Vulkollan: Covestro’s 2026 chemical recycling plant specs

September 26, 2026

Covestro Germany

Overview

Covestro has inaugurated a multi-million euro pilot plant in Leverkusen, Germany, for the chemical recycling of high-performance elastomers, specifically its Vulkollan® polyurethane elastomer. This initiative transitions a novel recycling process from lab to pilot scale, enabling over 90% (by mass) of selected post-consumer Vulkollan® materials to be recycled. The process is projected to reduce carbon emissions by up to two-thirds compared to fossil-based virgin material, marking a significant milestone in Covestro’s circular economy strategy for advanced polymers.

In Depth

Key Findings

Covestro has launched a new pilot plant in Leverkusen, Germany, dedicated to the chemical recycling of high-performance elastomers. This multi-million euro investment is specifically designed to advance a novel recycling process for the company’s high-performance polyurethane elastomer, Vulkollan®, moving it from laboratory development to pilot-scale operation. The new process demonstrates the capability to recycle over 90% (by mass) of selected end-of-life Vulkollan® materials, with the potential to reduce carbon emissions by up to two-thirds compared to using fossil-based virgin materials.

Technical/Clinical Details

The chemical recycling process developed by Covestro aims to depolymerize high-performance elastomers back into their molecular building blocks, such as monomers and polyols. These high-purity recovered raw materials can then be re-integrated into the production of new, high-quality Vulkollan® products, ensuring no compromise on performance while significantly boosting sustainability. The operation of this pilot plant will validate the technical and economic feasibility of the process, providing crucial data for future large-scale commercialization. This technology offers a sophisticated approach to breaking down complex polymer networks to extract valuable components.

Background & Context

Polyurethane elastomers are essential materials in various high-performance applications, including forklift wheels, wind turbine components, and industrial seals, due to their exceptional durability, abrasion resistance, and elasticity. However, their robust cross-linked structure has historically made mechanical recycling challenging, leading to significant waste streams. Covestro’s initiative directly addresses this industry-wide challenge by enhancing the circularity of high-performance polymers throughout their value chain and reducing reliance on virgin fossil resources. This move aligns with broader European Green Deal objectives and plastics strategies, emphasizing resource efficiency and waste reduction.

Strategic Significance & Outlook

The operationalization of the Leverkusen pilot plant represents a pivotal step towards establishing a circular ecosystem for Vulkollan®. Covestro plans to further optimize this process and explore its applicability to other high-performance polymers in the future. Should this technology achieve commercial scale, it stands to set a new standard for sustainable supply chains in the high-performance elastomer market, drastically increasing the utilization of recycled content. This will lead to substantial reductions in fossil resource consumption and CO2 emissions, contributing significantly to a more sustainable industrial landscape globally.

Source: https://www.covestro.com/press/toward-circular-elastomers-covestro-opens-pilot-plant-in-leverkusen/

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