FEASIBILITY STUDY: ADVANCING PLASTIC PYROLYSIS FOR LOW-CARBON MARINE FUEL IN MALTA

Sustainable Development Goals

Current Project Status:
Development Started 2018 | Feasibility Study
Organizations Involved:
Klean Industries, Platinum Group, Dolphin Industrial Services, MNWTP, WasteServ, 
Services:
Design & Engineering, Component Supply, Feasibility Study, Due Diligence, Supply Chain Management, Operator Training

The shipping industry faces increasing pressure to transition toward low-carbon fuels as part of global efforts to reduce greenhouse gas emissions. In Malta, Klean Industries is advancing plastic pyrolysis technology to convert non-recyclable plastics into sustainable marine fuel. This initiative reduces ocean-bound plastic waste and provides an alternative, low-emission fuel for the maritime sector. By integrating circular economy principles, Klean Industries is pioneering a scalable, cost-effective solution for marine decarbonization.

Introduction

Malta faces a pressing waste management challenge due to its high population density, limited land availability, and lack of economies of scale. The Maltese government introduced the 2014-2020 Waste Management Plan to meet EU targets for waste reduction, source separation, and increased recycling. However, despite these efforts, the country struggles with excessive waste generation and low recycling rates, particularly for plastics.

In response to these challenges, Klean Industries conducted a Detailed Feasibility Study (DFS) to evaluate the potential for advanced plastic recycling through pyrolysis. The study explored how non-recycled plastics could be converted into a low-carbon marine fuel, supporting Malta’s waste reduction goals while aligning with EU and IMO regulations on decarbonizing the maritime sector.

The Challenge

Malta generated nearly 2.9 million tonnes of waste in 2023, with construction waste making up the bulk at 2.2 million tonnes. While household waste saw a 10% decrease, the country remains one of the highest waste generators in the EU. Under the European Union’s Circular Economy Package, Malta must recycle at least 55% of municipal waste by 2025, increasing to 60% by 2030 and 65% by 2035. The country also faces ambitious packaging material recycling targets, requiring significant improvements in plastic waste management.

Plastic Waste Crisis:

• Malta’s plastic recycling rate was only 1% in 2019—among the lowest in the EU.
• In 2022, only 16.4% of plastic packaging waste was recycled, falling far behind EU averages.
• Plastic waste exports rose from 1% in 2016 to 36% in 2019, yet 58% of plastic waste remains in landfills.
• Poor waste separation at the source results in recyclable materials being landfilled, escalating financial and environmental costs.

To address these issues, the government approved the construction of a waste-to-energy (WTE) plant in Magħtab, expected to process 40% of the country’s waste and generate 69,000 MWh of electricity annually. However, this still leaves a substantial 60% of garbage requiring alternative recovery solutions—including non-recyclable plastics, which the DFS aimed to address.

The Solution: Plastic Pyrolysis for Low-Carbon Marine Fuel

In 2018, Klean Industries was engaged to conduct a DFS on advanced plastic recycling. The study identified a significant opportunity to recover plastic waste from Malta’s North Waste Treatment Facility (NWTF) and process it via pyrolysis. This thermochemical process converts plastics into valuable liquid fuel.

Key Strategic Initiatives:

Collaboration with Platinum Group & Dolphin Industrial Services:

• Secured a strategic site in Malta’s port area to develop a plastic pyrolysis facility.
• Targeting non-recyclable plastics from municipal waste streams to produce decarbonized, recycled oil.

Integration with Malta’s waste infrastructure:

• The NWTF processes 76,000 tonnes of municipal solid waste annually.
• Extracted plastics from mechanical treatment will be redirected to the pyrolysis plant instead of landfilling.
• The anaerobic digestion plant at NWTF will continue generating biogas and electricity for Malta’s grid.

Marine Fuel Applications:

• The recycled oil is designed to be blended with marine fuel, aligning with IMO and EU regulations.
• Supports EU Fit for 55 goals, integrating maritime fuel emissions into the EU Emission Trading Scheme (ETS).

Enhanced Transparency & Digitalization:

• The integration of Klean Industries' Klean Loop™ technology will digitally track and verify the recovery and conversion of non-recycled plastics into fuel.
• Klean Loop™ provides real-time data analytics, lifecycle tracking, and blockchain-secured transparency, ensuring accountability in the waste-to-fuel process.
• The technology will help governments, businesses, and regulatory bodies monitor environmental impact reductions and compliance with EU sustainability goals.

This project represents an innovative step in circular economy principles. It turns waste plastics into a valuable fuel resource, reducing landfill dependency and marine emissions.

The Outcome & Future Recommendations

Klean Industries’ DFS provided key insights into improving Malta’s waste recovery and circular economy transition. The findings align with recommendations from the Maltese National Audit Office and include actionable measures:

✅ Improve waste data transparency: Shorten reporting times for waste statistics to enable better decision-making.
✅ Enhance plastic market analysis: Authorities should collaborate to assess the volume of plastics placed on the market accurately.
✅ Implement economic incentives: Adjust landfill gate fees based on the ‘polluter pays’ principle to reflect actual waste management costs.
✅ Expedite plastic waste strategies: The 2021-2030 plastic waste strategy should be fast-tracked.
✅ Strengthen deposit & refund schemes: – Expand existing initiatives for beverage containers to include additional plastic waste streams.
✅ Make waste separation at source mandatory: Improve household, commercial, and industrial waste segregation policies.
✅ Reduce mixed (black bag) waste: Implement policies to divert plastics from landfills while developing new waste treatment infrastructure.
✅ Legislative intervention on plastic production: Introduce regulatory measures to limit plastic use and encourage sustainable alternatives.

Conclusion

The feasibility study demonstrated the viability of a plastic pyrolysis plant as a sustainable waste management solution for Malta. By converting non-recyclable plastics into low-carbon marine fuel, the project aligns with EU waste directives, supports IMO emissions targets, and fosters Malta’s transition to a circular economy.

This initiative provides a scalable, environmentally responsible model for addressing Malta's plastic waste crisis through strategic partnerships with Platinum Group and Dolphin Industrial Services and by leveraging existing waste treatment infrastructure. The integration of Klean Loop™ technology further enhances the project by ensuring unparalleled transparency, traceability, and regulatory compliance, creating a data-driven approach to sustainability.

With the support of policymakers and industry stakeholders, integrating plastic pyrolysis into Malta’s waste strategy could mark a transformative shift toward a cleaner, more sustainable future.

Klean Industries remains committed to advancing innovative waste solutions that drive sustainability and economic progress.

Join Us in Driving Sustainable Change

Klean Industries invites government agencies, industry leaders, and environmental organizations to collaborate on innovative waste-to-resource solutions. By implementing cutting-edge technologies like plastic pyrolysis and blockchain-based tracking, we can accelerate the transition to a more sustainable future.

✅ Are you interested in learning more about how this project can support Malta’s waste strategy?
✅ Looking for sustainable waste management solutions for your region or business?
✅ Contact Klean Industries today to explore partnership opportunities and discuss how to work together to create a cleaner, greener future.

If you would like to learn more about this project, please get in touch with us now >> GO.

This project addresses the SDGs by considering the following goals and associated targets. Developing a sustainable waste treatment framework ensures sustainable consumption and production patterns (Goal 12). Through a safe and inclusive waste disposal system, the SDG strives to protect ecosystems and prevent biodiversity loss (Goal 15).