Covestro has officially started up an elastomer pilot plant in Leverkusen, Germany, one of the first such facilities globally for these high-performance materials, according to Gasgoo. The project, which represents an investment in the tens of millions of euros, leverages German expertise in chemistry and engineering to advance the company's circular economy vision and support Europe's development of a closed-loop value chain for end-of-life elastomers.
The facility's core technology centers on Vulkollan, a high-performance polyurethane elastomer widely used in forklift tires, railway buffer components, automotive shock absorbers, and vibration control parts. Covestro's chemical recycling process can break down certain end-of-life Vulkollan materials into reusable chemical building blocks, achieving a recovery rate of over 90% by mass. Compared to fossil-based raw material routes, this process can reduce the carbon footprint by up to two-thirds.
From Lab to Industrial Scale
With the pilot plant in operation, the recycling technology has moved out of the laboratory. Covestro can now test different waste streams, continuously optimize the process, and accumulate data for future industrial-scale production. In addition to Vulkollan, the plant will also explore circular solutions for specialty cast elastomers and thermoplastic polyurethane (TPU).
Covestro is working with customers, recyclers, waste collectors, and logistics providers to build the collection and processing systems needed for closed-loop recycling. This collaboration aims to ensure a stable supply of end-of-life materials and controllable raw material quality, paving the way for an economically viable circular value chain for high-performance elastomers.
China as a Future Market
The experience gained from the Leverkusen pilot plant will also be introduced to China in the future, according to Gasgoo. China is one of the world's largest consumer markets for polyurethane elastomers, with growing demand for Vulkollan in automotive, material handling, and smart manufacturing sectors. The need for material recycling and carbon reduction is also becoming increasingly urgent. The Leverkusen plant will provide important technical foundations and reference pathways for Covestro's exploration of localized end-of-life elastomer recycling solutions in China.
