The plant, which shall create 35 new jobs, will be built at Chemical Park Delfzijl at the northern Coast of the Netherlands. It will use BioBTX's proprietary ICCP technology, which converts the type of mixed plastic waste that would otherwise be incinerated or put to landfill via catalytic pyrolysis into aromatic oil consisting of benzene, toluene and xylenes (B-T-X). These are the same building blocks the chemical industry uses today in coatings, pharmaceuticals and performance materials. They can also be used for the isocyanate production (MDI/TDI) of Covestro, out of which soft foam for e.g. mattresses or rigid foam for insulating refrigerators are made.

"We've followed BioBTX's progress for years and are very happy to now see the point where the technology proves itself at industrial scale," says Dr. Thorsten Dreier, Chief Technology Officer at Covestro. "This marks a very important step. Moreover, it processes mixed plastic waste instead of a single sorted stream, which is exactly the kind of recycling we need more of at scale to make a circular economy become reality."

In total, the plant is expected to recycle about 20,000 tonnes of waste and produce around 10,000 tonnes of renewable aromatic oil and 8,000 tonnes of sustainable by-products from it annually. Compared to conventional, fossil-based BTX production, the process is expected to cut greenhouse gas emissions of the resulting chemical building blocks by 70 to 80 percent.

“Reaching this key milestone in the development of BioBTX marks an important step in our journey towards our mission of making circular chemistry possible. I am very proud of the full BioBTX team and shareholders whose dedication and commitment has made this achievement possible. We are going to build our world’s first fully sustainable aromatic plant. A great accomplishment!” says Ton Vries, Co-founder and CEO of BioBTX.

This milestone concludes a 14-year journey from an idea in 2012 through lab- and pilot-scale to commercial execution. While this first plant focuses on mixed plastic waste, the ICCP technology is feedstock-flexible, with the potential to expand to other sources in the future, such as biomass.

The agreement marks a significant evolution in the two companies’ relationship – moving beyond traditional supply towards collaboration across the value chain, driven by a shared conviction that the future of mobility, energy and intelligent systems demands deep co-innovation. For Covestro, the partnership directly supports its “Sustainable Future” strategy by advancing innovations that enable circular solutions and drive growth in industries where material performance is becoming an increasingly important source of competitive advantage.

“At Covestro, we believe in the power of material science and collaboration to drive industry transformation – and this partnership with BYD is a strong example of that," said Lily Wang, President of Engineering Plastics at Covestro. "BYD's expanding portfolio represents some of the most exciting and demanding material challenges of our time, and that is exactly where Covestro’s depth of expertise becomes most valuable. We look forward to translating that expertise into tangible solutions together with BYD.”

“Covestro has proven itself as a trusted material innovation partner, and this agreement reflects our confidence in taking that relationship to a new level,” said Head of Materials, BYD. “As we continue to push the boundaries of what is possible in future mobility and beyond, we look forward to co-innovating with Covestro to develop the advanced material solutions that will redefine future industries and accelerate our global ambitions.”

Material expertise complementing BYD's cutting-edge applications

Under the MoU, the two companies will deepen their collaboration across new energy vehicles, power batteries, public transportation, energy storage, and new technology applications. The partnership will include joint innovation initiatives, technology co-development and strategic investment opportunities.

Covestro will provide dedicated R&D resources to co-develop new material technologies, volume supply security, early access to new material innovations and customized technical support. BYD in turn commits to proactively engaging Covestro in new projects and technology roadmaps across its entire business portfolio.

Covestro’s world-class material expertise in polycarbonate and polyurethane solutions, backed by decades of experience in automotive and electronics application, complements BYD’s key application areas:

• New energy vehicles: Proven material solutions in lighting, premium interior and exterior, and intelligent electronic components, delivering both aesthetic and functional value for smart mobility.
• Power batteries & energy storage: Lightweight, high-performance materials that balance safety, thermal management, and cost efficiency across EV and residential applications.
• Next-generation technologies: High-performance polymer solutions engineered for extreme demands – combining lightweight construction, structural integrity, thermal and electrical management, and durability to enable complex technology platforms of the future. 

Building a more sustainable industrial future

Beyond product co-development, the two companies are committed to advancing low-carbon and circular material solutions that reduce the environmental footprint of next-generation mobility, energy and intelligent systems. Covestro’s CQ (Circular Intelligence) labeled materials, made with at least 25 percent alternative raw materials, form a key part of this commitment.

With the acquisition, Covestro expands its production footprint for HDI derivatives and reaffirms its commitment in two important regions, while strengthening its ability to serve customers in the coatings and adhesives industry with greater flexibility and reliability.

HDI derivatives are essential building blocks for high-performance polyurethane coatings, adhesives and sealants. They are used in a broad range of applications, including automotive coatings, protective coatings for infrastructure, marine coatings, wood furniture, electronics and other demanding industrial applications.

“By adding these sites in Thailand and the US, we are strengthening our regional production capabilities and improving our ability to supply customers from locations close to them,” said Thomas Roemer, Head of the Business Entity Coatings and Adhesives at Covestro. “Reliable supply, regional availability and technical expertise are critical for our customers, especially in a challenging market environment. This acquisition helps us deliver even better on those needs.”

The two sites complement Covestro’s existing production network for HDI derivatives in major regions including Europe, Asia and North America. The additional capacities will further enhance Covestro’s ability to respond to customer demand and support long-term growth in high-performance and more sustainable coatings and adhesives applications.

“Strong customer relationships are built on trust, reliability and the ability to deliver value over time,” said Monique Buch, Chief Commercial Officer of Covestro. “This acquisition strengthens our position in a business where customers count on us for consistent quality, regional supply and application expertise.”

The acquisition follows Covestro’s earlier acquisition of the Resins & Functional Materials business from DSM and continued investments in organic growth, underlining the company’s commitment to the coatings and adhesives industry.

Fossil-based aniline production generates approximately 20 million tonnes of CO₂ emissions annually worldwide. To specifically reduce the carbon footprint of aniline production, Covestro uses a tailored microorganism in its bio-based process that converts industrial sugars from plant-based biomass into an intermediate product through fermentation. In a second step, chemical catalysis converts this intermediate into aniline with 100% plant-based carbon.

Continuous Fermentation Process: A Technological Breakthrough

Bio4PURConti aims to take this a step further: instead of the fed-batch method used so far, in which raw materials are added and product harvested in stages, the project targets a continuous fermentation technology for the first time. By using plant-based sugars, e.g. from hardwood biomass, it offers a renewable feedstock pathway. The resulting bio-based aniline is fully drop-in compatible with existing polyurethane value chains, meeting MDI specifications without requiring changes to downstream processes, making it a powerful lever for defossilization well beyond the chemical industry itself. The project scales from lab to 1.5 m³ semi-industrial demonstration at Bio Base Europe Pilot Plant (Ghent) and Covestro (Leverkusen), integrating cell recycling, real-time analytics and downstream processing. Key objectives include higher space-time yields and significant improvement in product carbon footprint.

"Bio4PURConti is a landmark project – not just for Covestro or the aniline market, but for the entire field of industrial biotechnology," says Dr. Markus Dugal, Head of Process Technology at Covestro. "Demonstrating continuous fermentation at semi-industrial scale for a high-volume raw material like aniline will set a new benchmark for what biotech processes can achieve in the chemical industry. Biology and engineering, when combined at scale, can fundamentally reshape how we produce the materials the world depends on."

A Consortium Driving European Biotech Leadership

The 10-partner consortium, spanning 7 countries, brings together leading industrial and academic organisations: Covestro Deutschland AG (Germany), Fibenol Imavere OÜ (Estonia), University of Stuttgart (Germany), Bio Base Europe Pilot Plant VZW (Belgium), Center for Advisory Systems in Technology, Dortmund e.V. – ZEDO (Germany), Norwegian University of Science and Technology – NTNU (Norway), Axel'One (France), VTT Technical Research Centre of Finland Ltd (Finland), Cluster Industrial Biotechnology – CLIB (Germany), and Asociación Española de la Innovación en el Marketing y la Inversión Sostenible – AEIMIS (Spain).

The project has a total budget of €8.4 million, with €7 million in EU funding, and runs for 42 months. Together, the consortium aims to significantly reduce the Product Carbon Footprint (PCF) of aniline in the future. As one of the world's leading aniline producers with a production capacity of over one million tonnes per year, Covestro is uniquely positioned to drive this transformation towards a more sustainable aniline production.

Funded by the European Union. Views and opinions expressed are however those of the author(s) only and do not necessarily reflect those of the European Union or the Circular Bio-based Europe Joint Undertaking (CBE JU). Neither the European Union nor the granting authority can be held responsible for them.
This project has received funding from the Circular Bio-based Europe Joint Undertaking under the European Union's Horizon Europe research and innovation programme under Grant Agreement No. 101292477.

The project is supported by the Circular Bio-based Europe Joint Undertaking and its members.

ISCC PLUS-certified chlorine from Covestro is produced by using electricity from renewable sources, supporting a more sustainable production process and contributing to lower greenhouse gas emissions.

As of January 2026, the entire CR production of ARLANXEO is based on ISCC PLUS-certified chlorine, marking an important milestone in the company’s sustainability journey and its commitment to a more sustainable value chain. 
This transition is resulting in an average reduction in global warming potential (GWP) of approximately 20% compared to 2025 levels¹, depending on the specific product grade.

“Integrating ISCC PLUS-certified materials into our production is a key step in reducing the environmental footprint of our CR rubber products,” said Niels van der Aar, Head of Sustainability at ARLANXEO. “It underlines our commitment to supporting customers with more sustainable material solutions while advancing transparency along the value chain by supplying corresponding product environmental footprint data for ARLANXEO’s entire CR product portfolio.” 
As a key chemical supplier to ARLANXEO, Covestro plays a crucial role in enabling this transition by supporting the availability of ISCC PLUS-certified chlorine.

“At Covestro, we support our customers in reducing emissions along the value chain by supplying more sustainable basic chemical raw materials from our multiple ISCC PLUS-certified production sites,” said Moritz Winterstein, Head of Trading Cluster Basic Chemicals EMEA at Covestro. “Our collaboration with ARLANXEO demonstrates how certified raw materials and renewable electricity can contribute to lowering the product environmental footprint of downstream applications and support customers in achieving their sustainability targets.”

The introduction of ISCC PLUS-certified feedstock, like ISCC PLUS Chlorine, strengthens the position of ARLANXEO as a leading supplier of more sustainable elastomer solutions, particularly for industries with ambitious climate targets, such as automotive, construction, industrial and adhesive applications.

