The Yokohama Rubber Co., Ltd. and Zeon Corporation have decided to work together to build a bench facility to showcase technologies for efficiently making butadiene from ethanol made from plant-based and other sustainable sources. Zeon's Tokuyama Plant in Sunan City, Yamaguchi Prefecture, will house the plant, which is expected to start up in 2026. It will make it possible to produce a specific quantity of butadiene and make it easier to gather the many types of data needed to develop mass manufacturing.

The New Energy and Industrial Technology Development Organisation (NEDO) chose two research and development themes in 2022 for its project, ‘Development of Technology for Producing Raw Materials for Plastics Using CO2 and Other Sources’, which is one of the Green Innovation Fund Projects of NEDO. This initiative is in line with one of those themes. The National Institute of Advanced Industrial Science and Technology (AIST), National University Corporation Institute of Science Tokyo (formerly Tokyo Institute of Technology) and the national research and development agency RIKEN are working together to develop two technologies that will allow for the highly efficient production of butadiene and isoprene from plant-based and other sustainable materials in the 2030s. Zeon and Yokohama Rubber are working towards the social implementation of these technologies. The bench facility to be installed at the Zeon plant is part of initiatives based on the theme ‘Highly Efficient Butadiene Synthesis Using Ethanol’.

The experiment at the new bench facility will show how to use a very effective catalyst to turn ethanol made from plant-based and other sustainable materials into butadiene. This will be the first stage in establishing the technology's use for the large-scale manufacturing of synthetic rubber from plant-based and other sustainable ingredients. From the butadiene produced at the bench facility, Zeon will create a prototype polybutadiene rubber (butadiene rubber). Yokohama Rubber will use the butadiene rubber to create prototype tyres and test the tyres' performance to gather information for a larger-scale technology demonstration.

Tyros B.V., a start-up company focused on the recycling of end-of-life tyres, is all set to move into a 2-hectare pyrolysis plant on the former UCB site in the port area of ​​Ostend, Belgium.

Tyros, which was established in May 2024, is investing in an electric pyrolysis reactor with the support of the Flemish government (EUR 1 million in strategic ecology support). Every year, 9,125 tonnes of rubber granulate will be transformed into important primary components including syngas, pyrolysis oil and recovered carbon black by this reactor. These basic materials end up in a number of industries, such as energy, petrochemicals, automotive and ink manufacturing. When compared to the conventional burning of rubber granulate, the usage of this technique is said to prevent the emission of over 21,000 tonnes of CO2 per year.

Over time, the facility will process 100,000 tonnes of tyres a year, of which 18,000 tonnes will be pyrolysed on-site. This will yield 6,800 tonnes of recovered carbon black and 5,000 tonnes of pyrolysis oil, two essential raw materials for circular applications. It is important to note that 100,000 tonnes per year is quite near to the total amount of tyre waste produced in Belgium.

Trucks will supply the tyres, and containers carrying the shreds will be carried by waterway for additional processing, which may need a feeder service between Ostend and Antwerp. The circular economy in the area is strengthened and marine traffic at the port is facilitated by this sustainable logistics concept. Tyros will generate dozens of new employment both directly and indirectly.

Construction of Sweden's first full-scale tyre recycling facility, using Enviro's patented pyrolysis technology, is advancing steadily since breaking ground in mid-February 2024.

According to recent contractor updates, the project, located outside Uddevalla in western Sweden, has reached several key milestones. Workers have installed L-supports and begun the groundwork for tyre storage facilities. The site's sprinkler system infrastructure, including the main tank and housing, is nearly complete, while interior construction has begun with wall installation and surface finishing.

The facility represents a joint venture between Enviro and Antin Infrastructure Partners, operating under the name Infiniteria, with support from tyre manufacturer Michelin. The plant will utilise Enviro's specialised pyrolysis process to recycle end-of-life tyres.

The contractor highlighted progress through a newly released video showcasing recent developments at the construction site.

