Key Findings: Covestro Pioneers Vulkollan® Chemical Recycling, Cutting Carbon Emissions by Up to Two-Thirds
Covestro has commenced operations at a new pilot plant in Leverkusen, Germany, dedicated to the chemical recycling of its high-performance cast elastomer, Vulkollan®. This breakthrough process allows for the efficient depolymerization of over 90% of end-of-life Vulkollan® materials into their original chemical building blocks. This innovation is projected to reduce carbon emissions by up to two-thirds compared to using fossil-based virgin materials.
Technical & Clinical Details: Over 90% Recovery Rate and Broad Application Potential
The chemical recycling technology implemented by Covestro effectively breaks down the complex cross-linked structure of Vulkollan® to recover high-purity monomers and oligomers as chemical feedstocks. The pilot plant is designed to process several tons of used Vulkollan® material annually, with the recovered building blocks being reintegrated into the production of new Vulkollan®. This establishes a closed-loop system for a material previously considered difficult to recycle.
- High Recovery Rate: Over 90% of end-of-life Vulkollan® material is recovered as purified chemical building blocks.
- Carbon Emission Reduction: Achieves up to a two-thirds (approximately 67%) reduction in carbon emissions compared to using fossil-based virgin materials.
- Process Objectives: The pilot plant’s primary goals include further process optimization, validation of technical feasibility, and data generation for future industrial-scale expansion.
- Expanded Scope: Covestro is actively investigating the application of this technology beyond Vulkollan® to include other specialty cast elastomers and thermoplastic polyurethanes (TPU).
Background & Industry Context: Commitment to Circular Economy and Resource Efficiency
Vulkollan®, a high-performance elastomer, is widely used in demanding applications such as forklift tires, amusement park wheels, and sealing materials due to its exceptional mechanical properties and durability. However, its complex nature has historically made it challenging to recycle, leading to incineration or landfilling. Covestro is committed to a “fully circular” vision, aiming for all its products to be circular by 2035. This pilot plant represents a significant step towards achieving that goal, particularly in enhancing resource efficiency for previously hard-to-recycle high-performance polymers.
This initiative aligns with global environmental directives, including the European Green Deal and the Circular Economy Action Plan, which incentivize companies to develop sustainable solutions and reduce their environmental footprint.
Future Outlook: Scaling to Industrial Production and Market Impact
The success of the Leverkusen pilot plant will lay the groundwork for realizing commercial-scale chemical recycling of Vulkollan®. As data collection and process refinement progress, larger industrial plants are expected to be considered within a few years. Once established, this technology is anticipated to significantly elevate sustainability standards within the high-performance elastomer market, bolster supply chain resilience for raw materials, and reduce dependence on fossil resources. Covestro’s efforts through this technology are set to further solidify its position as a provider of high-performance, environmentally responsible materials.
Get our weekly technology intelligence — free
Receive an infographic that lets you judge at a glance whether each field’s analysis report is worth reading.
Subscribe Free — Weekly Tech Intelligence
By subscribing, you’ll receive Troy-Technical’s weekly technology intelligence newsletter.
- Your email and selected fields are used only to deliver the newsletter.
- We never share your information with third parties.
- You can unsubscribe anytime via the link in each email.
See our Privacy Policy for details.
Takes about a minute · Unsubscribe anytime