In addition, ARLANXEO can also offer Baypren® Eco grades combining ISCC PLUS-certified chlorine and ISCC PLUS-certified butadiene, enabling further reductions¹ in environmental impact and supporting customers in achieving their sustainability targets without any compromise in performance.

_{¹ Relative changes in Global Warming Potential – GWP100 incl. biogenic [kg CO₂e] 
Example of the relative change of the Global Warming Potential (GWP100 incl. biogenic [kg CO₂e] for Baypren^® 116 M45 as from January 2026. In the graph also the Baypren^® Eco 116 M45 is added as Eco option. A full Product Environmental Footprint report is available upon request.}

The successful implementation exemplifies how “The Material Effect” elevates materials into solutions that matter. This was achieved through an innovative partnership between Toyota Motor Corporation, Toyota Motor Kyushu, INC., parts supplier Kojima Industries Corporation, and Covestro. Together, the four companies conducted comprehensive testing and evaluation to ensure the recycled material met all performance requirements without compromising quality standards.

Integrating high levels of post-consumer recycled content into visible premium interior parts has typically been a high technical hurdle - making use in such areas difficult with many resins - yet the Bayblend® resin used in the LEXUS ES demonstrates that this barrier can be overcome. This marks one of the first integrations of 35% post-consumer mechanically recycled content in visible components within a premium automotive segment.

Meeting Performance Standards 

By fusing premium materials with specialized expertise, Bayblend® T85X R35 CQ delivers on all specifications for multiple Lexus ES interior parts while incorporating post-consumer recycled content. The material delivers essential performance characteristics including durability, surface quality, dimensional stability, and processability while integrating seamlessly into existing manufacturing processes.

"This collaboration demonstrates that more sustainable materials can meet the required standards of premium automotive applications," said Fumihiro Togashi, Global Strategic Account Manager, Toyota Group at Covestro. “By working closely with Kojima Industries Corporation, Toyota Motor Corporation, and Toyota Motor Kyushu, INC. throughout the development process, we've proven that environmental responsibility and product excellence can go hand in hand.”

The material's versatility extends beyond pre-colored applications to paintable components, enabling use in both visible interior areas and exterior parts. Covestro ensures consistent quality and supply reliability by utilizing one of the most dependable post-consumer recycled sources in the plastics industry. The company's global production footprint further enhances cross-regional supply stability and provides capacity to support anticipated volume increases as more sustainable automotive materials gain broader market adoption.

Advancing Circular Economy Goals

This adoption aligns with the four companies' sustainability strategies. Covestro positions the circular economy as a strategic pillar and continues expanding related product families. Toyota Group leads industry initiatives in environmental stewardship and resource circularity. In parallel, Kojima Industries Corporation and Kojima Group drive sustainability across manufacturing and supply chains, supporting circular material use and responsible sourcing.

The partially recycled plastic solution supports fulfilling expected quotas related to the ELV Regulation, demonstrating how more sustainable materials can simultaneously meet performance and regulatory requirements in the automotive industry.

Looking Ahead

Covestro continues expanding its circular economy solutions through “The Material Effect” approach, including the recently launched "RV line”, part of the post-consumer recycled R series – featuring recycled end-of-life vehicle materials such as headlamps, with third-party certification. These developments address critical automotive industry challenges amid tightening environmental pressures and regulatory requirements.

The innovations will contribute to EU ELV recycling targets toward 2032. Through its global production and supply network, Covestro supports decarbonization and resource circularity in mobility while enabling automotive manufacturers to meet evolving regulations without compromising product quality - truly elevating materials into solutions that matter.

Across modern football, materials play a role in helping enable speed, control, comfort, durability and reliable performance, from equipment and apparel to infrastructure and digital connectivity.

Covestro is highlighting this “material effect” behind football: the often unseen contribution of material science to the way the sport is played, experienced and connected around the world.

The athletes enabled by materials

Modern football has become faster, more precise and more connected. Players sprint more, press harder, change direction faster and perform under intense physical and mental pressure. Behind this evolution are better training methods and data analytics, but also materials that help make high performance more reliable.

The football itself is a good example. Modern balls use advanced materials, carefully engineered surfaces and precise construction methods to support consistent weight, shape, rebound and flight behavior, even under demanding weather conditions. Compared with traditional leather balls, today’s footballs are designed for greater reliability and more predictable performance.

Footwear has also changed fundamentally. Modern football boots combine lightweight uppers, flexible structures and high-performance sole plates to support grip, acceleration, agility and ball control. The contact between player, pitch and ball has become a highly engineered interface.

Sportswear plays its part as well. Lightweight, breathable and durable textiles can help manage moisture and comfort during high-intensity performance. Covestro’s INSQIN^® waterborne polyurethane technology enables high-performance textile coatings that can provide softness, water resistance and long-lasting performance while supporting more sustainable manufacturing approaches.

Materials beyond the pitch

The material effect extends beyond players and equipment. Stadiums, training facilities and broadcast infrastructure also depend on advanced materials.

Lightweight and durable polycarbonate solutions have been used in large-scale roofing applications. They can help create weather-resistant structures that protect spectators while reducing weight and maintenance requirements.

At the same time, football is becoming increasingly digital. From connected match technologies and live analytics to broadcast systems, streaming platforms and fan experiences, every match depends on the reliable flow of data. Advanced polymer materials help protect cables, connectors and electronic components and support the infrastructure that brings the game to fans around the world.

As sport becomes more connected, the infrastructure behind it becomes more demanding. Data centers, communication networks and electronic systems require materials that can support reliability, protection and performance at scale.

Innovation is a team sport

The evolution of football shows how performance is rarely the result of a single factor. It comes from the interaction of talent, preparation, technology and the right materials.

The same applies in business. As customer challenges become more complex and markets move faster, innovation increasingly depends on collaboration across disciplines, industries and value chains.

“Innovation today needs to be fast, focused and collaborative,” said Monique Buch, Chief Commercial Officer at Covestro. “Co-creation with customers works much like collaboration in a football team: different strengths come together around one shared goal, focusing their preparation to secure the win, and trust and speed making the difference.”

From the pitch to the stadium and from equipment to digital infrastructure, football shows how advanced materials can help shape performance where it matters most.

The new compressor operates on the principle of a heat pump: Water vapor is generated during the production processes for TDI, a component of flexible foam. Covestro requires steam for many production processes, but the steam produced during TDI manufacturing is not hot enough. Therefore, some of it is released into the environment as waste heat. The compressor raises the steam to a higher temperature and pressure level, making it suitable for use in production processes.

“Energy efficiency is a key lever for transforming our production towards climate neutrality and a circular economy. The principle is: the less energy we need, the better,” says Thorsten Dreier, CTO of Covestro. “That’s why we’re using every opportunity to make our production even more energy-efficient with modern, innovative process technologies.” From 2005 to 2022, Covestro already reduced its energy consumption by around 40 percent. The next goal: By 2030, the company aims to consume 20 percent less energy per ton of product produced than in 2020.

This project is part of an energy efficiency strategy with which Covestro is driving its transformation to climate-neutral production. As part of the master plan, the company is continuously searching for further potential energy efficiency measures. “With these projects, we are not only reducing our CO₂ emissions, but also saving on energy costs,” says Andreas Doerfer, Global Energy Excellence Manager. “To achieve our energy efficiency target, we must utilize all available options for using the waste heat generated in our processes to manufacture our products.”

Following the installation of an energy-efficient reactor at the TDI plant last year, the new compressor for the Dormagen site is the next major project to future-proof the location: “This investment clearly demonstrates Covestro’s long-term belief in the Dormagen site and its commitment to investing here,” says Philip Bahke, Head of Operations in Dormagen and North Rhine-Westphalia.

Construction is scheduled to begin at the end of this year, with the compressor expected to go into operation in mid-2027.

For Schleswig-Holstein, the project represents an important step on the path to climate-neutral transformation of the state. This was emphasized by Tobias Goldschmidt, Minister for Energy Transition, Climate Protection, Environment and Nature of the state, at the groundbreaking ceremony: “The energy transition is Schleswig-Holstein's project of our time. The rapid expansion of renewable energies is a booster for our business location Schleswig-Holstein and makes future-oriented projects like the heat battery possible in the first place. Covestro and Rondo impressively demonstrate how they are driving the energy transition forward with innovative strength, technological know-how, and full confidence. Projects like this contribute significantly to energy sovereignty and to achieving our climate neutrality goals.”

The 100 MWh Rondo Heat Battery (RHB) is scheduled to go into operation by the end of 2026. Breakthrough Energy Catalyst and the European Investment Bank (EIB) are supporting the project. The battery will produce ten percent of the required steam at the site, saving up to 13,000 tons of CO₂ emissions per year.

"As an innovation company, we are always excited when we can further develop and test promising ideas that can bring us closer to our goals of a circular economy and climate-neutral production," says Dr. Thorsten Dreier, CTO of Covestro. "The heat battery is such an idea: a new technology that enables us to take another step forward on our path to a sustainable future."

The Rondo Heat Battery combines centuries-old materials with modern automation: electrical energy is stored in the form of heat – with the help of bricks that have been used as heat storage in steel mills for centuries. The heat drives an ordinary boiler that delivers emission-free steam. With electricity from renewable energy sources, a constant amount of steam can thus be continuously generated.

“This project shows how two of Europe’s central challenges can be solved together,” said Eric Trusiewicz, CEO of Rondo Energy. “As renewable power expands, it increasingly creates daily periods of abundant, low-cost electricity. At the same time, European industry needs reliable, affordable energy to remain competitive. Together with Covestro, we are demonstrating that clean industrial heat can be both highly reliable and a powerful tool for balancing the grid — while building the energy infrastructure needed to strengthen Europe’s industrial base and energy security.”

For Covestro, steam generation is an essential part of the production process and accounts for a large portion of energy consumption. The steam at the Brunsbüttel site is currently still generated with natural gas. Based on the experience with using the Rondo Heat Battery in Brunsbüttel, Covestro is evaluating whether deployment on a larger scale is possible.

Read more here ›

“For ten years, our people have proven that breakthrough innovations happen when curious minds meet courageous hearts,” said Markus Steilemann, CEO of Covestro. “I'm incredibly proud of our global team. Their passion, creativity, and resilience have formed the foundation of our culture. Thanks to their dedication, we continue to overcome challenges, seize opportunities, and create solutions that make the world a brighter place.”

