Technology
March 25, 2021
Covestro Recycling Project
Closing the loop for polyurethane mattresses
Covestro: a pioneer in foam recycling and cycle design
- Innovative process for recovering both core raw materials
- New pilot plant for chemical recycling put into operation
- Trailblazer for industrial recycling
- Co-shaping the circular economy in cooperation with value chain
Covestro has developed an innovative process for the chemical recycling of polyurethane (PU) flexible foam from used mattresses. It builds on its participation in the PUReSmart project, which is coordinated by Recticel company.
On average, mattresses contain 15 to 20 kilograms of foam, which results in a large amount of waste at the end of their useful life. The foam is primarily made of two important raw materials. While other chemical recycling approaches mainly focus on processing one of them, the Covestro process now enables the recovery of both raw materials.
Covestro has also recently started operating a pilot plant for flexible foam recycling at its Leverkusen site to confirm the positive laboratory results achieved to date. The first phase is to focus on recycling one of the raw materials, before the recovery of the second component is also to be piloted from summer this year. Covestro´s goal here is to industrialize chemical recycling processes for used flexible foams and ultimately to remarket both recovered raw materials.
Closing material loops
“The development of this innovative recycling technology and the investment in the pilot plant are further milestones in realizing our vision of fully aligning Covestro to the circular economy,” says CEO Dr. Markus Steilemann. “In doing so, we want to replace fossil resources in production, steadily further reduce the carbon footprint of our materials and create new solutions for dealing with plastic waste. Chemical recycling is particularly promising for this, and must be developed further and used more intensively overall. Above all, it should finally be put on an equal legal basis with other recycling methods.”
In cooperation with the companies Recticel and Redwave – a division of Wolfgang Binder GmbH – and as part of the PUReSmart research project, Covestro has also developed an intelligent sorting solution for separating the different PU foams from post-consumer mattresses. The software uses algorithms to correctly identify the different foam types, which facilitates an effective recycling process. This development is another element of Covestro’s digitalization strategy, combined with the new opportunities it entails for the chemicals and plastics industry.
Co-creation of a circular ecosystem
“Based on our competencies and experiences, we also want to take part in shaping the emerging value creation cycle,” says Daniel Meyer, Global Head of the Polyurethanes segment at Covestro. “To accomplish this, we rely on international cooperation with partners and also develop innovative business models. The aim is to generate new sustainable business opportunities with our customers, other partners and for ourselves.”
The project is an important step forward in taking the development of the circular economy at Covestro to entirely new heights. The increased use of used materials further contributes to solving the societal challenge of sustainable disposal of such waste and to achieving the European Union´s goals for the circular economy and for climate and environmental protection.
https://www.covestro.com/press/closing-the-loop-for-polyurethane-mattresses-public/
March 25, 2021
Covestro Recycling Project
Closing the loop for polyurethane mattresses
Covestro: a pioneer in foam recycling and cycle design
- Innovative process for recovering both core raw materials
- New pilot plant for chemical recycling put into operation
- Trailblazer for industrial recycling
- Co-shaping the circular economy in cooperation with value chain
Covestro has developed an innovative process for the chemical recycling of polyurethane (PU) flexible foam from used mattresses. It builds on its participation in the PUReSmart project, which is coordinated by Recticel company.
On average, mattresses contain 15 to 20 kilograms of foam, which results in a large amount of waste at the end of their useful life. The foam is primarily made of two important raw materials. While other chemical recycling approaches mainly focus on processing one of them, the Covestro process now enables the recovery of both raw materials.
Covestro has also recently started operating a pilot plant for flexible foam recycling at its Leverkusen site to confirm the positive laboratory results achieved to date. The first phase is to focus on recycling one of the raw materials, before the recovery of the second component is also to be piloted from summer this year. Covestro´s goal here is to industrialize chemical recycling processes for used flexible foams and ultimately to remarket both recovered raw materials.
