Sustainability and economic impact: MaxFlux™ technology in action

Introduction

Addressing plastic pollution demands solutions that are both sustainable and profitable. Sulzer’s MaxFlux™ hydrotreating technology offers operators a practical, advanced way to convert waste plastic pyrolysis oils (PPO) into valuable, ultra-clean products, all while improving carbon footprint and operational costs.

Environmental benefits

• Energy and Resource Savings

  • MaxFlux™ eliminates the need for large hydrogen recycle gas loops by dissolving hydrogen directly into the liquid phase, reducing compressor and utility requirements.

  • The high liquid flux operation enables superior mixing, translating into lower electricity and fuel gas consumption and simplified process control.

    
    

• Lower Emissions and Waste

  • Efficient impurity removal (nitrogen, sulfur, halogens, silicon, metals) ensures hydrotreating products meet even the tightest downstream specifications, reducing off-spec waste and avoiding contamination issues.

  • The streamlined process minimizes undesirable byproducts and over-cracking, meaning less waste sent to landfill or incineration.

    
    

• Reduced Carbon Footprint

  • The combination of less energy demand and higher product yields means a smaller CO₂ footprint compared to traditional hydrotreating.

  • Integration with broader plant utilities allows sites to better meet regulatory requirements for lower total emissions.

    
    

Economic advantages

• Lower Capital Investment

  • MaxFlux™ reactor designs remove the need for costly gas recycle systems, compressors, and complex internals, shrinking plant footprint and reducing capital expense for both grassroots and revamp projects.

    
    

• Reduced Operating Expenses

  • No gas phase quench means fewer moving parts and less maintenance, while stabilized reaction temperatures minimize catalyst deactivation and reduce frequent change-out costs.

  • Higher yield of saleable product contributes directly to improved margins.

    
    

• Longer Catalyst Life

  • Stable temperature profiles and excellent contaminant removal extend catalyst life, reducing replacement frequency and maintaining performance.

    
    

Supporting circularity

MaxFlux™ makes it possible to transform mixed plastic waste into cracker-grade feedstocks suitable for new polymer production, advancing the transition to a truly circular plastics economy and reducing reliance on virgin fossil resources.

Sustainability impact table

Feature	Sustainability Benefit
Direct hydrogen dissolution	Lower energy consumption, reduced CO₂ emissions
No gas recycle loop	Simpler ops, reduced utility/maintenance costs
Advanced impurity removal	Fewer byproducts and off-spec waste
High product yield	More recycled back into value chains
Longer catalyst life	Less waste, lower operational footprint

Conclusion

Sulzer’s MaxFlux™ technology merges sustainability with economic value by lowering emissions, slashing operational costs, and enabling plastics-to-plastics circularity. Its adoption empowers operators to meet green targets while protecting the bottom line, offering a future-oriented solution for modern chemical and recycling plants.