A decade of transformation

Over the past decade, Covestro has achieved major milestones on its journey toward becoming a more innovative, sustainable, and resilient company. Since 2015, Covestro has invested more than 4 billion euros in expanding and modernizing its global operations, with a clear focus on sustainable production technologies. A significant step was the successful integration of DSM’s Resins & Functional Materials business, which strengthened Covestro’s position in sustainable coating solutions and broadened its customer base.

The company has driven forward key technologies for renewable-based raw materials, pioneered new chemical recycling methods for high-performance plastics, and signed 11 power purchase agreements to significantly increase the share of renewable energy in its operations. In recognition of its commitment to innovation and people, Covestro has repeatedly been named a top employer in multiple regions, including Greater China, where the company operates 10 production sites alone.

People and values at the core

Covestro’s success over the past decade is rooted in its purpose “to make the world a brighter place” and a corporate culture defined by its C³ values: Curious, Courageous, and Colorful. These values shape how the company approaches innovation and collaboration. Curiosity drives Covestro to explore new solutions; courage empowers teams to make bold decisions; and diversity of perspectives fosters creativity and resilience.

The company’s “We Are 1” culture reflects this spirit of collaboration and shared purpose, connecting more than 17,000 employees across regions, functions, and backgrounds. It is this collective mindset that has allowed Covestro to evolve from a newcomer in 2015 into a trusted global partner shaping sustainable material solutions.

Celebrating a global community

To mark its 10th anniversary, Covestro is celebrating with employees around the world and launching initiatives that reflect the company’s deep appreciation for its people.

In Germany, large-format posters are being installed in and around production sites as a visible expression of thanks to employees. These posters complement small gatherings and celebrations taking place at the sites and within the plants. In addition, Covestro, together with the Works Council, is supporting local food banks at its German sites with donations – a way to also say thank you to the communities, with a special focus on those in need. In addition, a specially designed Covestro-branded bus is now on the road in Leverkusen – featuring materials produced by Covestro itself, including polycarbonates in the windows, polyurethanes in the seats, and special coatings for the exterior surfaces. 
In North America, Covestro has initiated the “10 for 10” corporate volunteering campaign, aiming to reach 10,000 volunteer hours by September 2025. For every recorded volunteer hour, Covestro donates 10 meals to local food banks, with a goal of up to 100,000 meals in total. This initiative reflects the company’s ongoing commitment to supporting the communities where it operates.

Across China and the Asia-Pacific region, the anniversary celebrations focus on employee recognition and community engagement. Highlights include a video campaign capturing personal stories from employees who have shaped Covestro’s first decade, a photo initiative where colleagues form “10” or “We Are 1” shapes, and the “Well Together” wellbeing program, which encourages employees to participate in activities such as running, cycling, and hiking to promote health, teamwork, and inclusion.

Looking ahead

As Covestro enters its second decade, the company remains committed to driving innovation and shaping a sustainable future. Strategic priorities include achieving full circularity, reaching climate neutrality across operations, accelerating the shift from fossil-based to renewable raw materials, and expanding digital capabilities, including the application of artificial intelligence to improve efficiency and develop new solutions.

Partnerships will play a central role in this transformation. Under this lens, the potential partnership with XRG also plays an important role, where we aim to jointly drive innovation, expand sustainable material solutions, and strengthen our position in global markets. By working closely with partners across value chains, Covestro is determined to enable next-generation materials that address global challenges while supporting sustainable growth.

Covestro uses natural gas as a feedstock as well as an energy source. The partnership will enable the supply of natural gas sourced from INEOS’ global LNG portfolio, providing a stable and predictable feedstock and energy stream for Covestro’s European operations. This strategic collaboration addresses the critical need for secure and diversified energy sources in Europe.

David Bucknall CEO, INEOS Energy said: “Our goal is to supply customers with vital energy throughout the energy transition, not just at the end. That means maintaining competitive hydrocarbon supplies as alternatives emerge and grow. This long-term LNG deal with Covestro does exactly that, providing reliable, cost-effective energy to help our industrial partners manage volatility and avoid shortages."

Thorsten Dreier, Chief Technology Officer of Covestro, added, "Securing a stable, competitive and predictable gas supply is essential for our operations right now. This agreement with INEOS provides us with the long-term security we need to maintain our production and contribute to the European economy. We value INEOS' commitment to supporting European industry and their proactive approach to addressing the region's energy challenges. This contract is an important building block for us as a company in the energy intensive industry to transition towards an affordable renewable energy supply."

This agreement reinforces the shared goal of both companies to maintain a strong and competitive industrial base in Europe. By ensuring a reliable gas supply, INEOS and Covestro are taking real, tangible steps to secure the future of their European manufacturing assets.

INEOS first entered the LNG sector in June 2022, signing a 20-year agreement with US-based Sempra Infrastructure to supply 1.4 million tonnes of LNG annually from the US Gulf Coast.

"With our automated laboratory, we can work together with our customers on the future of coatings and adhesives. Because it operates almost completely autonomously and learns from our existing knowledge and data lake as well as newly generated data, it makes the process of optimizing and developing formulations many times more efficient and precise. This allows us to optimize existing formulations faster or even develop completely new formulations for and together with our customers. We can say: We are reaching a new level of modern research," says Thomas Büsgen, head of the laboratory.

Testing Formulations with Covestro Binders and Crosslinkers 

Specifically, the new laboratory will test formulations with Covestro binders and crosslinkers for coatings and adhesives. Their clever selection ensures properties such as hardness, adhesion, opacity, gloss, or durability. Such formulations typically consist of seven to 15 components, whose combination determines the properties of the final product. The resulting high number of possible combinations means that standard formulations are usually used. The new laboratory now enables more extensive test series, also thanks to the computer-aided design of test series and the use of automation.

"Our new automated laboratory gives us more possibilities for testing formulations. It relieves our specialized laboratories of their standard tasks and can analyze samples more systematically. This allows us to focus our expertise and experience even more on customer-specific topics or try approaches we couldn't have implemented otherwise," says Martin Merkens, Head of Sales & Market Development EMLA in Covestro's Coatings and Adhesives business entity. “This will particularly help us in the area of circular economy: Alternative raw materials, for example bio-based or recycled materials, can be tested faster and evaluated for their properties in the final product.”

Facility to Run Tens of Thousands of Tests Annually 

The new facility can operate 24 hours a day, 7 days a week. The goal is to run tens of thousands of tests annually. This sets a new standard in terms of number, variety, precision, and testing speed. Another advantage: The automated laboratory generates a large amount of structured data. The knowledge about formulation possibilities and influencing factors thus will grow rapidly. The collected data, combined with measurement data from existing studies, is evaluated using special machine learning algorithms to further improve formulations. Artificial intelligence is also used to predict new experiments based on property goals and simultaneously verify them in the automated laboratory – creating a self-learning system.

In addition to formulating water- and solvent-based 1K and 2K systems, the automated laboratory also performs numerous material tests on the raw materials themselves, their formulations, and applied films. Application can even take place in different climates in the lab to simulate product use under application conditions. The progressing laboratory digitalization across Covestro also enables easy forwarding of generated samples to more specialized testing laboratories. This makes it possible to supplement the datasets with market-specific test results and identify relevant dependencies more quickly.

Covestro at European Coatings Show 2025 in Nuremberg 

At the European Coatings Show from March 25-27 in Nuremberg, experts from application development and segments such as automotive, printing & packaging, or construction & architecture will be present to discuss new, joint approaches made possible by the laboratory with customers. Visit the company's booth in Hall 4A, Stand 438. There you can learn more about the laboratory and other innovative material solutions and technical developments for the coatings and adhesives industry.

Follow further updates on this topic here. 

"The successful completion of this project shows that climate protection and competitiveness can go hand in hand," says Dr. Philip Bahke, Head of the North Rhine-Westphalia Site Network. "The modernized plant sets new standards in energy efficiency and underlines our path toward climate-neutral production. In light of persistently high energy costs, the project significantly strengthens the competitiveness of TDI production in Europe. My special thanks go to the entire project team, who professionally implemented this complex modernization during ongoing operations."

More Efficient Processes for More Sustainable Products

The modernized plant consumes 80 percent less energy than conventional processes, achieving a CO₂ reduction of 22,000 tons per year. This is made possible by a new reactor weighing over 150 tons (330,700 lbs) and almost 20 meters (65.6 feet) high, which uses the generated reaction energy for steam production. Covestro started the modernization in summer 2023. In total, the project installed over 3.5 kilometers of new pipelines, around 14 kilometers of cables, and hundreds of new equipment, valves, and monitoring instruments in the plant.

"In Dormagen, we operate Europe's largest TDI production plant. With the successful modernization, we can now offer our customers TDI with an even better carbon footprint," explains Dr. Christine Mendoza-Frohn, Head of Sales Performance Materials for the EMEA and LATAM regions. "This supports our customers in achieving their own sustainability goals and strengthens our position as a reliable partner for climate-neutral and circular solutions."

New Global Energy Efficiency Targets Presented

During the event, Covestro also presented its new, ambitious energy efficiency target for global production. The company targets a 20 percent reduction in CO₂ emissions from energy use per ton of product by 2030 compared to 2020, underlining the central importance of energy efficiency as a lever for achieving operational climate neutrality by 2035. The Dormagen TDI plant, with its annual capacity of 300,000 tons, serves as a prime example of the successful transformation of existing production facilities toward greater energy efficiency.

The Federal Ministry for Economic Affairs and Climate Action (BMWK) has supported this modernization through its federal funding program for energy and resource efficiency.

Further press release:

• Covestro publishes energy efficiency target ›

“While the decision to shut down the PO11-unit is difficult, we must ensure all assets within our portfolio are a long-term strategic fit,” said Aaron Ledet, executive vice-president I&D and Supply Chain at LYB. “We are prioritizing our core assets which play a key role in our technology differentiation and circularity strategy or provide attractive returns over the cost of capital. We take our obligations towards our employees, European employee reps, councils, and unions seriously. We have engaged with them in line with these obligations and will continue to do so. We would like to thank them for the constructive dialogue. We are also in communication with customers, suppliers and other parties across the value chain and will continue to do business as usual. There is no change to our working relationship, and we continue to focus on providing an exceptional customer and supplier experience.”

"As part of our Sustainable Future corporate strategy, we’re continuously working to optimally position Covestro to be a reliable partner for our customers and to operate competitively in a challenging market environment," said Hermann-Josef Dörholt, Head of the Performance Materials Business Entity at Covestro. "Due to global overcapacities, persistently weak demand, and high costs in Europe, we have jointly decided with LYB to close the PO11 plant. We will support LYB in implementing this change as socially responsibly as possible. At the same time, we remain committed to the European market and will continue to supply customers with our renowned polyether polyols portfolio.”

