Tyre Pyrolysis & Waste-to-Value Cluster – UAE

Overview

As part of a broader industrial decarbonisation initiative in the UAE, Bivios is leading the development of a tyre pyrolysis facility in the Hamriyah Free Zone. The project is designed to process whole end-of-life tyres (ELTs) using proprietary semi-batch thermal pyrolysis technology.

This facility forms part of a larger integrated waste-to-value cluster co-located with a bio-refinery and bitumen plant, and is positioned to demonstrate how circular economy solutions can drive both environmental and commercial performance.

Project Scope

• Client: Confidential (private sector industrial platform)

• Facility type: Tyre pyrolysis with mini-refinery integration

• Core outputs:

• Tyre Pyrolysis Oil (TPO)

• Recovered Carbon Black (rCB)

• Recycled steel wire

• Product upgrading: 

• On-site mini-refinery producing:Low-sulphur diesel

• Naphtha

• Heavy fuel oil
  

The Bivios Solution

Bivios provided end-to-end design and technical delivery support for the pyrolysis facility and its integration into the wider circular cluster, including:

• Techno-economic modelling to ensure commercial viability of TPO upgrading

• Life Cycle Assessment (LCA) to quantify emissions reductions

• Engineering coordination across pyrolysis and refining systems

• Design of an integrated logistics and supply chain model across all co-located facilities

• Alignment with regional sustainability priorities and electrification targets

Value Delivered

• Enabled waste-to-value processing for a high-volume, hazardous waste stream (tyres)

• Reduced lifecycle emissions through thermal recovery and circular product use

• Created a platform for upgraded low-emission fuels compatible with existing supply chains

• Supported UAE’s industrial sustainability goals through innovation and localisation

• Demonstrated real-world performance of integrated circular economy design

Strategic Context

The facility is part of a multi-plot cluster operated in the Hamriyah Free Zone, which includes:

• A bio-refinery, already in operation

• A bitumen (PMB) plant

• Planned electrification and renewable energy integration

Together, these assets form a low-carbon industrial zone with optimised infrastructure, logistics, and feedstock synergies — designed by Bivios to maximise both sustainability and commercial outcomes.

Strategic Significance

This project exemplifies how the circular economy can be delivered at scale — turning waste into fuel, pollution into products, and challenges into opportunities. By avoiding pre-processing and integrating refining on-site, the solution reduces emissions and costs while meeting the demands of real-world fuel markets.

It positions the UAE as a pioneer in smart waste valorisation and energy innovation — and reflects Bivios’ ability to design systems that go beyond theory and into measurable, market-ready performance.