Covestro and Fraunhofer UMSICHT Launch Smart Pyrolysis Pilot for Foam Recycling
- Covestro and Fraunhofer UMSICHT will operate a 2kt/year pilot plant for smart pyrolysis of polyurethane foam waste.
- The plant will produce high-purity recycled aniline for MDI production, reducing carbon footprint by up to 40%.
- The facility is scheduled to be operational by 2028.
- The project targets the recycling of rigid PUR/PIR foam waste, which is difficult to recycle.
Project Overview
Covestro and Fraunhofer UMSICHT have signed a contract to operate a pilot plant for smart pyrolysis of rigid polyurethane foam waste. The plant, with a capacity of 2kt per year, aims to produce high-purity recycled aniline for methylene diphenyl diisocyanate (MDI) production, significantly reducing the carbon footprint compared to conventional methods.
Timeline and Capacity
The pilot plant is scheduled to be operational by 2028. It will process end-of-life rigid PUR/PIR foam waste, primarily from insulation materials, which are challenging to recycle due to their crosslinked molecular structure.
Technological Development
The smart pyrolysis process developed by Covestro and Fraunhofer UMSICHT yields aniline with approximately 99% purity, suitable for producing recycled MDI that meets conventional quality standards. This initiative builds on research from the CIRCULAR FOAM project, an EU-funded effort involving multiple partners across Europe.
Market Context
The MDI market for rigid foam is expected to grow significantly in Europe, driven by demand for energy-efficient insulation. EU regulations increasingly require scalable end-of-life solutions for PUR/PIR rigid foam, presenting a challenge that this chemical recycling technology aims to address by recovering valuable raw materials.
Source: Covestro