The Maasvlakte site, a joint venture between LYB and Covestro, has been operational in the Rotterdam region since 2003. Between now and the end of 2026, LYB will carry out a process to safely shutdown and prepare the demolition of the asset.

In 2024, LYB announced a strategic review of European assets of its Olefins & Polyolefins (O&P) and Intermediates & Derivatives (I&D) business units. LYB has taken the next step in evaluating the option to seek alternative ownership for the O&P sites in the strategic assessment. At this time no decisions have been made and various outcomes remain possible.

The film documents the development of the innovative solar racing car “Covestro Adelie” and the participation of the team of around 50 students in the Bridgestone Solar World Challenge 2023 in the Australian outback. Using state-of-the-art technology and innovative high-performance materials from Covestro, the students have designed an energy-efficient and environmentally friendly racing car. The solar racer paves the way for the development of environmentally friendly vehicle technologies.

From design to the race track

The documentary follows Team Sonnenwagen from the design of the “Covestro Adelie” through to qualifying and then the race across Australia. In addition to the technical aspects of the racing car, the documentary also focuses on the emotions, challenges and tireless team spirit behind this ambitious project. In addition to the interviews with the dedicated students, numerous experts also have their say, including the renowned science journalist Ranga Yogeshwar, the Minister for the Environment, Nature Conservation and Transport in NRW, Oliver Krischer, the former Opel boss and CEO of Continental, Dr. Karl-Thomas Neumann, and Sucheta Govil from Covestro.

Available online on YouTube

“We are extremely proud that there is a documentary about our team and the great work of the past two years. This project is so important because it can play a small part in solving an important sustainability problem - greenhouse gas-neutral mobility,” says Sonnenwagen team leader Leonie Brandt.

The documentary “SONNENWAGEN - Future Mobility” will be available online on Team Sonnenwagen's YouTube channel from August 27, 2024 at 6:15 p.m. The trailer is already available HERE.

The first prize went to Isabel Payne, a Product Design Engineering student from the Glasgow School of Art. She created ‘SafiCase’ – a device for cleaning and steam sterilising re-usable menstrual cups using minimal water. The case is entirely self-powered, using a solar battery for the sterilising circuit. It is targeted at women who want something to use when they are nowhere near an electricity source or any running water. It is collapsible, so can be carried easily.

Chairman of judges, Richard Brown, said: “This is a great solution to safely clean a menstrual cup without power and to maintain hygiene. This product uniquely addresses the off-grid challenge and meets a very clear social need, not just for the traveller, but also, for example, displaced people. It was very well researched and is a worthy winner with a product idea that could be commercialised.”

Isabel said: “It means such a lot to have a platform for dealing with the issue of period poverty, which is rarely spoken about, despite affecting so many people worldwide and around 40 per cent of women in the UK. I hope this design helps bring awareness for reusable options and helps other people decide to invest time in designing more solutions, as there is very little innovation in this area.”

The judges awarded second place to Jake Lee (Product Design Engineering), also of Glasgow School of Art, for his product ‘SkinTemp’, a cold-water temperature sensor that alerts users to dangerous drops in body temperature. In third place was Glasgow School of Art’s Jem Mitchell, also a Product Design Engineering student, who produced ‘Sentree’, a solar powered sonic deterrent that protects trees from being overgrazed by animals such as deer.

Notes to editors
Established in 1985, Design Innovation in Plastics is the longest running student plastics design award in Europe. For more information visit www.designinnovationplastics.org.

The Institute of Materials, Minerals and Mining (IOM3) is a major UK engineering institution and is the professional body for the advancement of materials, minerals and mining to governments, industry, academia, the public and the professions. For more information visit www.iom3.org.

The Worshipful Company of Horners is one of the oldest livery companies in the City of London, formed to regulate the horn-working trade. In 1943 it adopted its modern equivalent, the plastics industry. For more information visit www.horners.org.uk.

Andrea Firenze, General Manager at Covestro Spain, said: "Commitment to sustainability is a non-negotiable part of everything we do, and this agreement allows us to take a further step in our mission to make energy use as efficient and sustainable as possible throughout our value chain. In the same way, through this alliance with bp, we will continue to promote the strategic positioning of our Tarragona site through a more stable, more predictable and, above all, more sustainable long-term energy supply." 

Jason Tate, head of European power trading and origination at bp, said: “This agreement highlights not just bp’s commitment to Spain. It’s an example of how bp is continuing to invest in developing our expertise and capability to support European commercial and industrial customers to help meet their decarbonization goals.” 

Under the terms of the power purchase agreement, bp has agreed to supply Covestro with a high double-digit GWh volume of renewable electricity for a period of 10 years, backed by an equivalent volume of Guarantees of Origin (GoO). The current plan is to source the renewable power from an already operational solar photovoltaic (PV) farm, in Teruel, in the Aragon region of eastern Spain, with which bp has an offtake agreement in place. 

Covestro aims to convert its production to 100 percent renewable energy as part of its climate goals until the end of 2035. At the end of 2023, Covestro fulfilled approximately 16 percent of its global electricity needs from renewable sources. 

bp has been active in the Spanish natural gas market for more than 20 years, through management of their LNG portfolio, and supply to C&I customers. In the power and renewables space, bp manages a portfolio of solar offtake and also supplies renewable power, a key growth area for the bp trading business in Europe. 

*Estimate based on a calculation of Scope 2 market-based CO₂ emissions user may have had to report if buying the same amount of grey electricity from their current local supplier.

The Breakthrough Energy Catalyst foundation set up by Bill Gates and the European Investment Bank (EIB) are supporting this installation of the Rondo RHB100 heat battery, which is scheduled to begin operation at Covestro’s Brunsbüttel site at the end of 2026. The project will then produce ten percent of the steam required at the site, saving up to 13,000 tons of CO₂ emissions per year.

Rondo Heat Batteries combine century-old materials and cutting-edge automation to capture electricity and deliver high-temperature heat and power. Electrical energy is stored as heat, using bricks that have been used for heat storage at steel mills for centuries. The heat powers an ordinary boiler to deliver zero-emission steam. Renewable electricity can be intermittently stored when there is an excess available and a constant amount of steam can still be generated continuously.

"As an innovation company, we are always excited when we can further develop and test promising ideas that can bring us closer to our goals of a circular economy and climate-neutral production," says Dr. Thorsten Dreier, CTO of Covestro. “The heat battery is such an idea: a new technology that allows us to go one step further on our way to a sustainable future.”

“Rondo Heat Batteries deliver deep decarbonization by changing the fuel, not the factory,” said Eric Trusiewicz, CEO of Rondo Energy. “We’re honored to be working with Covestro to prove our safety, reliability, and efficiency under real conditions on a large scale over a long period of time. And we’re excited to be deploying in Brunsbüttel, where large flexible electricity loads are particularly valuable to the electricity grid.”

For Covestro, steam generation is an important part of the production process and accounts for a large proportion of energy consumption. The learnings from this first heat battery installation will provide experience and insights for Covestro to be able to assess whether larger-scale deployments are possible.

In addition to the reduced complexity of the new production process, the connection to the existing infrastructure in Antwerp with four production lines for polycarbonate also has an advantageous effect, as it combines global scale in production with the flexibility of a stand-alone unit.

"The new production process is the first and only one of its kind in the world and enables us to offer a broad portfolio of material innovations," says Sucheta Govil, Chief Commercial Officer at Covestro. "With the new plant, we can now produce and launch new polymer materials on an industrial scale much faster than before. This is the result of several years of development work by our research and process technology teams, as well as our long-term experience with polycarbonates. In our Solutions & Specialties segment, we focus on sophisticated products with a high pace of innovation, which is a key success factor since customer requirements change quickly. The new production line is a prime example of how we implement this strategy and support our customers to the best extent."

"Compared to pure polycarbonates, the copolymers open up new possibilites for us to integrate further functionalities and properties into our materials," explains Lily Wang, Global Head of the Engineering Plastics business unit. "These can range from improved mechanical properties, a higher resistance against chemical attack to an enhanced flame retardancy. By that, we can offer innovative materials that meet the high requirements of our customers in a wider range of applications. We will focus first on materials for the electrical, electronics and healthcare industries, while future innovations might focus on mobility and other trends." To understand its customers' needs, Covestro will showcase some of the products that could be produced with the new plant at the Chinaplas exhibition in Shanghai in April and looks forward to talking to customers about these innovative material solutions.

Covestro is already making an important contribution to more sustainable vehicles and infrastructure with innovative material solutions. In this context, the company is also working in close partnership with Team Sonnenwagen, a team of around 50 students from RWTH Aachen University and Aachen University of Applied Sciences. It is dedicated to developing racing cars that are powered solely by the sun. Covestro shares the students' enthusiasm because the racing cars, with their high efficiency and use of new technologies and materials, are a powerful symbol of the mobility of the future. That is why Covestro is supporting the team as the main sponsor with material solutions and technical exchange for another two years.

"In order to create a climate-neutral and circular mobility of the future, business, politics and society must pull together. At Covestro, we are contributing to this transformation by offering the automotive industry raw materials based on biomass or recyclates and manufacturing our products as energy-efficiently and with as few emissions as possible," said Dr. Thorsten Dreier, Chief Technology Officer, during the discussion. "At Covestro, we want our production to be climate-neutral by 2035 and are relying on energy from renewable sources and innovative process technologies to achieve this."

Covestro's material developments focus on solutions for the major trends of electromobility, autonomous driving and the need for individualization. These include material solutions for compact, powerful and safe batteries for electric cars and robust charging systems, plastics for connected mobility and the Internet of Things, as well as various products for aesthetic and functional automotive interiors and exteriors.

Covestro has been supporting Team Sonnenwagen in the development of ever more efficient solar racing cars since 2017. The students are working together in a wide range of disciplines to improve the aerodynamics, optimize the chassis and install a particularly efficient photovoltaic system and battery. Participants at the NRW Mobility Day were able to take a look at the Covestro Photon, the predecessor model to the current Adelie racing car, and talk to team members. With the Photon, Team Sonnenwagen became European champion at the European solar race in Zolder, Belgium, in September 2022.

This site of Epurex Films, a wholly owned subsidiary of Covestro, houses research & development, application development and production for the semi-finished products. The company has invested a low double-digit million Euro amount in the expansion of the center of excellence for TPU-Films.

