company of CNPC Changqing Oilfield (SSOC).
YE Ye, South Sulige Operating Company of CNPC Changqing Oilfield (SSOC).
QIAO Peng, South Sulige Operating Company of CNPC Changqing Oilfield (SSOC).
Zhu Min, South Sulige Operating Company of CNPC Changqing Oilfield (SSOC).
Emissions of CO2 globally has been brought into attention in recent years through declarations by international leaders, and also by industrialists committing themselves to substantial reductions.
Owing to its role as a provider of transport fuels and chemicals, the refining sector produces an estimated 478,000 metric tons of CO2 every year, second only to power plants as a producer in CO2 emissions.
A refinery is generally a joint production process system. Nearly all of the energy consumed is fossil fuel for combustion; thus the petroleum refining industry is a significant source of GHG emissions (CO2, CH4, etc).
Due to the complex nature of the process involved, while it converts heavier oils into high quality oil products, fuels and other high value products, it also provides a way to curb CO2 emissions.
The study uses linear programming (LP) model to assess the impact of CO2 emissions on a refinery’s operational configuration, and energy using strategies. In the case of refineries, which usually operate on complex energy systems, CO2 emissions introduce an additional factor to the complexity of the energy costs reduction challenge.
Some of the areas in which a charge for CO2 emissions can drive changes in
refinery operation, and even in the actual configuration selected for the refinery, may involve the following:
Where potential schemes for reducing CO2 are being considered, the LP model can be used in an investment-modelling mode to look at the viability of these schemes and how that viability varies with emissions pricing. Where a number of potential schemes have been developed, the LP can be used to identify the best scheme to produce a given reduction on CO2, or it can be used to identify the optimum level of reduction at a given CO2 price.
The evaluation has been done for a typical existing refinery, with cracking and hydrotreating units. The refinery undergoes an increase in crude throughput and thus new secondary processing and residue upgradation units are planned to be installed.
The impact of carbon emission cost is then studied on the expansion refining scheme. It is envisaged that the optimization of the capacities of existing process units, fuel switching, crude substitution, relaxation in product specifications can lead to low CO2 emissions.
This paper concludes that with high dependence on the use of crude oil, suitable optimization of oil refineries during their planning stage must be done in order to mitigate their contribution to global warming.
Owing to its role as a provider of transport fuels and chemicals, the refining sector produces an estimated 478,000 metric tons of CO2 every year, second only to power plants as a producer in CO2 emissions.
A refinery is generally a joint production process system. Nearly all of the energy consumed is fossil fuel for combustion; thus the petroleum refining industry is a significant source of GHG emissions (CO2, CH4, etc).
Due to the complex nature of the process involved, while it converts heavier oils into high quality oil products, fuels and other high value products, it also provides a way to curb CO2 emissions.
The study uses linear programming (LP) model to assess the impact of CO2 emissions on a refinery’s operational configuration, and energy using strategies. In the case of refineries, which usually operate on complex energy systems, CO2 emissions introduce an additional factor to the complexity of the energy costs reduction challenge.
Some of the areas in which a charge for CO2 emissions can drive changes in
refinery operation, and even in the actual configuration selected for the refinery, may involve the following:
- Fuel substitution
- Crude substitution
- Hydrogen production
- Residue upgrading
Where potential schemes for reducing CO2 are being considered, the LP model can be used in an investment-modelling mode to look at the viability of these schemes and how that viability varies with emissions pricing. Where a number of potential schemes have been developed, the LP can be used to identify the best scheme to produce a given reduction on CO2, or it can be used to identify the optimum level of reduction at a given CO2 price.
The evaluation has been done for a typical existing refinery, with cracking and hydrotreating units. The refinery undergoes an increase in crude throughput and thus new secondary processing and residue upgradation units are planned to be installed.
The impact of carbon emission cost is then studied on the expansion refining scheme. It is envisaged that the optimization of the capacities of existing process units, fuel switching, crude substitution, relaxation in product specifications can lead to low CO2 emissions.
This paper concludes that with high dependence on the use of crude oil, suitable optimization of oil refineries during their planning stage must be done in order to mitigate their contribution to global warming.
Muhammed-Jamiu Umar
Speaker
Master's Student
King Fahad University of Petroleum and Minerals, Dammam
Saudi Arabia
The global plastic crisis has emerged as one of the most urgent environmental challenges of the 21st century, with annual production exceeding 390 million tons and recycling rates falling below 10%. In Saudi Arabia alone, over 3.4 million tons of plastic waste are generated annually, yet less than 15% is recovered. This widening gap between consumption and recycling capacity underscores the need for innovative waste-to-chemicals pathways that reduce environmental burdens while supporting the transition to a circular carbon economy.
