Research project identifies ways to convert forest industry's carbon emissions into raw materials for plastics – paving the path for a sustainable industry

A collaborative research effort between VTT Technical Research Centre of Finland and LUT University has unveiled innovative solutions for turning carbon dioxide emissions from the forest industry into valuable raw materials for plastics. This three-year project focused on the conversion of carbon dioxide (CO₂) and green hydrogen into renewable plastic feedstocks, highlighting the potential of renewable energy, hydrogen economy, and biogenic CO₂ emissions from the forest industry as significant contributors to the emergence of sustainable industries.

The Forest CUMP research project explored how CO₂, generated by the forest industry and waste incineration, can be captured and converted into high-value products like polypropylene and polyethylene – two of the most common plastics used in everyday life. Currently, the production of these plastics relies heavily on fossil fuels, but the findings from this research present a viable pathway for utilising renewable sources.

“We conducted pilot activities and modelling to explore how biogenic CO₂ recovery can be integrated into existing petrochemical facilities for the production of key plastics. To rapidly replace fossil-based raw materials with renewable ones, it's essential to adapt technologies to current production processes,” said Juha Lehtonen, Research Professor at VTT.

One of the major challenges in adapting renewable raw materials is the high cost of equipment used for hydrocarbon separation, which requires significant long-term investment. As a result, the project focused on optimising renewable processes to integrate with existing industrial infrastructure, reducing the need for expensive upgrades.

“Our research showed that the low-temperature Fischer-Tropsch process is a promising and cost-effective alternative for producing renewable polymers like polyethylene and polypropylene. This method allows the direct use of Fischer-Tropsch naphtha in existing petrochemical processes, eliminating the need for costly investments in new equipment, such as distillation and steam crackers,” Lehtonen explained.

Finland’s advantage: energy and hydrogen infrastructure
Finland holds a unique position, with abundant biogenic CO₂ resources that can replace fossil-based carbon sources. These resources, particularly from large-scale forest industry production facilities, are largely concentrated in Finland and are rare elsewhere in Europe.

“Capturing wood-based CO₂ represents a major opportunity for Finland to develop new industrial value chains while simultaneously reducing the reliance on fossil raw materials. The piloting and experiments conducted in the Forest CUMP project provide valuable insights into the potential of CO₂ as a plastic feedstock,” said Kaija Pehu-Lehtonen, Project Manager for Metsä Group’s carbon capture initiative.

In addition to these bio-based CO₂ reserves, Finland’s energy and hydrogen infrastructure is poised to support the increasing demand for renewable energy and hydrogen. As the global economy moves away from fossil fuels, securing a steady supply of green hydrogen will be key. Finland's potential for large-scale hydrogen production through water electrolysis, powered by renewable energy, presents a significant opportunity.

According to VTT’s research, converting 10 million tons of biogenic CO₂ into renewable products would require approximately 60 TWh of renewable electricity (close to Finland’s annual electricity consumption of 85 TWh). This process could produce roughly 3 million tons of diesel fuel, equivalent to Finland's total yearly consumption. Finland’s existing bio-based CO₂ sources, totaling about 30 million tons per year, already provide the raw materials and infrastructure needed for industrial-scale production.

While the primary focus of the Forest CUMP project was on plastics, the team explored the possibility of capturing bio-based CO₂ for use in long-lasting polymer products, rather than in fuels.

Building a sustainable business ecosystem
The Forest CUMP project also fostered collaboration between academic researchers and industry leaders, tackling critical future challenges. One key partner, Borealis, a provider of advanced polyolefin solutions, is integrating this research into its SPIRIT program, which promotes the green transition of the plastics industry.

“This project is a significant step towards shifting the plastics industry to renewable solutions,” said Ismo Savallampi, Renewable Feedstock Research Project Manager at Borealis. “We envision using bio-based carbon to create durable plastic products, such as coatings for electrical cables, pipes, and recyclable packaging. The technology identified in the research makes this feasible, but broader commercial adoption will require greater demand for renewable solutions and advancements in hydrogen economy technologies.”

Juha Lehtonen of VTT concludes, “Finland has immense potential to become a European leader in biogenic CO₂ utilisation. With around 30 million tons of bio-based CO₂ generated annually, Finland is well-positioned to become a major producer and exporter of carbon dioxide-based chemicals, polymers, and transport fuels.”