Chemical Recycling in Bulgaria: Unlocking a New Frontier in Circular Plastics
Chemical vs. Mechanical Recycling: Why Bulgaria Needs Both
Plastics recycling comes in two broad forms. Mechanical recycling grinds, washes and remelts waste plastics into pellets for reuse, but it only works well for clean, single-polymer streams and degrades polymer quality over time.
In contrast, chemical (or “advanced”) recycling breaks polymers down into their building blocks through processes like pyrolysis, gasification or depolymerization.
Because chemical recycling removes contaminants and yields high-grade feedstocks, it can turn dirty, multi-layer or hard-to-sort plastic waste into new polymers indefinitely.
EU recycling targets make chemical recycling urgent. Under the new EU Packaging Regulation, by 2030, 30% of PET in food-contact packaging must be recycled.
Meeting these recycled-content mandates requires breaking open plastic waste streams that current mechanical plants cannot handle. Chemical recycling is essential to close loops on plastics that otherwise escape the circular economy.
Pyrolysis Case Studies (Oil and Carbon)
Pirin-Tex (Gotse Delchev) has built a pilot pyrolysis unit to process its mixed production scraps (textile and plastics). The process generates petroleum derivatives and syngas used onsite, saving €1.15 million per year and avoiding 44.1 tonnes of CO₂ emissions. This on-site circular approach shows how mixed industrial waste can be converted into energy and raw materials.
MODUL Ltd (Stara Zagora) pioneered continuous pyrolysis for end-of-life tires and plastics. Its pilot plant processes up to 7,500 tonnes per year, producing equal amounts of pyrolysis oil and recovered carbon black. This proves that industrial-scale pyrolysis is viable in Bulgaria, especially for tires and high-energy waste.
Gasification & Syngas
Simitli (Blagoevgrad) will host Bulgaria’s first plastic-to-hydrogen plant using Distributed Modular Gasification technology from Hydrogen Utopia International. The system converts 40 tonnes/day of mixed plastic into syngas, which can generate power or be refined into 3 tonnes of hydrogen daily. This project links waste management to clean energy, producing minimal residue and no harmful emissions.
Depolymerization and Solvolysis
Bulgarian universities such as UCTM Sofia have conducted solvolysis and glycolysis experiments to break down polyurethanes and PET into reusable monomers. Though no large-scale plants exist yet, these R&D efforts are laying the groundwork for future depolymerization infrastructure.
Environmental and Economic Impacts
Chemical recycling reduces emissions by displacing fossil-based polymers. Pirin-Tex, for instance, replaces naphtha fuel with pyrolysis oil, cutting 44 tonnes CO₂ annually. It diverts waste that would otherwise be incinerated or landfilled, transforming plastic into useful intermediates like oil, monomers, or hydrogen.
Recovered materials like carbon black or pyrolysis oil hold higher market value than low-grade recyclate. Investments in chemical recycling stimulate job creation, local innovation, and domestic supply of raw materials.
Policy and Funding Outlook
EU Green Deal and Packaging Regulation mandates minimum recycled content, pushing innovation in chemical recycling. Horizon Europe and Bulgaria’s Recovery Plan provide funding for pilot projects and circular economy upgrades.
A €9.5 million Horizon project (MOBICCON-PRO) established a mobile recycling unit in Sofia, and Bulgaria’s RRP has granted over BGN 11.5 million to circular economy upgrades. With strong political backing and industrial interest, Bulgaria is set to expand its chemical recycling ecosystem.
Conclusion
Bulgaria’s plastics sector is embracing chemical recycling technologies—from pyrolysis (Pirin-Tex, MODUL) to gasification (Simitli DMG) and lab-scale depolymerization (UCTM Sofia). These methods unlock value from mixed or hard-to-recycle waste, reduce CO₂ emissions, and supply high-purity outputs like oil, syngas, and carbon black.
Supported by EU policy and funding, Bulgaria is well-positioned to become a regional leader in circular plastics. Chemical recycling complements mechanical systems and advances national sustainability goals.
References
- Pirin-Tex Pyrolysis Unit Report (2023)
- MODUL Ltd – Continuous Pyrolysis Technology Overview (2022)
- Hydrogen Utopia International – Simitli DMG Project (2024)
- UCTM Sofia – Research on Polyurethane and PET Solvolysis (2023)
- EU Packaging and Packaging Waste Regulation Summary (2023)
- Bulgarian Recovery and Resilience Plan – Circular Economy Grants (2024)
- Horizon Europe – MOBICCON-PRO Project Launch (2024)
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