The new capacity is intended to meet the growing global demand for multilayer TPU films. They are used in automotive interiors and construction, among other applications. Breathable, water-impermeable specialty films have also proven their worth in wound care and outdoor clothing.

"With this capacity expansion, we are strengthening our Bomlitz site and our position as a leading supplier of technical specialty films," said Dr. Thorsten Dreier, Covestro's Chief Technology Officer, at the inauguration. "At the same time, we are investing in promising technologies and applications and creating new jobs."

For Aleta Richards, global head of the Specialty Films business entity, the expansion offers opportunities to respond even better to individual customer needs and offer more sustainable products. "For some time now, we have also been developing customer-specific solutions with films made from alternative raw materials, as we are also seeing increasing demand in this area. The development and production of partially biobased products is therefore to become a new focus at the Bomlitz site."

Covestro is fully geared toward the circular economy and aims to become climate-neutral by 2035. In 2022 the Bomlitz site has switched its power supply completely to green electricity. Epurex Films is one of Covestro's three competence centers for specialty films in Germany, along with Leverkusen and Dormagen.

"With our multi-layered campaign, we are pursuing the goal of establishing contacts with many partners to advance the industry on its path to climate neutrality and the circular economy," explains Dr. Christian Haessler, one of the two project managers for K 2022 at Covestro. "This communicative 360° approach was also expressed in the motto of our appearance at K 2022, 'Crafting Connections With You'." The Red Dot label has established itself internationally as one of the most coveted seals of quality for good design.

Rüdiger Maeßen, CEO Europe at Uniplan, is equally positive: "The good co-creative collaboration and the innovative concept were fundamental to the success of this holistic campaign. Together with Covestro, we have driven the circular economy agenda in the industry by creating an authentic exchange on multiple channels. Therefore, we are even more pleased that the sustainable campaign approach not only convinced the global target audience, but also the jury of the Red Dot Award."

Creating connections with digital platform

In order to connect with target groups around the world at an early stage and offer them a holistic, long-term experience as a "home base," Covestro and Uniplan designed a digital event platform called "SPACE." It went live several months before the start of the trade show and provided information about planned activities at the booth and the company's major highlight topics:

• Crafting Circular Economy
• Crafting Electrification
• Crafting Sustainable Living
• Crafting Smart Designs

A stage for current trends

These Topic Clusters also formed the basis for the second pillar – the integrated STAGE booth concept. As the other Covestro project manager Dr. Christopher Stillings explains, "Not only the exhibits and topic clusters, but also the wide-ranging lecture program in the central Talks Arena were tailored to these topics. Inspiring guests from well-known companies and universities – all actors in their respective fields – captivated the audience with keynotes on current trends and technologies and during panel discussions. Not only booth visitors participated, but also viewers around the world who followed the live broadcasts via social media."

Another highlight is the Color Material Finish (CMF) Sample Library, a collection of plastic samples that makes materials visible and tangible. Part of Uniplan´s and Covestro's STAGE concept is that the booth – or parts of it – can be used repeatedly for further exhibitions. Sustainability aspects and the reduction of CO₂ emissions were also at the forefront in the selection of materials for the trade show appearance itself. The success proves both partners right: Thus, the quality of contacts was significantly improved compared to K 2019, and a positive response developed both externally and internally over a longer period of time.

Innovators in the spotlight

While innovative developments are showcased and (hopefully) get the attention they deserve, the researchers behind them are often not visible. In the video series "Meet The Innovators" Covestro gives a voice to some of them and their inventions – see the blog post. They were introduced to a larger audience at K 2022, but prominent guests continue to discuss important innovations and technologies in the "Meet The Innovators" livestream series.

Many inspiring encounters at K 2022 have already led to a large number of new partnerships, technologies and material solutions. They form a valuable basis for developments that Covestro plans to showcase at the next major trade show appearance at K 2025. The company's motto may be different then – but the message remains that partnerships are the key to achieving a climate-neutral and circular economy: "Crafting Connections With You".

A Red Dot Award rarely comes alone

Back in May 2023, Covestro and its partner Accesso Dynamics were honored with an award offered by Red Dot and Koelnmesse. At the furniture supplier trade show interzum 2023, they received the "Best of the Best" interzum Award for their Arfinio^® technology. This technology, first presented at K 2022, enables products with complex but seamless shapes. The development also contributes to sustainability, as the products are partly made from bio-based raw materials, are repairable and can be mechanically recycled at the end of their useful life.

Covestro and Uniplan were also nominated for the Heavent Award in the "Forum, Summit, Congress, Fair Award" category for their communication concept for K 2022. A total of 132 projects from event, experimental and live marketing agencies as well as companies and trade fair and congress organizers were submitted for this year's event competition.

"I am amazed by the increased efficiency and energy savings you achieve with each new car model," said Chief Technology Officer Dr. Thorsten Dreier in welcoming the guests. “The Covestro Adelie shows on a small scale what high-performance plastics can do for a sustainable future on a large scale. We are convinced that they are the key to sustainable mobility. That's why we are consistently driving forward material innovations and recycling solutions together with our partners in industry and science.”

Optimization through teamwork

Even during the two-year development period of the Covestro Adelie, the teamwork of around 50 students led to success: aerodynamics, electrical engineering, driving strategy, chassis, powertrain and structure interlock perfectly. More than 200,000 hours of calculations were required to optimize the exterior shape, plus 10,000 workshop hours for the body, and many more days for electrical and mechanical components and the development of the driving strategy.

"A lot of work, heart and soul and the concentrated experience from our three predecessor models have gone into the Covestro Adelie," confesses Clemens Odendahl, head of marketing at Team Sonnenwagen. "Now we hope to win the Challenger class, in which we are the only German team competing. There, it's all about performance and maximum energy efficiency."

Thanks to the optimizations, the structure of the new model weighs 16 percent less than that of its predecessor, the Photon, and the chassis even has 20 percent less weight. This improvement is also due to some Covestro materials, such as a battery cover made of the high-performance plastic polycarbonate and the construction of the seat shell with thermoplastic polyurethane. The Photon is also currently on campus and will remain there for some time.

More sustainable outfit

But the Aachen-based tinkerers are not only committed to more sustainability on the road – their official outfit was also produced using alternative raw materials with fewer petrochemical components. Both the shoes and the shorts were provided by Covestro's Chinese partner Huafeng. The two companies jointly developed a design for them using Huafeng's HAPTIC^® textile coating system, which is made with Covestro's partially bio-based Impranil^® CQ DLS/1 polyurethane dispersion.

Covestro wishes Team Sonnenwagen every success and victory in the Bridgestone World Solar Challenge. This time, 42 teams from 23 countries are taking part in what is probably the toughest solar car race in the world. Under harsh climatic conditions, they have to master the more than 3,000-kilometer route from Darwin to Adelaide as quickly as possible, right across the Australian outback.

"For me, the Sonnenwagen is a powerful symbol of future mobility, because it shows us that we need to ask crucial questions about materials science and design on the way there," said Sucheta Govil, Chief Commercial Officer at Covestro, in her welcoming speech. "For me, the Sonnenwagen team are exemplary for creativity and entrepreneurial spirit. The students proved an impressive motivation and know-how to develop and optimize new ideas for solar-powered, light-weight electric vehicles."

Multidisciplinary team

As many as nine disciplines of the Aachen-based team were involved in the design: the chassis, aerodynamics, structure, electrical engineering, driving strategy, production, sponsorship, marketing and logistics departments. "Close and efficient cooperation between these areas is very important, because we want to compete in the Challenger class at the race, where the main focus is on performance and maximum energy efficiency," explains Lina Schwering, 1st Chairwoman of Team Sonnenwagen. "A lot of working time has gone into the Adelie, which we have invested alongside our studies and during our free time, and a lot of commitment and heart and soul."

In total, more than 50 teams from 24 countries are setting out on the more than 3,000-kilometer route from Darwin to Adelaide – right across the Australian outback. There, people and models are exposed to very harsh climatic conditions with high temperatures and strong UV exposure from the sun during the race, but also during the preceding test drives. In addition, the vehicle is subjected to strong mechanical stresses that can affect the efficiency and performance of the battery.

Innovative materials

"The Sonnenwagen team therefore needed a lot of support in selecting the materials," says Andreas Brandt, Head of Group Marketing and project sponsor at Covestro. "The new Sonnenwagen incorporates innovative products with different functionalities from various business segments, which are tested under track conditions."

For example, the aerodynamic outer shell was made from milled SikaBlock® polyurethane foam blocks from Sika, a long-standing partner of Covestro and another sponsor of Team Sonnenwagen. The Leverkusen-based company provided raw materials for this and advised the team on the implementation. The Sikaflex® sealants for the solar cells are also based on components from Covestro. Other examples include a plastic sheet made of polycarbonate for the battery enclosure and thermoplastic cushioning materials for the driver's seat trim.

"Pushing boundaries is what we at Covestro have in common with the young talents of Team Sonnenwagen," says Sucheta Govil, summarizing her message. "We push the boundaries of innovation in materials, driven by our commitment to sustainable mobility of the future. With our products and solutions, we materialize the circular economy."

"For me, the chemical industry is predestined for the use of AI because we have a lot of complex processes going on that cannot be described by fixed rules," says Walter Grüner, Head of IT & Digitalization at Covestro. "They are not suitable for automation. We rather need learning systems to which we grant a certain degree of decision-making autonomy. In doing so, we focus primarily on the development of systems that work in a complementary manner to humans and support their abilities."

With the introduction of AI in the chemical industry, questions about technical, operational and organizational implementation are also increasingly emerging. This includes, for example, the role of AI in decision-making, but also its implementation along value chains.

Artificial Intelligence – great opportunity for chemical industry

Under the motto "Shaping industrial change with AI", the participants exchanged in a generic way views on the following topics:

• AI system to assist decision making or as an autonomous decision-maker?
• AI awareness, literacy and capabilities
• Production technology vs. supply chain management: independent or joint optimization?
• Needs and requirements for external data generation (monitoring)?

"It is precisely the exchange across company boundaries that helps us a lot in the upcoming transformation because overall challenges become clearer," says Nils Janus, Global Head of Advanced Analytics at Covestro. "This increases efficiency and saves time."

Overall, there was agreement among the participants: Artificial intelligence offers great opportunities for the chemical industry. The new systems help to create a common ecosystem for cross-divisional production planning. It must be decided on a case-by-case basis and each company has to decide individually and independently how much autonomy these systems will be given. With regard to access to the systems, the participants saw a strong democratization of artificial intelligence. Companies could support employees in learning more about data and AI and bring them into contact with experts when it comes to the widespread use of AI solutions in the company. The generation and dissemination of ESG (Environmental, Social and Governance) data are currently the biggest drivers for using external data sources. Here, all participants saw opportunities to intensify the use of external sources.

