Covestro, a leading global supplier of high-tech polymer materials, has announced plans to build a pilot plant dedicated to the recycling of elastomers, with an investment in the double-digit million euro range. The project, which will be based at Covestro's Leverkusen site in Germany, is set to take approximately one year for technical completion. This new initiative focuses on recycling Vulkollan, a key material in many high-performance applications, marking a significant step towards greater sustainability in the elastomers industry.

The innovative recycling technology is designed to recycle more than 90% of end-of-life materials, such as forklift tires, and reduce the carbon footprint by up to two-thirds compared to virgin material. Dr. Thomas Braig, Head of Covestro’s Elastomers business entity, emphasized that the pilot plant demonstrates the company's commitment to circular solutions. It serves as an important milestone in advancing elastomer products while addressing customer demands for end-of-life solutions and carbon footprint reduction. Additionally, the pilot plant encourages collaboration within the value chain to develop a circular setup for end-of-life materials.

Vulkollan is commonly used in durable, high-performance applications, including forklift wheels, railway bumpers, and automotive vibration control elements. Its durability enables more sustainable operation, with longer lifespans and extended maintenance intervals, reducing unplanned downtime. The new recycling process will allow end-of-life Vulkollan to be repurposed into new automotive jounce bumpers and forklift tires, using a mass balancing approach. This chemical recycling method is a significant departure from traditional mechanical recycling, as it breaks down elastomeric materials into their chemical building blocks, producing purified monomers that can be reused without compromising quality.

Markus Dugal, Head of Process Technology at Covestro, noted that this chemical recycling process overcomes the challenges posed by elastomer materials, which are designed for long-lasting performance. Unlike downcycling, which is often used for less durable materials, this method recycles a high mass fraction of the material, reducing the environmental impact of elastomer production.

The pilot plant will play a key role in refining the recycling process at a larger scale, testing various waste streams and end-of-life materials. It will also serve as a platform for Covestro to engage with potential partners and customers, paving the way for the development of a larger commercial recycling plant. This investment aligns with Covestro’s broader goals of reducing its environmental impact, promoting circular economy principles, and maintaining its position as an innovation leader in the polymer industry. The company is inviting discussions with partners and customers to explore future collaborations and the environmental benefits of circular elastomer solutions.