Plastics manufacturer Covestro and Fraunhofer UMSICHT have agreed to set up and operate a pilot plant for the chemical recycling of rigid polyurethane foam.

The plant is scheduled to go into operation in 2028 and process around 2,000 tonnes of end-of-life foam annually, according to Fraunhofer UMSICHT. The cooperation will focus on the smart pyrolysis technology developed by Covestro, which is said to convert hard-to-recycle PUR/PIR rigid foams – such as those from refrigerators or construction applications – back into high-purity aniline. This is then to serve as a feedstock for the production of MDI (methylenediphenyl diisocyanate) and, according to the information provided, achieves the same quality as conventionally produced material – with a CO₂ footprint reduced by up to 40 per cent. Fraunhofer UMSICHT states that it is contributing its process engineering expertise and existing infrastructure in the field of pyrolysis and chemical recycling to the project. The aim would be to scale the process from pilot scale towards industrial application, whilst optimising key operating parameters. The plant is also intended to supply sufficient product volumes for further testing and product development. The focus would be deliberately on rigid foam applications, as these are currently considered particularly difficult to recycle due to their highly cross-linked molecular structure. The technology would base on several years of research within the framework of the EU project “Circular Foam”, which is coordinated by Covestro. Following successful laboratory and demonstration trials, the pilot plant now is said to mark the next step towards the commercial implementation of chemical recycling solutions for rigid polyurethane foam.
 
Sources:

• Fraunhofer UMSICHT press release (10.3.2026)
• Photo: © Sabrina Bauer / Fraunhofer UMSICHT