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Germany polymer firm, Covestro, has opened a new pilot plant at its Leverkusen (Germany) site for the chemical recycling of high-performance elastomers, moving a recycling process it has been developing in the lab into pilot-scale operation.
The company described it as one of the first installations of its kind worldwide to this material class, and said the project — backed by an investment in the double-digit millions of euros — draws on German chemical and engineering expertise to advance the methodology toward manufacturing consumption.
The process targets Covestro’s own high-performance polyurethane elastomer, Vulkollan, which is utilized in applications such as forklift wheels, railway buffer elements, automotive jounce bumpers and vibration-manage components. Covestro said its chemical recycling process breaks down selected end-of-life material into purified building blocks to reuse, enabling greater than 90% of the material by mass to be recycled, with the possible to cut the carbon footprint by up to two-thirds compared with fossil-based virgin material.
The pilot plant will allow the company to test different discarded materials streams, refine the process and generate data to support a future manufacturing-scale rollout.
Ms. Monique Buch, Chief Commercial Officer of Covestro, said turning circularity into “technically robust and commercially viable solutions” was central to the company’s strategy, adding that the pilot plant responds to growing customer demand to circular solutions.
Mr. Thomas Braig, Head of the Business Entity Elastomers at Covestro, called the plant “a key measure in our pre-industrialisation journey,” saying it would let the company demonstrate the technical feasibility of the recycling process, refine it systematically, and lay the groundwork to manufacturing consumption in partnership with customers and partners.
Covestro said it is working with customers, recyclers, discarded materials collectors and logistics providers to build the collection and return systems needed to closed-loop solutions, calling such partnerships essential to securing consistent, suitable end-of-life feedstock and building an economically viable circular value chain to high-performance elastomers. Beyond this material, the company said it plans to consumption the pilot plant to explore circular solutions to selected speciality cast elastomers and thermoplastic polyurethanes (TPU) as well.
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