Evonik, Toyotsu Chemiplas and Sanyo Chemical pilot polyurethane foam recycling model in Japan
- Partners will collect post-consumer polyurethane foam and post-industrial scrap for recycling.
- Evonik will apply a hydrolysis-based chemical recycling process to recover polyols and amines.
- Recycled polyols are intended as high-purity, drop-in feedstock and new foam has already been produced using 100% recycled polyol.
- The consortium will evaluate collection, sorting, quality and lifecycle impacts with the aim of commercialising a scalable model in Japan.
Project overview
Evonik, Toyotsu Chemiplas and Sanyo Chemical have launched a joint initiative to develop a polyurethane foam recycling model in Japan that converts discarded foam into recycled polyols and amines for use in new polyurethane products.
Roles and feedstock
Toyotsu Chemiplas will coordinate the initiative and provide collection and logistics capability. Sanyo Chemical will contribute polyol development and process-technology expertise. Evonik will supply its hydrolysis-based chemical recycling process and technical support.
Process and outputs
Evonik’s hydrolysis process is designed to produce high-purity, consistent recycled polyols that serve as drop-in replacements and can materially reduce carbon footprint compared with virgin materials. The process also recovers amines; new polyurethane foam has already been produced using 100% recycled polyol derived from the process.
Evaluation and scale-up
The partners will jointly assess the full value chain — collection, sorting, chemical recycling, product manufacture and quality testing — and update lifecycle assessment data with the objective of commercialising and scaling the recycling model across Japan.
Source: Evonik