Tech4Good Spotlight: AC Biode’s Plastalyst Supports Ukraine’s Circular Economy

• AC Biode’s participation in Tech4Good Challenge supports Ukraine’s recovery, local production, and circular economy
• AC Biode’s Plastalyst converts plastic and organic waste into hydrogen and valuable chemicals
• It involves a low-temperature, low-pressure process that reduces energy costs and environmental impact compared to the widespread pyrolysis
• Local facilities based on the Plastalyst technology are poised to create jobs, strengthen industry, and promote sustainable, high-value green chemical production

Amid ongoing Russian attacks that have severely damaged Ukraine’s energy infrastructure, Tech4Good launched a global initiative in late 2024 to identify and implement innovative energy solutions aimed at strengthening the nation’s resilience. The Challenge attracted 75 submissions worldwide, with six cutting-edge projects selected for deployment, including biomass-based energy systems, micro wind turbines, and portable solar generators.

Turning Trash into Power

Among the top six innovators, AC Biode, a Japanese-Luxembourgish startup, was chosen to present its groundbreaking Plastalyst technology. The project introduces onsite methane power generation and Plastalyst, a system for catalytic decomposition of plastic and organic waste into hydrogen and other valuable outputs. Backed by a team of experienced engineers and sustainability experts, AC Biode combines deep technological expertise with a strong commitment to supporting Ukraine’s recovery and long-term energy independence, representing the collaborative spirit of Japan and Luxembourg in global innovation for good.

On October 29th, AC Biode was among three companies from the Tech4Good Global Challenge #1: Energy for Ukraine that showcased their resilient and sustainable energy technologies at the 14th International Festival of Innovative Projects “Sikorsky Challenge 2025.”

ITKeyMedia spoke with AC Biode’s CEO Tadashi Kubo to explore in detail how Plastalyst could drive the progress of Ukraine’s energy resilience and circular economy:

How did the idea for AC Biode and Plastalyst come to be? What was the inspiration behind its development?

Tadashi Kubo: The venture was sparked by the incessant news regarding global pollution and waste problems. While studying at the University of Cambridge, I started discussions with our future CTO, Dr Atsushi Mizusawa, about launching a company. Dr Mizusawa, an expert with over 25 years of experience developing new catalysts, invented Plastalyst based on his determination to make complex chemical reactions commercially viable. We initially developed specialized catalysts and applied for our first patent, focusing on niches where others never venture, such as PVC recycling, after learning the true needs of the chemical industry.

What challenges did your team face while developing the Plastalyst solution? How did you overcome them?

TK: A primary challenge involves the technological readiness of Plastalyst, as it is still in the demonstration phase and scaling up—for example, dealing with side products found in the 100L reactor—can reveal unforeseen issues. We must also assess the long-term durability of our unique non-rare earth, non-precious metal catalyst under continuous operation. These technological risks get addressed by employing a phased approach, incrementally increasing reactor size from 2L upwards to allow careful monitoring and early issue identification. AC Biode overcomes these hurdles by continuously working with commercial partners like Bosch during development and by conducting experiments to evaluate catalyst performance over extended periods.

What are the key advantages of Plastalyst compared to competitors in the market?

TK: Plastalyst’s core advantage lies in its low operating conditions, functioning below 200°C and 15 bar, drastically reducing energy requirements and operating costs, requiring 10x less investment than competitors that stick to  pyrolysis. Uniquely, our process uses only industrial water as a solvent, which is environmentally friendly and cheaper, avoiding the need for expensive organic solvents or waste drying. The technology can process difficult, multi-layered, and deteriorated waste, including PVC, rubber, and composites (CFRP), which are problematic for many chemical recyclers. This resilience is highly beneficial for rebuilding Ukraine, where damaged waste management systems likely deal with complex and unsorted waste streams.

What are Plastalysts’s expected measurable long-term environmental benefits?

TK: A key measurable long-term environmental benefit is our goal of diverting 10.6 Mt of waste from incinerators by 2040, resulting in an accumulated saving of 10 Mt of CO2 compared to incineration. The Plastalyst process itself is highly sustainable, operating with no CO2, dioxin, or tar emissions during the reaction, unlike traditional disposal methods or pyrolysis. Using Plastalyst to produce new plastics leads to a 90% lower carbon footprint compared to incumbent solutions like pyrolysis. In Ukraine, this supports the transition to a greener industry by closing the material loop for waste that currently exits the material cycle.

