The Company

Since it was founded in 1929, this company has been a vital part of its customers’ lives, consistently adapting to change and evolving to better serve society’s needs. Over the years, the company has focused on the values that drive it, building a stronger connection with its target audience. Thanks to this vision, it has grown into a leader in the energy sector, expanding its operations across five continents.

Its goal is clear: transformation means progress, and development equals evolution. As such, the company’s focus is clear and consists of raising the quality of its products, services, and experiences, always with the mission of positively impacting people’s lives. Energy and mobility form the foundation of its value proposition, with collaboration viewed as a key factor in achieving the goal of making the world a better place.

The Challenge

Circularity is one of the fundamental pillars of this company’s transformation strategy. In mid-2022, to make its operations more sustainable, the company created a specialized team. This team’s mission is to identify and implement solutions to revalue the waste generated both in its facilities and by society, minimizing the amount of waste sent to landfills while paying close attention to the raw materials consumed.

With two hybrid parks, combining solar and wind energy, known as Energy Parks (EP), the company faces the challenge of maximizing waste valorization. This effort involves developing innovative solutions, such as producing benzene and propylene, creating advanced fuels (HVO 2G), and manufacturing construction materials from used catalysts.

The company has set an ambitious goal for 2030, which is to increase waste circularity by 50% compared to 2019, which means recovering an additional 8,000 tons of waste in its hybrid parks. It also aims to increase the use of renewable and circular raw materials to 15% by 2030. Additionally, the company has committed to reducing the amount of waste sent to landfills by 20% by 2025 as a starting point toward achieving the desired circularity. To meet these objectives, the company is investing in new technologies, waste co-processing projects, and public-private partnerships, fostering an industrial symbiosis that involves various sectors. Transforming the production model into a more sustainable and circular one is a key focus of this initiative.

The Approach

The company implemented a structured approach organized into five phases, beginning with an initial waste analysis and culminating in the establishment of commercial partnerships for waste valorization. This strategy follows the principle of continuous improvement, to reduce waste and optimize related processes.

Waste Analysis Phase

In this initial phase, a detailed waste characterization was conducted, identifying which materials could be targeted for reduction and treatment actions. The identified waste included biological and hydrocarbon sludge, contaminated soil, and used catalysts from the fluid catalytic cracking (FCC) unit.

Research and Innovation Phase

This phase focused on finding innovative solutions to revalue waste, with a focus on reducing the amount of waste sent to landfills and consequently increasing its valorization.

Project Definition and Development Phase

After conducting pilot tests, the most promising initiatives, both technically and economically, were selected for implementation. For example, spent FCC catalysts proved valuable in the construction industry, while a drying solution was introduced for the sludge, significantly reducing its moisture content.

Approval Phase

During this phase, the proposals were formally approved, and the necessary funds were allocated to implement the projects.

Implementation Phase

The implementation phase included various actions to recycle 1,000 tons of waste per year and recover hydrocarbon and biological sludge, resulting in a total valorization of approximately 705 tons in 2023. Additionally, the company adapted its processes to convert used cooking oil and animal fats into HVO (hydrotreated vegetable oil), a biofuel, with a production of 19,761 tons in 2023.

In addition to the actions already implemented, new initiatives have emerged and are currently in the implementation phase, such as solar sludge drying, which reduces moisture by 80%, and the valorization of biological and hydrocarbon sludge using fly larvae.

The entire project was carried out within a continuous improvement framework, utilizing structured methodologies to assess the starting point, define action plans, and eliminate waste in the related processes. It also required cross-functional coordination and the implementation of agile solutions at every stage.

Results

In 2023, the company processed approximately 40,678 cubic meters of waste in its hybrid parks, including animal fats and used cooking oils, which were used to produce HVO.

Over the past two years, 2022 and 2023, the total amount of waste generated by the company’s hybrid parks reached 143,657 tons. However, the company’s commitment to waste valorization has shown breakthrough results. In 2023, the company achieved a waste valorization rate of 70.9%, surpassing the 64.4% rate recorded the previous year, reflecting an increase of 10.09%.

This progression highlights the company’s dedication to giving a second life to the waste it generates, with a clear upward trend in waste valorization. At the same time, efforts were made to minimize the amount of waste sent for disposal or to landfills. Additionally, new types of waste, such as biological sludge, were successfully valorized, further advancing the company’s circular economy goals.

Collaborative agreements were also established with universities and other partners, aimed at identifying new technologies and solutions for waste valorization. As a result, the company expanded its knowledge and expertise in innovation and sustainability.

This case study illustrates how an energy sector company transformed its environmental challenges into innovation and sustainable growth opportunities. By adopting a circular economy approach, the company implemented advanced technological solutions and strategic partnerships that significantly increased waste valorization and reduced landfill dependency. Through its ongoing commitment to process improvement and collaboration with universities and experts, the company not only surpassed its ambitious environmental targets but also reinforced its position as a leader in the transition to a more sustainable and efficient production model.

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