“Catalyst technology” might not sound exciting, but it actually is core to the way we make fuels, plastics, and chemicals every day. Zeopore, a spin-out from KU Leuven, now has developed a process that fine-tunes these catalysts to make industrial refining and recycling more efficient and eco-friendly.
At the heart of its innovation is a tiny structural change in “zeolites,” a mineral widely used in oil refining, petrochemicals, and plastic recycling. With Zeopore’s adjustment at the nanoscale, refineries use less raw material and emit fewer greenhouse gases, saving both money and the environment.
This has major potential because even small efficiency gains add up to massive global impact in an industry that processes hundreds of millions of barrels of oil every year.
Environmental Impact of the New Zeopore Catalyst Technology
By improving catalytic efficiency, Zeopore’s technology can deliver substantial reductions in CO₂ emissions and resource consumption in both fossil-based and renewable fuel processes. Enhanced catalysts allow chemical reactions to be more selective and complete, which means less waste byproducts and lower energy input for a given output.
According to Zeopore, their mesoporous zeolites lead to “higher product quality, lower energy use, and less waste” across several refining and petrochemical processes. Zeopore’s CEO estimates that using highly porous zeolites can save on the order of $30–50 million per year, per refinery in improved yields and efficiency.
These gains reflect not just economic value but also avoided resource use – millions of barrels of crude and associated emissions. With nearly 1000 oil crackers worldwide, scaling such catalysts industry-wide could unlock over $30 billion in value while significantly cutting the carbon footprint of fuel production.
A key environmental contribution of Zeopore’s technology is in enabling circular economy solutions like biomass conversion and plastic waste recycling. With the world slowly but steadily shifting away from pure fossil feedstocks, catalysts must handle more complex, oxygen-rich or bulky molecules. Zeopore’s mesoporous catalysts make it feasible to convert bio-based feeds and polymer waste into fuels and chemicals efficiently, which helps replace petroleum inputs and reduce waste incineration. This has direct climate benefits: incinerating 1 ton of plastic waste releases nearly 3 tons of CO₂ into the atmosphere.
By contrast, advanced recycling routes can dramatically lower this impact. A recent Argonne National Lab study found that using pyrolysis oil from waste plastic to produce new plastics can cut greenhouse gas emissions by ~18–23% compared to conventional oil-based production. Even more striking, an LCA from University of Warwick showed an 80% reduction in CO₂ equivalent emissions when diverting waste plastics to an advanced recycling process (hydrothermal conversion) instead of incineration.
These studies confirm that chemical recycling, if implemented at scale, is far superior to incineration in climate terms.
Market Potential
Zeopore’s growth trajectory and market outlook appear strong, given the substantial value its technology offers and the urgent industry need for such solutions. Since its founding in late 2017, the company has evolved from a university spin-off into a venture-backed firm with an industrial pilot plant. It raised a significant financing round in 2020 led by Capricorn Partners’ Sustainable Chemistry Fund (with participation from KU Leuven and other investors) to accelerate commercialization
By 2020 Zeopore had already validated its mesoporous catalysts in major refining processes and was negotiating joint development and licensing deals with leading catalyst developers and refining companies worldwide. This early traction – essentially getting the attention of industry giants – is a positive indicator for adoption.
Today, Zeopore is positioning itself to tap into global petrochemical and recycling markets worth billions. The global refinery catalyst market alone is around $5 billion/year and forecast to reach $6–7 billion by 2030. These include catalysts for FCC, hydrocracking, reforming, etc., which are dominated by a few large companies (BASF, Albemarle, Grace, etc.) and increasingly by Asian suppliers (Asia-Pacific held ~36% of the market in 2023)
Zeopore’s strategy isn’t to become a full-fledged catalyst manufacturer competing head-on with these incumbents; rather, it aims to partner or license its mesoporization technology to them. By offering a step-change improvement to the catalyst performance (at minimal added cost), Zeopore provides value that established catalyst vendors can pass on to refiners. This collaborative approach is evident: Zeopore reports it is engaging with a leading European manufacturer to deliver mesoporized zeolite samples for testing, and exploring business models from technology licensing to product supply. If those trials convert to agreements, Zeopore’s reach could scale rapidly via the sales channels of much larger companies.
Industry Trends and Strategic Fit
Zeopore’s approach fits perfectly with growing industry needs in green chemistry, carbon reduction, and the push for a circular economy. The chemical industry is under intense pressure to use less energy, reduce waste, and reuse carbon wherever possible. Zeopore steps in by making catalysts more effective, especially for processes that cut CO₂ emissions or convert waste into valuable products. Below are a few major trends that show why Zeopore’s technology is so relevant:
- Green Chemistry and Process Intensification:
Chemicals must be made in cleaner, more efficient ways. Improved catalysts do exactly that: they increase yield, reduce unwanted byproducts, and save energy. Zeopore’s method is water-based and avoids toxic additives, aligning with greener manufacturing. Any reduction in energy use, even a few degrees of lower reaction temperature, adds up to large CO₂ savings across multiple reactors. - Carbon Capture, Utilization, and Storage (CCUS):
Heavy industries are looking at ways to capture CO₂ and turn it into fuels or other products. Zeopore’s catalysts boost the efficiency of these “CO₂-to-chemicals” routes, allowing more of the captured carbon to end up in useful products instead of going back into the atmosphere. This is crucial as climate targets get stricter and more companies invest in carbon capture. - Shifting to a Circular Economy:
The industry is moving away from a throwaway model to one where waste becomes feedstock. This includes recycling plastics and converting them into new raw materials. Zeopore’s mesoporous catalysts help break down tough plastic waste at lower temperatures and with higher yields, lowering waste and making the process more attractive. They also increase efficiency in refineries, which means using fewer fossil inputs for the same amount of fuel or chemical production. - Decarbonizing the Chemical Sector:
Big chemical players aim to reach net-zero by 2050. That requires everything from renewable power to new catalysts that work with bio-based feeds. Zeopore’s technology directly cuts energy use in refining while also helping shift to sustainable aviation fuels, renewable diesel, and efficient petrochemicals. As oil demand for transport levels off, demand for plastics and specialty chemicals continues, and Zeopore’s catalysts help extract maximum value from each barrel of oil. - Collaboration and Open Innovation:
Achieving climate goals involves many partners, from universities and startups to large global firms. Zeopore started at KU Leuven and works with multiple customers to refine and test its catalyst solutions. This open approach makes it easier to adopt new technology at scale. By acting as both a catalyst supplier and a research collaborator, Zeopore is set to become a key player in developing sustainable industrial processes.
By helping capture and reuse carbon – and by making it easier to switch to alternative raw materials – Zeopore directly supports the move toward cleaner, circular operations. The company’s plan to expand from traditional oil refining to newer, greener markets reflects the industry’s path toward sustainability. If it keeps innovating and evolving, Zeopore could well become a driving force in making global fuel and chemical production more eco-friendly.