Covestro Launches Elastomer Recycling Pilot Plant in Leverkusen

Covestro has inaugurated a pilot plant for the chemical recycling of high‑performance polyurethane elastomers at its Leverkusen site in Germany. The investment, described as a “double‑digit million‑euro” outlay, moves the recycling process for Vulkollan elastomers from laboratory development to pilot‑scale operation. The technology breaks down selected end‑of‑life Vulkollan material into purified building blocks, enabling the recovery of more than 90% of the material by mass. Covestro claims the process can cut the carbon footprint by up to two thirds compared with fossil‑based virgin material.

The pilot facility will be used to test various waste streams, fine‑tune the recycling method and generate data needed for potential industrial‑scale production. Thomas Braig, head of Covestro’s elastomers business, said the plant is a key step in the company’s pre‑industrialisation journey, allowing it to demonstrate technical feasibility and systematically refine the process.

Covestro is also collaborating with customers, recyclers, waste collectors and logistics providers to set up collection and return systems for end‑of‑life elastomers. Beyond Vulkollan, the plant will be employed to explore recycling routes for selected specialty cast elastomers and thermoplastic polyurethanes (TPUs). Vulkollan is employed in applications such as forklift wheels, railway buffer elements, automotive jounce bumpers and vibration‑control components.