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Shell Polymers plans to use pyrolysis oil derived from recycled plastics to manufacture polyethylene resin at its complex in Monaca, Pennsylvania. The recycled feedstock will be supplied by Freepoint Eco-Systems, which operates an advanced recycling facility in Hebron, Ohio.

In a statement, Shell described the agreement with Freepoint as a 鈥渓andmark feedstock agreement.鈥� Laura Chamorro, Shell鈥檚 commercial general manager, said the deal enhances the company鈥檚 ability to deliver advanced recycling and mass-balanced products certified by ISCC Plus. 鈥淲e are committed to helping our customers access certified, flexible solutions that support their sustainability goals,鈥� Chamorro said.

The partnership also bolsters Shell鈥檚 offerings in mass-balanced products, which company officials see as key to expanding sustainable options in the U.S. plastics market.

Freepoint鈥檚 Hebron plant is expected to be fully operational later this year. Once online, the facility is projected to recycle approximately 200 million pounds of plastic annually, producing up to 130 million pounds of pyrolysis oil for use as feedstock. In April, Freepoint delivered its first shipment of pyrolysis oil to a Shell refining site in Norco, Louisiana.

Shell鈥檚 Monaca plant, located near Pittsburgh, began operations in 2022 and was the first major U.S. resin production facility built outside of Texas or Louisiana in more than four decades. The complex has an annual production capacity of about 3.5 billion pounds of polyethylene. Positioned near the Marcellus and Utica shale fields, the facility typically uses natural gas liquids from those formations as feedstock.

Officials noted that the Monaca site is strategically located within range of over 70% of the North American polyethylene processing market, giving it a competitive advantage for distribution and logistics.

Freepoint is also expanding internationally. In May 2024, the company announced plans to construct its first pyrolysis facility outside the United States. The new plant, to be located in the Ghent-Terneuzen Canal region of Belgium, is expected to recycle roughly 180 million pounds of plastic annually.

Shell and Freepoint say their partnership marks a significant step toward advancing the circular economy for plastics, providing a scalable solution to reduce plastic waste and increase the use of recycled materials in manufacturing.

The use of pyrolysis oil in resin production aligns with Shell鈥檚 broader sustainability goals and industry efforts to incorporate more recycled content into plastic products, particularly in response to growing demand for environmentally responsible packaging and materials.