The project marks Sweden's first venture into full-scale tyre recycling using this patented technology, signalling a significant step forward in sustainable tyre disposal solutions.

Orion S.A. has secured a long-term agreement with Polish firm Contec S.A. to supply tyre pyrolysis oil to produce circular carbon black, marking a significant step towards sustainable tyre manufacturing.

The speciality chemicals company, which trades on the New York Stock Exchange, will use the oil to manufacture circular grades of carbon black for tyre and rubber goods manufacturers.

"With the ConPyro TPO supplied by Contec, Orion will be able to make large-scale volumes of circular grades of carbon black that will supply growing demand from the world's leading tyre and rubber goods producers," Orion CEO Corning Painter said. "This is yet another way that Orion is accelerating the transition to a circular economy."

The process involves exposing end-of-life tyres to high temperatures to create a feedstock that can be converted into virgin carbon black. Orion has distinguished itself as the only manufacturer to produce circular carbon black using 100 percent tyre pyrolysis oil as feedstock.

The Warsaw-based supplier's CEO, Krzysztof Wróblewski, emphasised the partnership's significance: "At Contec, sustainability is one of our core values. This partnership is a clear confirmation to the market that the industry is continuously evolving, and the circular economy is no longer just a vision for the future – thanks to the collaboration with Orion, it is becoming a tangible reality today."

The agreement enables Orion to diversify its sources of tyre pyrolysis oil whilst meeting the increasing demand for sustainable alternatives in tyre manufacturing. The company reports that its circular products have demonstrated the capability to replace virgin carbon black in numerous applications.

PCBL Chemical is positioning itself for significant growth through strategic expansions and capacity additions across multiple business segments, capitalising on emerging global chemical market opportunities. 

The company is making substantial investments in its manufacturing capabilities, with a notable recent development being the allocation of 116 acres of land in Andhra Pradesh’s Naidupeta region.
This new site represents the company’s sixth manufacturing location, which can house roughly 400,000-450,000 metric tonnes per annum (MTPA) of carbon black capacity. It is strategically positioned near major ports like Kattupalli and Krishnapatnam, enabling efficient logistics and cost-effective goods movement. 
“The first phase of this expansion will involve establishing a 150,000  MTPA carbon black plant, with an estimated investment of approximately INR 9.5-9.6 billion and a projected timeline of 2-2.5 years,” said Raj Gupta – Chief Financial Officer – PCBL Chemical Limited.

Current manufacturing capacity has already been expanded, with the company recently commissioning a specialty line of 20,000 MTPA in Mundra, bringing its total capacity to 790,000 MTPA. The company is simultaneously pursuing multiple expansion tracks, including a brownfield expansion of 30,000 tonnes in Tamil Nadu and a second phase expansion of 60,000 tonnes, accompanied by a 12 MW green power project.

In the speciality chemicals domain, PCBL is making significant strides. The company has launched ECOZENTM6000, a new product grade based on recycled materials, demonstrating its commitment to sustainability. 
The company has also been certified with International Sustainability and Carbon Plus (ISCC) certification, underscoring its dedication to responsible production and circular economy principles.

The company is particularly bullish about its export markets, especially in Europe and North America. Despite current geopolitical challenges stemming from restrictions on Russian Carbon Black exports, PCBL sees this as an opportunity to expand its market presence. The company has increased its international sales volumes, with western market contributions rising from 7-8 percent historically to approximately 35 percent currently.

The specialty Carbon Black segment shows promising growth, with projected full-year sales volume expected to reach 63,000-64,000 tonnes, compared to 57,000 tonnes last year. “Management anticipates gradual margin improvements in this segment over the next 2-4 years as they move up the value chain,” said Gupta.

A particularly exciting development is the company’s nano-silica project. PCBL is currently establishing a pilot plant for sampling, with plans to develop a 2,000-tonne commercial facility. “Now, this 2,000 tons, based on our back of the envelope calculation, should give us somewhere around INR1,700-1,800 crores kind of a top line and roughly about INR800-900 crores kind of EBITDA,” said Gupta.