This study investigates thermochemical conversion routes for transforming mixed plastic waste into high-value light olefins, specifically ethylene and propylene, which serve as essential building blocks for the petrochemical industry. Two distinct pathways were designed and rigorously modeled using Aspen Plus® process simulation. At a proposed scale of 40,000 kg/hr (equivalent to diverting over 350,000 tons of plastic waste per year), these routes demonstrate both environmental and economic potential, contributing directly to decarbonization strategies in the Gulf region.
The first pathway integrates pyrolysis, hydrotreating, and steam cracking. Mixed plastic waste undergoes pyrolysis to yield pyro-oil, gases, and char. Subsequent hydrotreating upgrades pyro-oil into lighter hydrocarbons, which are then cracked to maximize olefin production. Simulation results indicate overall olefin yields of up to 70 wt.% with approximately 30 wt.% as light olefins, alongside a 40–60% reduction in CO₂ emissions compared to conventional fossil-based naphtha cracking. Process efficiency exceeds 90% with minimal char formation, enabling effective resource recovery.
The second pathway employs steam gasification followed by a methanol-to-olefins (MTO) process. Gasification converts plastic feedstock into high-quality syngas, with sensitivity analyses performed to optimize temperature and steam-to-plastic ratio. The syngas is subsequently synthesized into methanol, which is upgraded to light olefins via MTO. Although more complex, this route offers flexibility for integration with existing petrochemical infrastructure and can diversify product streams while enabling future syngas-based energy systems.
Both pathways demonstrate substantial decarbonization potential, with estimated reductions of 0.6–1.0 million tons of CO₂ annually at the proposed scale. While pyrolysis delivers higher olefin yields and simpler operation, the gasification–MTO route provides strategic advantages for infrastructure integration and syngas valorization. Together, these findings highlight the role of advanced thermochemical technologies in addressing plastic waste, reducing emissions, and reinforcing the circular carbon economy.
By linking waste management with petrochemical innovation, this work presents a viable pathway to produce sustainable olefins at scale. The outcomes align with global energy transition goals and Saudi Arabia’s Vision 2030 strategy, offering practical contributions toward cleaner production, carbon reduction, and sustainable growth in the energy and chemicals sector.
Co-author/s:
Umer Zahid, Associate Professor, King Fahd University of Petroleum & Minerals.
This study investigates thermochemical conversion routes for transforming mixed plastic waste into high-value light olefins, specifically ethylene and propylene, which serve as essential building blocks for the petrochemical industry. Two distinct pathways were designed and rigorously modeled using Aspen Plus® process simulation. At a proposed scale of 40,000 kg/hr (equivalent to diverting over 350,000 tons of plastic waste per year), these routes demonstrate both environmental and economic potential, contributing directly to decarbonization strategies in the Gulf region.
The first pathway integrates pyrolysis, hydrotreating, and steam cracking. Mixed plastic waste undergoes pyrolysis to yield pyro-oil, gases, and char. Subsequent hydrotreating upgrades pyro-oil into lighter hydrocarbons, which are then cracked to maximize olefin production. Simulation results indicate overall olefin yields of up to 70 wt.% with approximately 30 wt.% as light olefins, alongside a 40–60% reduction in CO₂ emissions compared to conventional fossil-based naphtha cracking. Process efficiency exceeds 90% with minimal char formation, enabling effective resource recovery.
The second pathway employs steam gasification followed by a methanol-to-olefins (MTO) process. Gasification converts plastic feedstock into high-quality syngas, with sensitivity analyses performed to optimize temperature and steam-to-plastic ratio. The syngas is subsequently synthesized into methanol, which is upgraded to light olefins via MTO. Although more complex, this route offers flexibility for integration with existing petrochemical infrastructure and can diversify product streams while enabling future syngas-based energy systems.
Both pathways demonstrate substantial decarbonization potential, with estimated reductions of 0.6–1.0 million tons of CO₂ annually at the proposed scale. While pyrolysis delivers higher olefin yields and simpler operation, the gasification–MTO route provides strategic advantages for infrastructure integration and syngas valorization. Together, these findings highlight the role of advanced thermochemical technologies in addressing plastic waste, reducing emissions, and reinforcing the circular carbon economy.
By linking waste management with petrochemical innovation, this work presents a viable pathway to produce sustainable olefins at scale. The outcomes align with global energy transition goals and Saudi Arabia’s Vision 2030 strategy, offering practical contributions toward cleaner production, carbon reduction, and sustainable growth in the energy and chemicals sector.
Co-author/s:
Umer Zahid, Associate Professor, King Fahd University of Petroleum & Minerals.
