Major Breakthrough Achieved in the Process of Chemical Recycling of Polycarbonate

Covestro, a leading material supplier, has achieved a pioneering feat by introducing an ingenious chemical recycling technique designed to revert polycarbonate to its fundamental monomers, effectively repurposing them as alternative raw materials within the production cycle. This innovative approach aligns with Covestro's commitment to sustainable practices and marks a significant stride toward circularity within the industry.

The practical realization of this chemical recycling endeavor has commenced on a pilot scale at Covestro's Leverkusen facility in Germany. The aim of this preliminary implementation is to fine-tune the process for optimal efficiency and effectiveness, setting the stage for future large-scale deployment.

Dr. Thorsten Dreier, Covestro's Chief Technology Officer, emphasized the company's intrinsic responsibility as a producer of plastics such as polycarbonate to address the entire lifecycle of these vital materials. He highlighted the inherent advantage of comprehending the design of their products, enabling Covestro to strategically pursue innovative recycling solutions.

Covestro has strategically integrated mechanical recycling of polycarbonate into its sustainability strategy, utilizing this process when waste streams are sufficiently uncontaminated, and the recycled material aligns with the specifications required for future applications. Chemical recycling supplements this approach, addressing larger waste streams that may not be suitable for mechanical recycling. These materials can now undergo treatment to yield plastics that meet the highest quality standards, enhancing Covestro's commitment to resource efficiency. The pioneering chemical recycling process, a result of collaboration across international teams, is centered around a tailored chemolysis method tailored specifically for polycarbonate. Markus Dugal, Head of Process Technology at Covestro, elucidated that this process is adept at recycling pre-sorted waste streams containing over 50% polycarbonate content. Successful demonstrations have been conducted on various plastic waste streams containing polycarbonate. Dugal noted that through chemolysis, the recycling cycle can be seamlessly closed, resulting in direct precursors of polycarbonate and thereby creating an exceptionally sustainable recycling process.

One of the remarkable aspects of this breakthrough is that the recycled product can be incorporated into the production of polycarbonate without additional processing, exemplifying its quality and feasibility as a raw material. This feature is particularly beneficial for applications requiring superior standards, including the automotive sector, where factors like safety, optical clarity, and aesthetics hold paramount importance. Lily Wang, Head of the Engineering Plastics business entity at Covestro, affirmed the significance of these high-quality recycled raw materials for such applications in both the automotive and consumer electronics sectors. Furthermore, Covestro remains committed to advancing the realm of innovative polycarbonate recycling. In addition to the introduced chemical recycling process, the company is actively exploring alternative methods within its research laboratories. This includes investigating chemolytic alternatives, exploring enzymatic breakdown of plastics, and venturing into intelligent pyrolysis processes. Promising alternatives discovered through these research avenues will also be subjected to testing and validation using the pilot plant.

In conclusion, Covestro's breakthrough in chemical recycling for polycarbonate stands as a testament to the company's dedication to sustainable practices and circularity within the materials industry. Through innovative approaches, collaboration, and a resolute commitment to environmental responsibility, Covestro paves the way toward a more sustainable and eco-conscious future.