Digitalization drives sustainability

Digitalization is a key driver to improve sustainability and make the circular economy a reality. Covestro is focusing on more data-oriented corporate governance to drive digital transformation.

Covestro is advancing the use of artificial intelligence (AI) both in its own company and in the chemical industry. To this end, the materials manufacturer is investigating how digital technologies can make processes more efficient and sustainable as part of several pilot projects across different divisions.

The R&D teams of Solar Coating Solutions booked their first successes back in 2005 with the development of a new and innovative anti-reflective coating, which could be used in different applications. Around 2010, however, the solar industry worldwide started to emerge and turned into a business opportunity with a huge market demand and growth potential. This was the trigger for the decision to build a dedicated production plant for solar glass coatings in the Netherlands, more specifically on the Brightlands Chemelot Campus in Geleen.

With the solar photovoltaic industry growing globally, the Solar Coatings Business also spread its wings and installed teams in China and in the US. Thanks to smart decision taking, to the expertise of its business development teams in the regions and to the excellent performance and quality of its solar glass coatings, the Netherlands’ plant today remains the largest independent producer outside China. Additionally, during the past ten years the solar glass coatings product portfolio developed from a ‘one fits all solution’ to a highly diversified offering.

Robert von Beulwitz, Managing Director of the Solar Coating Solution, explains: ʺToday we offer amongst others combined anti-reflective and anti-soiling coatings for modules used in desert environments, high power coatings for large utility scale solar parks and special aesthetic coatings for pitch black appearance of solar panels mounted on residential rooftops – mainly in the Netherlands. Our latest innovation being the development and commercialization of a retrofit coating application for older solar parcs. With the expansion of the industry and of our portfolio, we also saw our employee base rising and I would like to thank each and every one of these colleagues for the relentless efforts they deliver every day!ʺ

"All these different solar coating products were developed in the Netherlands by listening to end market requirements around the world. And all of them are produced by employees in our production facility on the Brightlands Campus in Geleen. I am very proud about this story with which – from the Netherlands – we empower solar energy and harvest more energy from the sunʺ, adds Aukje Doornbos, Managing Director of Covestro in the Netherlands.

"With this we have fully achieved the goal of developing a technology to chemically recycle these products and convert polyurethane into a high-quality recycled material," says Bart Haelterman, R&D Director at Recticel. "For the first time in history polyurethane is truly fitting into a circular economy." The European Union funded the PUReSmart project with six million euros over a four-year period under its Horizon 2020 research and innovation program (agreement No. 814543).

Building on the PUReSmart project, Covestro is working with partners from the waste management industry to drive the further development of flexible foam recycling through to industrial use. "Our goal is to turn waste into valuable raw materials and to anchor the principle of the circular economy in our company and along the value chain with our partners to achieve this," says Christine Mendoza-Frohn, Head of Performance Materials Sales EMEA & LATAM of Covestro. ʺThat’s why we make innovative recycling a priority. We call this ongoing Evolution of Recycling: Evocycle^® CQ. The first initiative of this kind is dedicated to the chemolysis of PU mattress foam and is called 'Evocycle^® CQ Mattress'. This underlines our willingness to further invest in this technology," says Mendoza-Frohn.

Raw materials in high yield and purity

Unlike other chemical processes for recycling PU flexible foam, the process does not use fossil-based polyol. It requires only the pre-sorted foam from mattress waste, a glycol and an additive. During chemolysis, the polyol and toluene diamine (TDA), the precursor to TDI, are recovered in high purity and yield. After reprocessing, they can be used again as often as required for the production of new PU flexible foams. This ensures a sustainable circular economy for PU flexible foam with a reduced CO₂ footprint.

The goal: an industrial value cycle

Covestro's first initiative, Evocycle^® CQ Mattress, transforms end-of-life mattress foam directly back into its main building blocks, giving old foam a new life within an optimized circular system. The company aims to close the loop in the PU mattress industry by converting waste into valuable resources, reducing the use of fossil fuels and significantly lowering CO₂ emissions. However, there are still many steps to be taken before this vision becomes reality, especially with regard to upscaling the process.

The journey began for Covestro in 2019, leading to the start of a pilot plant at its Leverkusen site as early as 2021 to verify the positive laboratory results achieved to date. If the trials continue to be successful, the company plans to build a larger recycling plant to validate the technology in an industrial simulation environment.

However, an effective and cost-efficient supply of used PU mattresses is also crucial to building a circular economy. To achieve this, large quantities must be collected, broken down into individual components such as springs, textiles and foam parts, and the foam components pre-sorted according to purity and density. This can only succeed in close cooperation with partners – in this case in the recycling industry. Covestro is already cooperating on this with companies such as Interzero and Ecomaison (formerly Eco-mobilier).

Covestro started working in the field of continuous fiber-reinforced thermoplastic composites in 2015 with the acquisition of TCG Thermoplast Composite GmbH. Following the strategic decision to discontinue the Maezio^® product line after almost eight years, Covestro searched intensively for a buyer for the Markt Bibart site. As this attempt was ultimately not successful, Covestro decided to close the site later this year. Most recently, 48 of the approximately 7,600 employees in Germany were employed there. “We have initiated an extensive sales process, which, unfortunately, was not successful. Our focus on the ground is now on providing the best possible support to all colleagues. To this end, we will be working closely with the local employee representatives to find fair solutions for all those affected and to ensure that the closure process is socially responsible,” emphasizes Site Manager John Bauer.

A focus on core business

Thermoplastic fiber composites are a highly specialized and competitive niche business. Covestro has invested in building up the business since taking over the site in 2015 and has made very good technical progress in production. Nevertheless, the company has not succeed to scale business with sufficient success in the market. There are only a few synergies with the core business of the Engineering Plastics business entity and the vast majority of key account business. In addition, the typical customers for thermoplastic composites only order on the basis of joint, complex and time-consuming technical application development, and then only in very small quantities. This is in marked contrast to the far predominant distribution model and key account business in the Covestro Group.

Covestro is thus sharpening its focus on its core Engineering Plastics business by discontinuing the Maezio^® products. Major customers in the automotive, electronics and healthcare divisions, among others, use these high-quality polycarbonates for further processing in a wide range of products.

"The joint project with Covestro is an important building block in making our entire value chain climate-neutral. By sourcing raw materials for these products with a significantly reduced carbon footprint, we will be able to reduce our reported indirect emissions by up to 120,000 metric tons of CO₂ equivalents per year," says Dr. Hubert Fink, member of the LANXESS Board of Management. With its Net Zero Value Chain Initiative, the specialty chemicals group plans to eliminate Scope 3 emissions within its upstream and downstream supply chain by 2050. This includes indirect emissions, particularly from purchased raw materials, but also in logistics or disposal. For Scope 1 and 2 emissions, the company aims to be climate neutral as early as 2040. "With this program, we are taking the next step towards a climate-neutral product portfolio and also supporting our customers, who are increasingly looking for sustainable solutions," says Fink. 

Chlorine, caustic soda and hydrogen are basic building blocks for many products in the chemical industry. However, their production is very energy-intensive. LANXESS uses the raw materials supplied by Covestro, for example, for products that are then used in the food and agricultural industries. Covestro produces the three basic raw materials at its North Rhine-Westphalian sites in Leverkusen, Krefeld-Uerdingen and Dormagen. Both the former have already been certified to the internationally recognized ISCC PLUS standard for the production of the strategic raw material chlorine, while this is also planned for Dormagen in the near future. The correct allocation of the electricity to the products is ensured via this certification and the use of the renewable energy is proven by the invalidation of certificates of origin at the Federal Environment Agency. 

Covestro is also actively involved in various projects to build a hydrogen economy that uses mainly or exclusively green hydrogen as an energy carrier. Among other things, the company is supporting, in cooperation with Hydrogenious LOHC Technologies, to build the world's largest plant for storing renewable hydrogen in liquid organic carriers in Dormagen, Germany. 

With regard to its energy supply, Covestro focuses on power purchase agreements (PPAs) for renewable energy or high-level certificates. Only recently, the company signed PPAs with Chinese supplier CGN New Energy on wind and solar power that will cover around 30 percent of the electricity needs of its important production site in Shanghai. Under another, utility Ørsted will supply offshore wind energy starting in 2025, which is expected to meet 10 percent of the electricity needs of Covestro's sites in Germany. ENGIE, Belgium's largest renewable energy producer, will provide onshore wind energy to meet 45 percent of the electricity demand of Covestro's Antwerp production site in Belgium. 

Currently, two of its own ships and two additional chartered ships belong to Tailwind Shipping Lines. In addition to the non-food products from and for Lidl, Tailwind offers space on these ships also for interested companies. Covestro uses this now to also become more independent from the busy main routes and shipping companies and to increase the speed and punctuality of its own deliveries.

"Ocean shipments have been severely disrupted since the pandemic began, and the scheduling accuracy of large shipowners has fallen from 70 to 20 percent," says Sucheta Govil, Chief Commercial Officer at Covestro. "To increase our reliability and punctuality, we are therefore actively looking for alternatives. With Tailwind, we have found a partner to navigate the direct route from Asia to Europe with its ships - and who is therefore exactly where it helps us."

Smaller vessels, more flexibility and punctuality

The Tailwind ships have a capacity of around 5,000 "Twenty Foot Equivalent Units", or TEU, per month. TEU is a standard measure for shipping containers. Large ships from the big shipping companies can hold three to five times more. However, those mega ships can also only discharge at large ports and travel rather fixed routes with pre-determined stops, which increases the susceptibility to delays.

"We now determine the route ourselves. And because our ships are smaller, we can also have them sail to and discharge at smaller ports. This gives us a great advantage in terms of flexibility, speed and thus also punctuality," says Wolf Tiedemann, CEO of Sales, Logistics and Central Divisions of Lidl Stiftung & Co. KG. "This allows us to import our own goods reliably from Asia - but at the same time we still have room that we can offer. We are pleased to have found a first interested customer and partner with Covestro and hope to be able to expand the cooperation further and find other interested parties."

A first container of Covestro materials successfully completed the route from the company's largest production site near Shanghai to Europe. Currently Covestro ships a good 8,000 containers a year on that route alone. How many of these will be transported by Tailwind in the future is currently being negotiated.

