Viva Energy has taken a significant step forward in Australia’s push for a circular economy, successfully processing more than 9.5 tonnes of plastic pyrolysis oil (PPO) at its Geelong Refinery. The trial marks the largest volume of PPO ever processed at the site and is a key milestone in the company’s ambition to convert discarded soft plastics into new food-grade recycled plastics.
The trial forms part of Viva Energy’s joint project with Cleanaway, Australia’s largest waste management company, to develop a soft plastics recycling facility. While small volumes of PPO have previously been tested, this large-scale run enabled comprehensive assessment of the refinery’s infrastructure capability and the downstream impact on product quality.
The PPO used in the trial was produced by Alterra in Akron, Ohio, using end-of-life plastic. Alterra’s advanced thermochemical liquefaction process breaks down post-consumer plastics into feedstock suitable for new plastics production. The imported material was approved by the federal government to ensure the trial reflected commercially viable PPO volumes and quality standards.
A key objective of the trial was to determine whether contaminants such as chlorides and metals would affect either the design of the proposed recycling plant or the refinery’s ability to process PPO at industrial scale. The outcomes will help guide future investment and refine the feedstock requirements to maximise the amount of soft plastics that can be recycled.
Viva Energy and Cleanaway are currently undertaking a full feasibility study for the project. The Front-End Engineering and Design (FEED) phase is expected to begin once the federal government finalises the framework for Extended Producer Responsibility (EPR), which will underpin national packaging reform.
Bill Patterson, executive general manager – Refining at Viva Energy, said the successful trial represents a new chapter for the Geelong Refinery.
“Over many decades the Geelong Refinery has played an important role in making fuels and other products which are essential to our way of life in Australia,” he said. “We want to continue to do this, and this initiative is a critical step in demonstrating the various roles our facility can play in the energy transition, establishing a circular economy and helping to address Australia’s discarded plastic issue.”
Valerio Coppini, chief commercial officer at Alterra, said the trial validates the value of its recycling technology.
“Our technology has proven the ability to add value to end-of-life, post-consumer plastics by successfully converting them into feedstock for chemicals and new plastic production,” he said. “We look forward to growing with Viva Energy and Cleanaway in Australia to divert plastic from landfill, displace fossil-derived material, and reduce emissions.”
The trial’s success adds momentum to Australia’s broader efforts to develop viable domestic solutions for soft plastics recycling and reduce reliance on virgin plastics.
