ESAF Pyrolysis Technology · In Partnership with Virentis Climate
ESAF's patent pending modular pyrolysis technology converts non-recyclable plastic waste into EN590-grade diesel and sustainable aviation fuel. Delivered in partnership with Virentis Climate as the UK route-to-market.
Economics
Configure plant size, feedstock type, and carbon credit pricing to see estimated UK economics.
Estimated total installed
£480k – £600k
Estimated oil yield: 87% (range: 85–90%)
Diesel per day
10,677 L
Carbon black per day
960 kg
Revenue per tonne
£824
Simple payback
2 months
Annual CO₂e credits
12,989
PDF includes technical specs, ESAF credentials, and next steps
All figures are estimates based on ESAF Group technical specifications and current UK market pricing. Actual results depend on feedstock quality, local fuel pricing, off-take agreements, and operational efficiency. Carbon credit revenue requires Verra-approved methodology and successful project registration. Equipment pricing is indicative (±25%) and subject to formal quotation.
The Process
A six-stage thermochemical process converting PE, PP, and PS plastic waste into drop-in liquid fuels in an oxygen-free environment.
Plastics sorted by polymer type and shredded to <20 mm particles. PE/PP/PS with less than 10% contamination.
Depolymerisation at 400–500 °C in an oxygen-free nitrogen atmosphere. Long-chain polymers break into smaller hydrocarbons.
Pyrolysis oil separated by boiling point into naphtha, kerosene, diesel, and wax fractions.
Catalytic removal of sulfur, nitrogen, and oxygen. Produces ultra-clean fuel with sulfur below 10 ppm.
ESAF's patent pending catalyst converts n-paraffins to iso-paraffins. Freezing point below −50 °C — exceeding diesel spec by 12 °C.
Final product meets ASTM D1655 (Jet A-1) and EN 590 (Diesel) specifications. SGS tested and certified.
Sustainable Aviation Fuel
ESAF holds an active international patent for converting pyrolysis oil into aviation-grade jet fuel — the long-term premium market.
"Process for Producing Aviation Turbine Fuel from Plastic-Derived Pyrolysis Oil"
Proprietary hydrotreating and hydroisomerisation process produces specification-grade fuel meeting ASTM D1655 and D7566 standards.
Freezing point below −50 °C through advanced hydroisomerisation — exceeding standard diesel by 12 °C. Critical for high-altitude aviation performance.
70% liquid fuel recovery with optional hydrocracking to boost kerosene-range products from heavy fractions.
Feedstock
Designed for waste streams that cannot be economically mechanically recycled — the fractions currently going to energy-from-waste or landfill.
PE/PP/PET combinations from household or industrial sources. Limited mechanical recycling outlets — confirmed suitable by multiple pyrolysis operators.
Food-contaminated packaging, soiled agricultural plastics, and other streams uneconomical to wash and reprocess mechanically.
Residual fractions from MRFs and PRFs. The material that currently has nowhere to go except EfW or landfill.
Off-cuts, reject material, and production waste from manufacturing — particularly PE and PP streams.
PVC must be excluded from feedstock. PET limited to less than 10% of total input. Pre-processing (sorting, shredding, washing) is a critical stage.
UK Market
A growing number of UK pyrolysis operators are already processing plastic waste — but carbon credit integration, modular equipment supply, and feedstock coordination remain underserved.
UK plastic waste export restrictions coming into force in 2026 make domestic processing capacity increasingly valuable
Several UK councils have recently granted planning permission for plastic-to-fuel facilities
Existing UK operators need better equipment, carbon credit integration, and coordinated feedstock supply — that's where ESAF and Virentis come in
ESAF's modular units and integrated Verra carbon credit methodology give operators a turnkey upgrade path
Whether you're a recycler with non-recyclable fractions, a waste processor exploring advanced recycling, or an investor looking at circular economy infrastructure — let's talk.
Carbon credits from mechanical recycling are available today through Virentis Carbon — no pyrolysis plant required.
FAQ
Whether you're a UK recycler looking to unlock carbon credit revenue, or a defence prime seeking next-generation materials — we'd like to hear from you.