Closing material loops
“The development of this innovative recycling technology and the investment in the pilot plant are further milestones in realizing our vision of fully aligning Covestro to the circular economy,” says CEO Dr. Markus Steilemann. “In doing so, we want to replace fossil resources in production, steadily further reduce the carbon footprint of our materials and create new solutions for dealing with plastic waste. Chemical recycling is particularly promising for this, and must be developed further and used more intensively overall. Above all, it should finally be put on an equal legal basis with other recycling methods.”
In cooperation with the companies Recticel and Redwave – a division of Wolfgang Binder GmbH – and as part of the PUReSmart research project, Covestro has also developed an intelligent sorting solution for separating the different PU foams from post-consumer mattresses. The software uses algorithms to correctly identify the different foam types, which facilitates an effective recycling process. This development is another element of Covestro’s digitalization strategy, combined with the new opportunities it entails for the chemicals and plastics industry.
Co-creation of a circular ecosystem
“Based on our competencies and experiences, we also want to take part in shaping the emerging value creation cycle,” says Daniel Meyer, Global Head of the Polyurethanes segment at Covestro. “To accomplish this, we rely on international cooperation with partners and also develop innovative business models. The aim is to generate new sustainable business opportunities with our customers, other partners and for ourselves.”
The project is an important step forward in taking the development of the circular economy at Covestro to entirely new heights. The increased use of used materials further contributes to solving the societal challenge of sustainable disposal of such waste and to achieving the European Union´s goals for the circular economy and for climate and environmental protection.
https://www.covestro.com/press/closing-the-loop-for-polyurethane-mattresses-public/
March 19, 2021
Repsol To Build PU Recycling Plant
Repsol’s new PU foam recycling plant will be capable of processing over 2,000 t of waste per year. (Source: Repsol) 18. March 2021
Repsol: Construction of Spain’s first PU foam recycling plant
Repsol announced that it plans to build Spain’s first plant for chemical recycling of polyurethane foam at its Puertollano Industrial Complex. According to the company, the new recycling facility is expected to be completed by the end of 2022 and will entail an investment of approximately EUR 12 million. Once operational, the plant will be capable of processing around 2,000 metric tons of polyurethane foam per year, the equivalent of 380 linear kilometers of mattresses placed side by side. Repsol plans on using this circular economy project to produce circular polyols from recycled polyurethane foam.
The company said that integrating this new recycling plant into the Puertollano petrochemical complex will ensure the quality of this circular product by allowing the maximisation of synergies with the facility’s standard processes. This investment marks yet another step forward in Repsol’s commitment to the transformation of its industrial area. It involves turning production centres into multi-energy hubs capable of generating products with a low, zero, or even negative carbon footprint. Repsol has already announced investments totalling EUR 700 million in decarbonisation and circular economy projects to be carried out through 2025 at the Puertollano Industrial Complex alone. This helps ensure a competitive future for the industrial facility, said the company.
In the words of José Luis Bernal, executive director of Repsol Chemicals: “The polyurethane foam recycling plant represents a chance to create new business models that reflect Repsol’s environmental commitment while also helping our customers meet their sustainability objectives and respond to the growing need to recycle and extend the useful life of our products.”
Repsol said it has adopted the circular economy as a tool for using resources more efficiently, thus, enabling the company to reduce CO2 emissions. In December 2019, Repsol became the first company in its sector to announce it was reorienting its strategy to reach carbon neutrality by 2050. The company’s circular economy strategy dates back to 2016. Today, it includes over 200 initiatives applied throughout the value chain, from obtaining raw materials to marketing of products and services. All industrial complexes are being adapted to use waste from a variety of sources as raw materials in new products, with the aim of using a total of 2 million t of waste by 2030. With this strategy based on new recycling processes, Repsol said it has positioned itself as one of the petrochemical companies with the strongest commitments to sustainability and with one of the most extensive catalogs of circular products, ranging from polyolefins recovered through mechanical recycling processes to polyolefins, styrene, and other chemically recycled products.