Such achievement serves as a clear proof point of the company´s commitment towards circularity, leading the transition within the different segments served by Covestro not only in Brazil, but also in important countries such as Chile, Uruguay, Colombia, Argentina and Costa Rica, among others.

"This is an extremely important step for us as it makes the transformation towards the circular economy tangible, supporting our customers in achieving their sustainability goals and accelerating the substitution of fossil raw materials", says Andreas Stumpf, Managing Director of Covestro Brazil.

ISCC PLUS certification contributes to more sustainable production processes and markets, increasingly encouraging the participation of supply chain entities. At a local level, the certification can make fairer work relationships, more efficient processes and promote the reduction of greenhouse gas emissions and the use of fossil resources, while expanding the possibilities for the international market, mainly the European one.

"The Brazilian certification project of Covestro shows that it is possible to contribute to more sustainable production even in complex production chains with materials of different origins and destinations. It is another important step in promoting genuinely sustainable production chains", states Felipe Bottini, founding partner at Green Domus, ISCC recognized certification body in Brazil.

Customer focus: driving mindset change in Brazil

ISCC PLUS certification enables Covestro to supply attributed MDI and TDI, attributable to bio-based as well as bio-circular raw materials, to a variety of industries, for example for composites, flexible foams for mattresses and rigid foams for refrigerators, thus expanding Covestro's supply of more sustainable raw materials, which has a direct impact on reducing greenhouse gas emissions.

"For us, it is of utmost importance to be at the side of our customers and enhance their awareness about climate neutrality. Now, with such products, we can effectively contribute to their sustainability goals and reduction in carbon footprint", says André Borba, Marketing and Sales Manager for the Performance Materials segment in the Latin America region.

In order to reflect this commitment, and to make it even clearer how these products support its circular vision as well as the customers´ path towards sustainability, Covestro created a distinctive branding for products driving circularity.

Products carrying the CQ suffix are produced using partially alternative raw materials today – such as feedstocks from waste, biomass or renewable energy. These material solutions can be implemented via segregated or mass-balanced chains of custody. By activating multiple circular production pathways, we enable clients to increase their use of renewable resources, and lowering their overall environmental impact.

The range of solutions carrying CQ will constantly grow. The first products available are the climate neutral³ products Desmodur^® CQ 44V70L MS and Desmodur^® CQ 44V20L MS from Covestro, as well its Desmodur^® CQ 44V70L MB, Desmodur^® CQ 44V20L MB and Desmodur^® CQ T80 with a significantly improved carbon footprint. The abbreviation ‘CQ’ stands for circular intelligence. Together, C and Q underline how essential thought-leading, innovative solutions can drive circularity forward.

¹ ISCC ("International Sustainability and Carbon Certification") is an internationally recognized system for sustainability certification of biomass and bioenergy, among others. The standard covers all stages of the value chain and is widely used worldwide. ISCC PLUS includes further certification options for technical-chemical applications, among others, including plastics from biomass.   
² Biological and bio-circular attributed MDI and TDI are assigned biological raw materials as well as wastes and residues of biological origin based on a mathematical algorithm using the mass balance method.   
³ Carbon neutrality is the result of an internal assessment of a partial product life cycle from raw material extraction (cradle) to the factory gate (Covestro gate), also known as cradle-to-gate assessment. The methodology of our life cycle assessment is based on ISO standards 14040 and 14044.

"All our solutions under the umbrella CQ prove that we are continuing to work on making our vision of the circular economy a reality, to help customers and partners achieve their sustainability and climate goals. In this way, we also aim to meet consumer demands for more sustainable products," says Sucheta Govil, Chief Commercial Officer of Covestro. "And this is just the beginning. In the long term, Covestro also wants to offer every one of its products in a climate-neutral¹ version."

Evocycle^® CQ: a new name for all innovative recycling technologies and cycle designs of Covestro

Plastic waste is a valuable raw material and should not simply be disposed of. Therefore, Covestro is taking pride in proving that the path to circularity is possible for all stakeholders – and makes innovative recycling a priority. For the continuous evolution of recycling, the company now introduces the name "Evocycle^® CQ". It is an extension to the CQ label and stands for recycling technologies which enable the use of recycled plastics and recycled raw materials from the Covestro portfolio within a streamlined closed-loop system.

What’s more, the company is not active here alone, rather collaborating with partners from all fields of recycling and reuse to unlock its potential across the entire value chain. That’s how it transforms the industry turning waste into valuable resources, reducing the use of fossil fuels and significantly reducing CO₂ emissions.

The first initiative is called Evocycle^® CQ Mattress: Covestro, together with partners, has developed an innovative technology for the chemolysis of polyurethane flexible foams from used mattresses, in which both main components – the polyol and the precursor to the isocyanate TDI – can be recovered. With this, end of life mattress foams are directly transformed back into renewed polyurethane building blocks.

Since last year the company is operating a pilot plant at its Leverkusen site confirming the positive lab test results. And the journey continues: Covestro is working with recycling specialists such as Interzero and Eco-mobilier², as well as other partners along the value chain, to ultimately close the material cycle for polyurethane mattresses completely and on an industrial scale.

From mass-balanced raw materials to green hydrogen

Raw materials produced from biomass and, in particular, from biowaste and residual materials are also becoming increasingly important. Covestro relies primarily on the latter raw materials because they are available in large quantities and can be used to manufacture a wide range of plastics. Through mass balancing, they are offered in the same good quality as their fossil-based counterparts without customers having to change their processing operations. Covestro works with a number of suppliers who offer the raw materials using a mass-balance approach certified to the internationally recognized ISCC PLUS standard. The starting point also includes fossil raw materials, with the biological portions being allocated to the products by a third party audited allocation method.

Covestro is thus converting its production to the use of alternative and, above all, mass-balanced raw materials, in some cases also using renewable energy from wind and solar power. Many of the company's sites are now also ISCC PLUS certified, including Leverkusen, Dormagen, Krefeld-Uerdingen, Antwerp, Filago, Shanghai, Map Ta Phut and Changhua.

Green hydrogen generated with the help of wind or solar energy also plays an important role for the chemical industry – both as an alternative raw material and as a source of clean energy. Covestro, together with partners, is committed to the urgently needed market ramp-up. The company uses hydrogen and its derivatives to produce high-performance plastics.

¹ Climate neutrality is the result of an internal assessment of a partial product life cycle from raw material extraction (cradle) to Covestro's factory gate, also known as cradle-to-gate assessment.
² The company "Eco-mobilier" has changed its name to "ecomaison" at the beginning of October 2022.

“We have set ourselves the goal to become fully circular. To this end, we want to convert our raw material base to 100% renewable sources. We are very pleased to have found a partner in SOL Kohlensäure who will support us in this transformation with a pioneering spirit,” explains Daniel Koch, Head of NRW Plants at Covestro.

“We at SOL Kohlensäure are advancing the shift to more sustainable CO₂ sources. In this way, we are increasing security of supply, becoming independent of fossil raw materials, and reducing our environmental footprint at the same time,” emphasizes Falko Probst, Sales Manager at SOL Kohlensäure.

From waste product to raw material

The CO₂ used is obtained by SOL Kohlensäure from various sources, such as bioethanol and biogas plants. In these plants, CO₂ is produced as a by-product during the treatment of various biomasses, such as plant residues.  This is separated by SOL Carbon Dioxide, purified and then made available to Covestro production as a raw material. 

In this way, the supply partnership supports the circular concept and contributes to reducing emissions. 

Covestro’s Lower Rhine sites in Leverkusen, Dormagen and Krefeld-Uerdingen are ISCC PLUS certified and can supply their customers with more sustainable products made from renewable raw materials.

Goal of climate neutrality by 2035

Covestro has set itself the goal of becoming fully circular. This also includes using alternative raw materials. Biomass, CO₂, as well as end-of-life materials and waste replace fossil raw materials such as crude oil or natural gas. Carbon is managed in a circular way. In realizing these ambitions, both companies are relying on long-term supply partnerships.

In addition to biogenic CO₂, Covestro is investigating the use of other technical gases from renewable sources. The materials manufacturer is already offering its customers its first sustainable products, such as climate-neutral¹  MDI. With the expansion of its alternative raw material base, this portfolio is set to grow further in the coming years.

ISCC (“International Sustainability and Carbon Certification”) is an internationally recognized system for the sustainability certification of biomass and bioenergy, among others. The standard applies to all stages of the value chain and is recognized worldwide. ISCC Plus also encompasses other certification options for instance for technical-chemical applications, such as plastics from biomass.

¹ _{Climate neutrality is the result of an internal assessment of a partial product life cycle from raw material extraction (cradle) to the factory gate (Covestro gate), also known as cradle-to-gate assessment. The methodology of our life cycle assessment, which has been critically reviewed by TÜV Rheinland, is based on ISO standards 14040 and 14044. The calculation takes into account biogenic carbon sequestration based on compensation measures.}

"The development of these resins is very important to us. After all, it contributes to the expansion of alternative energies and strengthens our strategic orientation to sustainably reduce the CO₂ footprint and take even more steps towards climate neutrality," explains Klaus Franken, Head of Application Development Wind and Pultrusion at Covestro. "To be competitive, the wind industry faces the constant challenge of reducing the Levelized Cost of Electricity. We can help here by enabling our customers to produce rotor blades faster and thus more cost-effectively. At the same time, higher energy yield through optimized blade properties and longer service life also play a role."

Close cooperation with customers

One goal of the Wind Technology Center is to develop robust materials that combine the properties important for rotor blades, such as strength, stiffness and temperature resistance. Existing products are continuously optimized and completely new formulations are developed and tested. Another goal: application technology development in close cooperation with customers. Klaus Franken explains: "Here we can simulate our customers' manufacturing processes and show how our PUR resins help them to realize both their rotor blade designs and the manufacturing process in the best possible way."

Covestro attaches great importance to optimally tailoring its products to the needs of its customers. That is why a number of cooperative ventures with European and Asian wind turbine manufacturers are already in place. The focus here is on constructing and testing prototypes.

The high-tech center is located in Leverkusen and was completed and put into operation at the beginning of this year. It comprises two interconnected units: a laboratory area for chemical development and an Upscaling Plant. The latter is home to processing technology and application development.

Development and application go hand in hand

The center offers clear advantages: "Chemical development and application technology can work hand in hand here. On top of that, the physical proximity makes it easier to exchange information directly and quickly. We use identical resources and the same infrastructure and quickly obtain a comprehensive depiction of the process. This helps us to pursue our goals in a results-oriented manner and without losing knowledge, and enables us to offer new, innovative solutions to our customers," explains Technical Center Manager Frank Grimberg. "Process and plant safety, explosion protection, machine safety and, of course, occupational safety are always in the spotlight here," explains Tobias Wollersheim, who as Project Management was responsible for planning and implementing the investment.

