Sustainable Development Goals
Location:
Abbotsford, British Columbia (Sumas Industrial Area), Canada
Project Status:
Detailed Feasibility Study Completed | Initial Funding Secured | Site Finalized
Project Basis:
30 tonnes per day (10,000 tonnes per year) non-recycled plastic pyrolysis into refinery feedstock
Organizations Involved:
Klean Industries, Terragreen Investments (TGI), Blue Planet Recycling
Services / Equipment:
Design & Engineering, Detailed Feasibility Studies, Due Diligence, Supply Chain Management
Terragreen’s Abbotsford project is a plastics-to-fuel development built around a deliberately different design: a fully containerized, modular, stackable pyrolysis plant. Klean’s completed Detailed Feasibility Study defined a 10,000-tonne-per-year facility in Abbotsford, British Columbia, that converts non-recycled polyolefin plastics into refinery feedstock, pyrolysis oil for sustainable aviation fuel and decarbonized road fuels.
The development already has its foundations in place: initial funding secured, the site finalized in the Sumas Industrial Area, and feedstock arranged with Blue Planet Recycling. What remains open, and what makes the case commercially honest, is the offtake: securing a refinery partner to take the high-quality pyrolysis oil.
Most plastics-to-fuel projects fail on the same two questions: can the feed be processed reliably, and will anyone take the oil at a price that works. Non-recycled polyolefin plastics, films, multilayer packaging, contaminated industrial scrap, carry real hydrocarbon value, but they sit outside mechanical-recycling programmes and need a conversion route with a defined product specification.
The second question is the harder one. Pyrolysis oil is only commercially useful when it can meet the acceptance requirements of a refinery or a fuel blender. Producing the oil is not the same as selling it. Terragreen and Klean therefore had to design both a plant and a market entry around that specification.
Klean’s study defined a 10,000-tonne-per-year facility processing polyolefin-rich plastics through an advanced thermal conversion route. The recovered output is a plastic pyrolysis oil (approximately 8,000 tonnes per year) intended as refinery feedstock for sustainable aviation fuel and decarbonized road fuels, alongside a recovered carbon char suitable for cement or asphalt applications.
The engineering point of difference is the fully containerized, modular, stackable design. Rather than a bespoke single-unit plant, the system is assembled from shipping-container modules, a configuration that shortens permitting, engineering and construction lead times, and can be scaled or relocated as feedstock and offtake develop.
Klean’s scope covered the full development chain: design and engineering, a detailed feasibility study, due diligence, and supply-chain work that connected the feedstock and the product market. The partnership also established a reference point for replication, the companies have explored additional facilities across Canada, the United States and Africa.
Anchor the feedstock and the funding before scaling
The development secured two of the three commercial pillars early. Blue Planet Recycling arranged the feedstock, and initial funding was secured with the site finalized in the Sumas Industrial Area, a logistics hub on the Canada–US border with direct access to power, gas, water and transport infrastructure.
The offtake is the remaining question - and it is being worked deliberately
The recovered oil is aimed at refinery co-processing and marine-fuel blending. The study examined the regional refinery landscape; those buyers are within reach, but the offtake commitment is not yet signed. That honesty is the point: Klean’s feasibility work established that the technology and the feedstock are ready, and that the market is the variable that now determines the investment decision.
Klean delivered a completed Detailed Feasibility Study for the Abbotsford development, announced publicly in July 2025. The recorded achievements:
The project now advances through permitting and construction. The remaining commercial milestone is the offtake: converting strong interest in the recovered oil into a committed refinery or fuel-buyer agreement.
1. The design is the differentiator.
A fully containerized, modular, stackable plant shortens permitting and construction and can scale with feedstock and offtake - a fundamentally different build model from a bespoke single-unit facility.
2. Two of three commercial pillars are already secured.
Initial funding and the site are in place, with feedstock arranged through Blue Planet Recycling.
3. The offtake is the honest open question.
A 10,000-tonne-per-year plant’s economics turn on a committed refinery or fuel buyer - and that is exactly the step Klean’s feasibility and offtake-development work is built to close.
These are selected achievements and lessons. Further technical and commercial insights are available through an engagement with Klean.
A plastics-to-fuel project lives or dies on the offtake. Klean’s feasibility work can establish - before capital is committed - whether the feedstock, the design and the product specification can support a real fuel or refinery buyer. For the Abbotsford development, the design and foundations are defined; the market is the remaining variable, and it is being worked with the same rigour as the engineering.
New equipment developments begin with a paid Detailed Equipment Quotation (DEQ), establishing the proposed configuration and preliminary investment basis. A Detailed Feasibility Study (DFS) develops the technical and commercial case, followed by Front-End Engineering Design (FEED) to prepare the project for an investment decision.
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ABOUT THE INFORMATION PRESENTED
This case describes the completed Detailed Feasibility Study and the development position of the Abbotsford project as publicly announced. Processing capacity, product volumes and market routes are development parameters. The offtake and refinery arrangements remain under development. Detailed engineering, financial and commercial information is available within an agreed engagement and appropriate confidentiality arrangements.
