Prototypes made from chemically recycled material

Four of BASF’s partners in the ChemCyling project want to showcase first prototypes that were created during the pilot phase of the project at K 2019.
Stefan Gräter (left) and Andreas Kicherer (right) are working on the ChemCycling project to produce new products from chemically recycled plastic waste.BASF's ChemCycling project focuses on recycling plastic waste in chemical production rather than disposing of it. Plastic waste is converted into new raw materials by thermo-chemical processes and fed into the BASF Verbund in place of fossil resources. The resulting new chemical products have the same quality as products from fossil raw materials.

Jaguar Land Rover (JLR) has developed a plastic front-end carrier prototype for its first electric SUV, the I-Pace, out of Ultramid B3WG6 Ccycled Black 00564. “As part of our commitment to accelerate closed loop manufacturing across our operations, we are always looking for advances in technology that will help to reduce waste,” said Craig Woodburn, Global Environmental Compliance Manager at JLR. “The ability to convert consumer waste into safe, quality parts for premium products through the ChemCycling process is an important step in advancing our ambition to deliver a zero-waste future.”

Storopack used Styropor P Ccycled to make insulation packaging for temperature-sensitive pharmaceutical products as well as boxes for transporting fresh fish and protective packaging for electronic devices. “We were particularly impressed by the fact that Styropor P Ccycled can be used in food packaging. There are already various recycling options for Styropor, and ChemCycling helps raise the recycling share even further,” said Storopack’s Chairman of the Management Board, Hermann Reichenecker. Storopack and BASF are thus forging a new path in the circular economy.

Südpack produced a polyamide film and a polyethylene film that were processed into specially sealed packaging for mozzarella. Until now, multi-layer packaging has usually been considered to be only recyclable to a limited extent. “Film packaging must fulfill important roles: product protection, hygiene and shelf life while using a minimum amount of plastics. That is why it is made up of several materials and layers with various properties and barriers. Through innovations such as ChemCycling we come closer to solving the problems associated with recycling of flexible packaging,” said Johannes Remmele, Managing Partner of Südpack.

Schneider Electric manufactured a circuit breaker from chemically recycled Ultramid. “We actively assess the ability of secondary raw materials, such as recycled plastics, to meet our demanding quality standards, and stringent industry regulations and norms. We rely on BASF expertise to demonstrate the end-to-end sustainability benefits while offering an appealing cost. We are hopeful this experimentation with BASF will open room for more circular innovations in Energy Management and Distribution,” said Xavier Houot, Schneider Electric’s Senior Vice President Group Environment, Safety, Real Estate.

“The pilot projects with customers from various industries show that products made with chemically recycled raw materials exhibit the same high quality and performance as products made from primary materials. ChemCycling, which uses a mass balance approach to mathematically allocate a share of the recycled material to the final product, can help our customers to achieve their sustainability goals,” said Jürgen Becky, Senior Vice President Performance Materials. The certified products are indicated with the addition of “Ccycled” to their name. The prototypes presented at the press conference are part of the ongoing pilot phase of the ChemCycling project.

“With the ChemCycling project, BASF is aiming to process pyrolysis oil derived from plastic waste that currently cannot be recycled, such as mixed or contaminated plastics. If we are successful in developing the project to market readiness, ChemCycling will be an innovative complement to existing processes for recycling and recovery to solve the plastic waste problem,” said Stefan Gräter, head of the ChemCycling project at BASF.

If established recycling processes are combined with new ones such as chemical recycling, the experts believe that a 50% reuse and recycling rate for plastics worldwide can be reached by 2030 (today: 16%). The share of chemical recycling could then rise from 1% currently to around 17%, which is equivalent to recycling of around 74 million metric tons of plastic waste.

To move from the pilot phase to market roll-out, however, various issues will need to be resolved. The existing technologies for transforming waste plastics into recycled raw materials must be advanced and adapted for the use at industrial scale, in order to ensure the consistently high quality of the pyrolysis oil. BASF is currently investigating various options for supplying the company’s Production Verbund with commercial volumes of pyrolysis oil in the long term. Besides the technical issues, economic aspects also play a role. For chemical recycling to find acceptance in the market, regulators must also recognize the process officially as recycling. Within this framework, they have to define how chemical recycling and mass balance approaches can be included in the calculation of recycling rates required by law.

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