Covestro and the Fraunhofer Institute for Environmental, Safety and Energy Technology UMSICHT have signed a contract to operate a 2kt per year pilot plant for smart pyrolysis of rigid polyurethane foam waste. The plant will be operational by 2028.
The agreement scales up technology to convert insulation waste from appliance and construction into high-purity re-aniline for the production of MDI (methylene diphenyl diisocyanate). The resulting MDI meets the same purity standards as conventional MDI with up to 40% lower carbon footprint compared with conventional fossil-based production routes.
“The contract with Fraunhofer UMSICHT is a decisive step toward industrializing our smart pyrolysis technology,” said Dr Markus Dugal, head of process technology at Covestro. “This partnership combines our chemical and technology expertise with Fraunhofer’s process engineering capabilities and assets to scale a technology that is able to prove chemical recyclability of end-of-life polyurethane materials and that could fundamentally change how we source raw materials for MDI production. By recovering high-value molecules from waste streams, we’re turning the circular economy from vision into reality while significantly reducing the carbon footprint of our products.”
Under the agreement, Fraunhofer UMSICHT will draw on its pyrolysis research expertise and existing chemical recycling infrastructure to implement and scale up Covestro’s proprietary smart pyrolysis process. The pilot plant has an annual capacity to recycle 2kt of end-of-life foam per year. The resulting amount of aniline could be used to produce insulation for roughly 200,000 refrigerators.
The plant is scheduled to begin operations in mid-2028 and will process rigid PUR/PIR foam waste primarily from end-of-life insulation PU materials. The technology specifically targets rigid foam because it is notoriously difficult to recycle due to its crosslinked molecular structure.
Moving toward industrial implementation
“This project represents the culmination of several years of intensive joint research,” explained Prof. Dr.-Ing. Manfred Renner, head of Fraunhofer Institute UMSICHT. “It’s perfectly in line with Fraunhofer’s mission to bridge the gap between research and application: we are not just demonstrating technical feasibility but actively moving toward industrial implementation.”
Dr Alexander Hofmann, head of thermochemical conversion technologies at Fraunhofer UMSICHT, said, “The project is underpinned by our own research and technology developments in chemical recycling and downstream processing. The pilot plant will allow us to optimize process parameters at scale and provide sufficient material for further processing tests and market development.”
The smart pyrolysis process yields aniline with approximately 99% purity, suitable for producing recycled MDI that meets the same quality standards as conventional MDI.
Related news, Kia focuses on NVH reduction in EV2 development
