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A pioneering research project led by VTT Technical Research Centre of Finland and LUT University has identified new ways to convert biogenic carbon dioxide (CO2) emissions from the forest industry into raw materials for plastics.
The Forest CUMP project, which ran for three years, explored various carbon capture and utilisation (CCU) technologies to create renewable plastic feedstocks using biogenic CO2 and green hydrogen. The findings could lay the foundation for a new, sustainable industrial sector.
The project investigated how CO2 emissions from the forest industry and waste incineration can be captured and transformed into high-value products like polypropylene and polyethylene. These two plastics are widely used in everyday items, but their production currently depends on fossil fuels.
“We investigated through pilot activities and modelling, how the biogenic carbon dioxide recovery chain can be adapted to existing petrochemical plants and the production of key basic plastics,” said Juha Lehtonen, research professor at VTT. “For rapid and significant replacement of fossil feedstocks with renewable ones, technologies need to be adapted to the currently existing production facilities.”
One of the critical challenges in transitioning to renewable plastic feedstocks is the cost of modifying existing petrochemical facilities. Large-scale petrochemical plants use expensive long-term equipment to process hydrocarbons.
The research concluded that the low-temperature Fischer-Tropsch process presents a technically and economically viable solution. This method enables Fischer-Tropsch naphtha, a light hydrocarbon fraction, to be used in existing petrochemical processes without requiring significant new investments.
The research project examined the entire chain, from CO2 capture to the production of ethylene and propylene — two essential building blocks for plastics. The process involved:
Capturing and purifying CO2 emissions from flue gases, increasing the CO2 concentration from 10-15 per cent to around 95 per cent.
Developing carbon capture technology with partners like CarbonReuse Finland, Ekotuhka Oy and LUT University.
Converting the recovered CO2 into hydrocarbons at VTT Bioruukki Pilot Centre, optimising the production of ethylene and propylene.
Demonstrating the feasibility of this process using local flue gas CO2.
Finland possesses significant reserves of biogenic CO2, largely generated by the forest industry. Unlike many parts of Europe, the Nordic country has abundant and easily accessible sources of renewable CO2. The project’s results suggest that Finland could leverage this resource to develop new industrial value chains while simultaneously reducing fossil fuel reliance.
“The capture of wood-based carbon dioxide offers a significant opportunity for Finland to build new industrial value chains while simultaneously reducing the use of fossil raw materials,” said Kaija Pehu-Lehtonen, project manager at Metsa Group. “The experimental work and piloting conducted within the Forest CUMP project provide valuable insights into the potential of carbon dioxide as a raw material for plastics.”
Another advantage is Finland’s well-developed energy and hydrogen infrastructure, which supports the large-scale use of renewable energy sources. One of the biggest challenges in replacing fossil-based hydrocarbons is securing sufficient green hydrogen. Finland’s capacity to generate green hydrogen through water electrolysis using renewable energy makes it an ideal location for scaling up CCU-based plastic production.
VTT’s research estimated that converting 10 million tonnes of biogenic CO2 into renewable products would require around 60 terawatt-hours (TWh) of renewable electricity — almost 70 per cent of Finland’s current annual electricity consumption. However, the country has around 30 Mt of bio-based CO2 available each year, meaning the necessary raw materials and infrastructure for large-scale production are already in place.
The Forest CUMP project involved a collaboration between business partners and researchers to address challenges in the green transition. Borealis, a leading provider of sustainable polyolefins, participated in the initiative as part of its SPIRIT programme, which focuses on advancing renewable solutions in the plastics sector.The research outcomes provide a blueprint for industries looking to replace fossil-based plastics with renewable alternatives.