How do you envision the local manufacturing process working in Ukraine? What role do you see for Ukrainian companies in this initiative?

TK: AC Biode’s business model involves licensing its technology rather than owning recycling facilities, so Ukrainian companies play a central role. An essential part of the goal is that after the reconstruction, generously funded by governments like Japan, Ukrainian companies will own the new infrastructure, not foreign companies. For constructing recycling facilities, AC Biode primarily handles the engineering, anticipating that the procurement of standard machines can be done locally within Ukraine, to fuel local engineering businesses. Ukrainian companies can serve as main local connections, while larger companies like AgroVista provide essential roles in supplying waste and handling logistics for initial testing. Such a strategy reduces reliance on imports and aids in reconstruction and job creation, with a typical 10t/day facility creating around 7 direct and 20+ indirect jobs.

How do you validate the technology’s performance in real-world conditions?

TK: The technology’s performance is validated through numerous paid pilot projects conducted with industrial partners globally, such as Bosch and Toyota, with over 30 pilots already completed. Testing with real-world waste is crucial because waste samples from clients often contain contaminants and quality variations not encountered in initial laboratory experiments. For the Ukraine initiative, performance will be specifically validated by obtaining problematic straw waste samples from AgroVista and chemically recycling them in the AC Biode laboratory to assess the 100% breakdown potential. Furthermore, AC Biode ensures performance is maintained during upscaling by incrementally increasing reactor size,e.g., currently testing at 400L, to carefully monitor for issues like side products.

How do you plan to keep the costs affordable while maintaining high performance, especially in emerging markets like Ukraine?

TK: To reiterate, Plastalyst maintains low costs due to its low-temperature, below 200°C, and low-pressure operation, requiring 10x less investment and 2x lower operating costs compared to pyrolysis. Affordability is enhanced because the process uses only industrial water as a solvent, eliminating the need for expensive organic solvents or waste drying, which cuts preparation costs. The use of a non-rare earth, non-precious metal catalyst further ensures the technology remains cost-effective. In emerging markets like Ukraine, AC Biode keeps costs low and accelerates scaling by primarily licensing its technology and forming joint ventures rather than owning and operating facilities, thus reducing operational risks.

What other countries or regions do you see as potential markets for AC Biode after Ukraine?

TK: AC Biode already has a strong global presence, having completed pilots in over 15 countries across five continents. Our current major focus is Southeast Asia, where we are building a demonstration plant in Indonesia with PLN and Temasek Foundation to convert palm oil waste into hydrogen. We’re also engaged in the Vietnamese market where the ability to recycle large volumes of unsorted waste aligns with the national legislative push for a circular economy. Due to the low energy consumption that allows operation on renewable energy like solar power, our technology is also highly suitable for both low-income countries and remote areas such as the Maldives.

How do you assess the impact of your solutions’ in crisis situations like Russia’s war against Ukraine?

TK: The Plastalyst solution is directly poised to support the reconstruction of Ukraine’s damaged waste management system, transforming waste into valuable chemicals locally. By converting materials like agricultural straw into chemical intermediate products such as methanol and acetic acid, the technology enables local production and reduces reliance on imports. To understand this potential, one should look at the numbers. Ukraine produces around 100 mt of straw a year, which, if processed with Plastalyst, is converted into 5 mt Hydrogen and 57 mt useful biochemicals worth USD 43B USD for the Ukrainian economy. This process helps upgrade Ukraine’s industrial structure by transforming low-value commodities into high-value green chemicals suitable for export, benefiting the chemical and manufacturing industries. Crucially, establishing local recycling facilities creates stable jobs, promotes green industrialization, and offers roles that require less physical labor and show higher gender neutrality.

AC Biode’s Plastalyst technology offers Ukraine a transformative solution for rebuilding its damaged waste management infrastructure while generating valuable green chemicals and hydrogen locally. Its participation in the Tech4Good Global Challenge #1: Energy for Ukraine underscores the importance of innovative, sustainable technologies in supporting the country’s recovery, energy independence, and circular economy development. By enabling local production, job creation, and environmentally responsible recycling, AC Biode offers an invaluable contribution to Ukraine’s long-term resilience and industrial modernization.