The circular economy is compelling major corporations to rethink resource management strategies, especially in sectors reliant on plastics and high-performance polymers. This momentum behind post-industrial recycling will continue to grow in the energy sector, propelled by regulations such as the EU Green Deal, extended producer responsibility legislation in the US, and escalating investor expectations for corporate environmental accountability.
Businesses are increasingly recognising that linear models (extract, use, discard) are neither sustainable nor economically viable, and that innovative recycling initiatives are essential for achieving sustainability goals, regulatory compliance, and financial efficiency.
Opportunities in high-performance polymer recycling
Labyrinth seals, widely used in centrifugal compressors and pumps within the oil and gas sector, frequently utilise high-performance polymers such as polyether ether ketone (PEEK). Known for their exceptional durability, chemical resistance, and thermal stability, these polymers enable labyrinth seals to function reliably under extreme conditions, with many seals in use for up to ten years. However, the eventual wear and replacement of these components presents both environmental challenges and valuable opportunities for circular resource recovery.
Douglas Mahler, Senior Business Development Manager, Energy Segment at Mitsubishi Chemical Group’s Advanced Materials division, comments: “The appetite for takeback programmes in the energy industry is increasing significantly, driven by sustainability goals and regulatory pressures. There’s a clear move towards circular material flows, not just emission reductions, making recycling essential for companies striving to meet ambitious environmental targets.”
Innovative recycling processes at Mitsubishi Chemical Group
Mitsubishi Chemical Group’s Advanced Materials division (MCG) is pioneering sophisticated recycling solutions aimed at transforming complex post-industrial polymer waste into high-value materials for reuse. Since its acquisition of the Minger Group in 2020, a Swiss company with proprietary technologies for recycling engineering plastics like PEEK, the division has primarily focused on transforming waste material from its customers’ manufacturing processes into recycled materials. Now, MCG is looking for opportunities to expand its capabilities to include recycling of complex post-industrial components such as labyrinth seals.
According to Markus Wehinger, product manager at MCG, Advanced Material division, Polymer Recycling: “We offer solutions based on standard recycling grades, as well as customer-specific open or closed-loop solutions, catering to different materials, including our own grades and others. The growing demand for recycling, driven by regulatory changes and sustainability pressures, is pushing us to continually evolve our technology and market reach.”
MCG employs mechanical recycling processes, managing each stage to ensure optimal quality in a process that includes careful sorting, washing, purification, and demetalisation. Subsequent stages involve advanced homogenisation, milling, grinding, and pelletisation, transforming waste into consistently high-quality, reusable polymers. The company’s facility in Lenzburg, Switzerland specialises in recycling challenging materials such as PEEK, fluororesins, and polyoxymethylene (POM).
One innovative aspect of MCG’s recycling facility is its integration of optical and X-ray inspection methods, making it the first company globally to utilise such advanced technology. This sophisticated system precisely identifies and removes minute contaminants, ensuring the purity required for materials in critical industrial applications.
Addressing the complexities of end-of-life recycling
Recycling end-of-life parts used in industrial applications such as pumps and compressors is not without its challenges. Labyrinth seals often incorporate carbon fibres, which complicate recycling by increasing equipment wear and potentially reducing the mechanical integrity of recycled materials.
Even without the presence of carbon fibres, recycling end-of-life seals made from advanced materials such as Ketron PEEK comes with a range of challenges, from understanding the impact of different industrial environments on the material’s quality and potential degradation to navigating the regulatory and compliance hurdles that come with transporting used materials across borders.
Partnering for sustainability in the energy sector
Embracing circular economy strategies through partnerships with industry leaders such as MCG provides a practical and transformative pathway towards sustainability, positioning OEMs as innovators in environmental stewardship and industrial responsibility.
Rather than disposing of end-of-life materials in landfill, where they will sit for thousands of years, OEMs can get involved in MCG’s Statera™ programme, promoting circularity for engineering plastics. As part of the multi-pronged programme, the company reclaims end-of-life parts from its clients, establishing custom takeback plans which simplify the OEMs’ waste stream management. At the same time, this helps MCG to guarantee a consistent supply of source materials from which to produce its Sterra™ products – a portfolio of engineering plastics made from recycled content. If used parts are too contaminated to be recycled and transformed into a Sterra™ grade, they are disposed of safely and sustainably, often as a fuel for a high-temperature furnace. The benefit for energy OEMs is clear: responsible disposal and reduced climate impact made seamless.
Meanwhile, the Sterra™ portfolio exhibits identical performance characteristics to virgin counterparts, with verified lifecycle assessment (LCA) data and data-driven impact estimates available to support the 90% reduction in cradle-to-gate carbon footprint from using these materials.
From increasing the use of recycled content in the oil and gas supply chain where possible or simply providing the waste material with which to power programmes like Statera™, embracing innovative recycling solutions before they become imperative will be crucial for the long-term success and competitive advantage of companies within the energy sector and beyond. As regulatory environments become increasingly rigorous and sustainability expectations continue to rise, the best time to start is now.
To learn more about the use of polymers in labyrinth seal applications, download the whitepaper below.
