Covestro plans to invest in building a polyurethane elastomer recycling test plant in Germany
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Recently, Covestro announced plans to invest tens of millions of euros in building an advanced elastomer recycling pilot plant at its facility in Leverkusen, Germany; the construction of this pilot plant is expected to take one year. Covestro’s development of this technology for recycling Vulkollan® represents an important step forward for the elastomer industry toward sustainable development. This technology can recover over 90% of waste materials such as forklift tires, and it can also reduce the carbon footprint by up to two-thirds compared to the original materials. It is reported that Covestro’s Vulkollan® is a cast polyurethane elastomer, produced through a chemical reaction involving Vulkollan® polyol, Desmodur® 15 (NDI), and ethylene glycol. Vulkollan® is one of the strongest elastomers on the market, boasting the highest mechanical strength and the greatest dynamic load-bearing capacity. Therefore, the ultra-high-performance elastomer Vulkollan® is the best choice for carrying out challenging tasks in numerous technical fields. Thomas Braig, Global Head of Covestro’s Elastomers Business Unit, said: “The pilot plant and our commitment to demonstrating the feasibility of elastomer recycling reflect our strong commitment to circular solutions and represent an important milestone for our elastomer products.” By successfully scaling up this new recycling process, we have met customers’ demands for end-of-life solutions and reduced carbon footprints, while ensuring the high quality of our elastomer products. At the same time, this pilot plant also invites participants in the value chain to collaborate on developing recycling systems and a reverse value chain for end-of-life materials. ” A pioneer in the field of chemical recycling of elastomers, Covestro’s customers use the Vulkollan® system to manufacture parts for many applications that require high levels of durability and performance. Typical applications of Vulkollan® parts are forklift wheels, railway bumper components, and automotive vibration control components as well as bumpers. The superior quality of Vulkollan® enables target applications to operate in a more sustainable and cost-effective manner, thanks to a longer lifespan, longer maintenance intervals, and fewer unplanned downtime incidents. Thanks to the high throughput of the recycling process, scrap Vulkollan® material can be reintroduced into new automotive bumpers and forklift tires through a mass balance approach. The new chemical recycling process has revolutionized the elastomers industry. Unlike mechanical recycling methods, this approach breaks down obsolete elastomer materials into their chemical constituent raw materials to obtain purified monomers, which can be reused in these materials with known and proven quality. Promoting sustainable development and industry cooperation, Markus Dugal, head of process technology at Covestro, explained: “The new chemical recycling process addresses the unique challenges of elastomeric materials, which are considered to be durable.” For such high-performance applications, degenerate loops are not feasible. This technology enables us to recycle high-quality waste materials, thereby reducing the environmental impact of elastomer production. This is a reflection of Covestro’s spirit of innovation. ” This pilot plant will play a key role in refining the recycling process beyond laboratory scale, testing it using various waste streams and different types of end-of-life materials. It will also serve as a platform for Covestro to interact with potential project partners and customers, paving the way for the development of larger-scale commercial recycling plants in the future. Covestro’s investment in elastomer recycling is in line with its broader strategic goals of reducing its environmental impact, promoting the principles of a circular economy, and maintaining its leadership in innovation within the polymer industry. The company invites potential partners and customers interested in cyclic elastomer solutions to participate in discussions on future collaborations and applications, as well as to understand the environmental benefits of these solutions across the entire value chain.
Since 2001, the total investment in Covestro’s integrated site in Shanghai has exceeded 3 billion euros, making it Covestro’s largest production site worldwide. Currently, the Shanghai facility has 11 factories equipped with advanced production technologies, covering Covestro’s main product lines; these products are widely used in industries such as construction, automotive, and electronics. For example, the Shanghai integrated facility uses a gas-phase process to produce isocyanate, a key chemical; this process can reduce energy consumption by up to 60% and solvent consumption by 80% compared to the liquid-phase method ； The Shanghai integrated facility also applies oxygen depolarized cathode technology in chlorine production, reducing electricity consumption and carbon dioxide emissions by as much as 30%, thereby significantly improving the production of this energy-intensive product ； Last year, the Shanghai facility also announced that, through a catalyst upgrade project, it had successfully reduced nitrous oxide and nitrogen oxide emissions from its nitric acid plant by 65% and 30% respectively. “Whether at Covestro’s integrated facility in Shanghai or at other facilities around the world, we are equipped with advanced processes and technologies. Covestro has announced that by 2025 it aims to reduce carbon dioxide emissions per ton of product produced by 50% compared to 2005 levels, and these technologies help us move steadily toward achieving this goal. ”Dr. Chen Yun, General Manager of Covestro’s integrated facility in Shanghai, said, “The honor of being recognized as a green factory proves that with the right technologies and measures, the chemical industry can be clean, efficient, and sustainable, while also coexisting harmoniously with local communities.” ”