March 19, 2021
Repsol To Build PU Recycling Plant
Repsol’s new PU foam recycling plant will be capable of processing over 2,000 t of waste per year. (Source: Repsol) 18. March 2021
Repsol: Construction of Spain’s first PU foam recycling plant
Repsol announced that it plans to build Spain’s first plant for chemical recycling of polyurethane foam at its Puertollano Industrial Complex. According to the company, the new recycling facility is expected to be completed by the end of 2022 and will entail an investment of approximately EUR 12 million. Once operational, the plant will be capable of processing around 2,000 metric tons of polyurethane foam per year, the equivalent of 380 linear kilometers of mattresses placed side by side. Repsol plans on using this circular economy project to produce circular polyols from recycled polyurethane foam.
The company said that integrating this new recycling plant into the Puertollano petrochemical complex will ensure the quality of this circular product by allowing the maximisation of synergies with the facility’s standard processes. This investment marks yet another step forward in Repsol’s commitment to the transformation of its industrial area. It involves turning production centres into multi-energy hubs capable of generating products with a low, zero, or even negative carbon footprint. Repsol has already announced investments totalling EUR 700 million in decarbonisation and circular economy projects to be carried out through 2025 at the Puertollano Industrial Complex alone. This helps ensure a competitive future for the industrial facility, said the company.
In the words of José Luis Bernal, executive director of Repsol Chemicals: “The polyurethane foam recycling plant represents a chance to create new business models that reflect Repsol’s environmental commitment while also helping our customers meet their sustainability objectives and respond to the growing need to recycle and extend the useful life of our products.”
Repsol said it has adopted the circular economy as a tool for using resources more efficiently, thus, enabling the company to reduce CO2 emissions. In December 2019, Repsol became the first company in its sector to announce it was reorienting its strategy to reach carbon neutrality by 2050. The company’s circular economy strategy dates back to 2016. Today, it includes over 200 initiatives applied throughout the value chain, from obtaining raw materials to marketing of products and services. All industrial complexes are being adapted to use waste from a variety of sources as raw materials in new products, with the aim of using a total of 2 million t of waste by 2030. With this strategy based on new recycling processes, Repsol said it has positioned itself as one of the petrochemical companies with the strongest commitments to sustainability and with one of the most extensive catalogs of circular products, ranging from polyolefins recovered through mechanical recycling processes to polyolefins, styrene, and other chemically recycled products.
March 12, 2021
Vita Opens Innovation Center
Technical Innovation Centre launched by MP
It has been a Budget Week like no other with a big focus on kick-starting the economy and ‘building back better’. At The Vita Group, we continue to invest in the future, ensuring we’re able to sustainably deliver the very best products and solutions for our customers for generations to come. As part of this mission, we are proud to unveil our fourth innovation hub with the launch of Vita’s new Innovation Centre in Accrington, Lancashire.
The Accrington Technical Innovation Centre will work in partnership with employees and customers across our European footprint to lead research, development, and collaboration on highly engineered and customized polyurethane foam, including driving forward sustainable solutions through the use of biopolyols.
Vita’s four state-of-the-art innovation centres in Accrington, Corby, Middleton and Lithuania collectively represent a £1.3m investment for the Group, 80% of which has been allocated to its sites in the North West.
The centre was officially opened by Sara Britcliffe MP for Hyndburn & Haslingden, at a virtual launch event hosted from the site in Accrington. It offered guests a virtual tour of the new facility, as well as an overview of the site from Group CEO Ian Robb and Technical MD Stuart Roby.
Joining via video link, Sara Britcliffe MP said: “The Innovation Centre is a fantastic example of the type of investment needed in our area to help make the vision of a levelling up agenda a reality. As we start to ease restrictions, I am eager to put Hyndburn & Haslingden firmly back on the map, and work with local businesses like The Vita Group to make our area an innovation hub for the entire region, bringing forward more exciting projects like this, driving jobs and growing the next generation of innovative businesses and facilities.”
A huge congratulations to all involved and welcome to our new colleagues who will help to make this new facility a world-class centre of excellence, combining Vita’s technical expertise in foam chemistry with the latest state-of-the-art testing equipment and systems.
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