Another positive aspect: with the innovative technology center, Covestro is increasing its attractiveness as an employer. Indeed, wind technology offers a wide range of new, interesting fields of work that arouse curiosity and offer diversity. Covestro has taken on a newly qualified chemical technician from its own training program to operate the machines. He is being intensively trained in the processes and machine technology.

This much is clear: Things are moving in the area of wind energy.

Quotes

"With this strategic investment, Covestro aims to further enlarge the capacity and improve the reliability of its global supply of Desmodur^® 15 based products," says Philip Bahke, Head of Operations at Covestro Elastomers.

"On top of addressing our customers’ demand, Covestro's Barcelona site has been operating entirely on renewable energy since the beginning of 2022," says Sucheta Govil, Chief Commercial Officer at Covestro. "This approach is part of our ambition to reduce our environmental impact while offering our customers greater access to our solutions and specialties products."

"We are opening the new production unit for our Desmodur^® 15 prepolymers in Barcelona in parallel to the ongoing expansion of our NDI capacities in the Asia-Pacific region with the Map Ta Phut plant in Thailand," explains Thomas Braig, Head of Covestro Elastomers. "This new production unit will help us to support our customers’ growth in the cast polyurethanes high-end applications segment." The abbreviation NDI stands for naphthylene diisocyanate.

"Thanks to this new production line, our Vulkollan^® licensees, as Desmodur^® 15 prepolymers processors, will be able to further develop their business," explains Abdel Arhzaf, Head of NDI-Vulkollan^®. "Through these investments, we intend to support the demand for ultra-high-performance elastomers used for superior applications as e.g. in the material handling industry and also for a growing number of engineering applications."

Combining the highest mechanical characteristics with dynamic load-bearing capacity, elastomers based on Desmodur^® 15 prepolymers are not only one of the most powerful cast polyurethanes in the market, they are also as easy to process as conventional prepolymers. 

The new capacity is intended to meet the growing global demand for multilayer TPU Films. They are used in automotive interiors and construction, among other applications. Breathable, water-impermeable specialty films have also proven their worth in wound care and outdoor clothing. The new facilities are scheduled for completion as early as the end of 2023.

"With this capacity expansion, we are strengthening our Bomlitz site and our position as a leading supplier of technical specialty films," said Dr. Klaus Schäfer, Chief Technology Officer of Covestro, at the groundbreaking ceremony. "At the same time, we are investing in promising technologies and applications and creating new jobs."

For Aleta Richards, global head of the Specialty Films segment, the expansion offers opportunities to respond even better to individual customer needs and offer more sustainable products. "For some time now, we have also been developing customer-specific solutions with films made from alternative raw materials, as we are also seeing increasing demand in this area. The development and production of partially bio-based products is therefore to become a new focus at the Bomlitz site."

Covestro is fully geared toward the circular economy and aims to become climate-neutral by 2035. To this end, the Bomlitz site plans to switch its energy supply completely to green electricity starting this year.

Epurex Films is one of three Covestro competence centers for specialty films in Germany. The other two centers in Leverkusen and Dormagen are focused on research, production and application of polycarbonate films.

For Covestro, offering renewable TDI via mass balance is only a logical next step of making this important chemical raw material even more sustainable, as Dr. Klaus Schäfer, Chief Technology Officer of Covestro, explains: "Already years ago, our unique gas phase technology was a milestone towards more energy efficiency in the production of TDI. After that we committed ourselves to ensure a further reduction in emissions from our production by switching to green electricity. This additional improvement now makes it clear how consistently we are pursuing our path to climate-neutral production³ and the circular economy: By using mass-balanced renewable raw materials, we are now also striving to significantly reduce our indirect emissions in the supply chain and to offer products with a reduced carbon footprint."

"With our shift to mass-balanced products, we are helping customers in various industries achieve their climate targets and drive the transition to a circular economy," says Sucheta Govil, Chief Commercial Officer of Covestro. "At the same time, we are strengthening the use of alternative raw materials and reducing CO₂ emissions along various value chains." Customers can use this TDI as a drop-in solution, meaning it can be implemented rapidly and easily in existing production processes without the need for technical modification.

Flexible PU foams made with TDI and long-chain polyols are important materials in the manufacture of seat cushions and mattresses. Renewable TDI meets demands for more sustainable production while ensuring the good quality, optimal comfort and high breathability known from fossil-based TDI. It also meets the expectations of the automotive industry, which is looking for alternative raw materials for car seat cushions with a lower carbon footprint.

Sinomax as pioneer for more sustainability

Only late last year, Covestro signed its first commercial supply contract with Sinomax, a global manufacturer and distributor of polyurethane comfort products based in China. Both companies share a clear commitment toward the circular economy, and Sinomax wants to be the first customer to use the new TDI to reduce its CO₂ emissions. The mass-balanced TDI required for this is supplied by the ISCC PLUS-certified Shanghai site of Covestro. Thanks to its global presence, the company can also supply larger amounts of mass-balanced TDI.

In this mass balance approach, raw materials derived from biomass or waste are fed in at an early stage of raw material extraction and mathematically attributed to the finished products. This saves fossil raw materials and reduces greenhouse gas emissions, while the quality of the mass-balanced products remains the same compared to purely fossil-based ones. Manufacturers can continue to use their proven formulations, equipment and processes, meanwhile gradually transforming their product portfolio towards a more sustainable one and achieving their climate targets.

_{¹ The renewable TDI is produced with the help of the mass balance approach using renewable raw materials - from virgin biomass and bio waste and residues - which are mathematically attributed to the product.}

_{² According to an internal assessment of a partial product life cycle from raw material extraction (cradle) to the factory gate (of Covestro), also known as cradle-to-gate assessment. The methodology of our LCA is based on the ISO 14040 and 14044 standards. The calculation takes into account the biological origin of the carbon based on preliminary data from the supply chain. No compensation measures were applied.}

_{³ The term “climate-neutral production” refers to the Covestro target of reducing scope 1 and scope 2 emissions to zero by 2035.}

Covestro is also providing its companies in Slovakia and Poland, where many Ukrainian refugees are currently arriving, with further EUR 40,000, which will be donated to local aid organizations. Even though the group itself only has a small business commitment in the region affected, it feels an obligation to the people in need.

In view of the worsening humanitarian situation in the middle of Europe, Covestro CEO Dr. Markus Steilemann has stated clearly: “Violence must never be the answer to any conflict. I am shocked and saddened by the terrible events! The violence must stop before more people lose their livelihood, are injured or killed. Supporting people in need is a matter close to our hearts.”  

In addition to emergency financial aid, Covestro is currently examining further measures to support the global aid efforts. 

"I am very pleased that we can now offer our customers even more certified mass-balanced products and thus help them even better to achieve their sustainability goals and drive the transition to a circular economy," says Sucheta Govil, Chief Commercial Officer of Covestro. "In doing so, we are also supporting the use of alternative raw materials and reducing CO₂ emissions along the value chains."

Dr. Klaus Schäfer, Chief Technology Officer at Covestro, adds, "The raw materials we use for these products meet the high sustainability requirements of the ISCC Plus standard all the way back through the supply chain. That's why we want to make greater use of alternative raw materials such as these renewably attributed precursors in our production. In addition to the three German sites, also our plants in Antwerp and Shanghai are already ISCC Plus certified, with more sites to follow."

In the mass balance approach, bio-based or recycled raw materials – in this case reprocessed residual materials – are fed in at an early stage of raw material extraction and mathematically attributed to the finished products. This saves fossil raw materials and reduces greenhouse gas emissions, while the quality of the mass-balanced products remains the same compared to purely fossil-based ones. Manufacturers can continue to use their proven formulations, equipment and processes.

ISCC ("International Sustainability and Carbon Certification") is an internationally recognized system for sustainability certification of biomass and bioenergy, among others. The standard covers all stages of the value chain and is widely used worldwide. ISCC Plus includes further certification options for technical-chemical applications, among others, including plastics from biomass.

Covestro and Tekmar Group have embraced this challenge and are collaborating to develop more sustainable subsea products by leveraging each other’s expertise in their respective fields.

Covestro Elastomers develops cast elastomer systems to provide solutions for the offshore energy market. Tekmar is a leading producer of polyurethane based cable protection systems for the global offshore energy markets.

A key component of the cable protection system is the bend restrictor, which along with the rest of the system, is designed to protect cables in the ocean for decades. So, why not propose an alternative polyurethane elastomer system for more sustainable casting of these products? One of the major challenges is the reconciliation of sustainability and technical performance, without any compromise on quality. To solve this, Covestro has developed a new polyurethane elastomer system based on its CO₂ Technology, now called Triturn^®, which positively contributes to reducing the products´ carbon footprint.

The new system for bend restrictors from Covestro, which was recently honored with the UTECH Europe Award 2021 in the CASE category (CASE stands for coatings, adhesives, sealants and elastomers), allows to reuse CO₂ as a valuable material source in polyol production and to reduce up to 20 percent of the fossil raw materials which is normally used for the polyol. The new system also makes significant technical gains by being easier to process and improving non-aging properties in salt water. Tekmar is using the new PU system to manufacture sample products at its facility in the North East of England and is currently conducting a range of tests on the products.

Marc Bell, Managing Director at Tekmar Energy, says: "Tekmar is committed to developing more sustainable solutions for the offshore energy markets. Working with Covestro enables us to explore alternative solutions which we can share with our customers to support their transition to cleaner energy and net-zero emission targets."

Through a long-term collaboration, Covestro and Tekmar are proactively shaping the subsea protection industry by introducing an alternative and more sustainable solution to move the offshore industry forward.

Demand for high-performance batteries is expected to grow rapidly in the coming years. Covestro brings extensive plastics processing expertise to the table and will showcase a battery module it has developed in-house at the show, allowing it to test its own materials. The company also performs CAE component simulations and provides support to customers with moldflow analyses and injection molding upon request.

Covestro's booth, number 205 in Hall 4, will focus on high-performance plastics for key battery components such as cell holders for dimensionally accurate placement in housings. These include, in particular, flame-retardant polycarbonate blends from the Bayblend^® FR portfolio, which feature exceptionally good dimensional stability, as well as good electrical properties. As a result, they enable dimensionally stable parts with tight tolerances and thus mass production of battery modules. They also exhibit high impact strength.

Since the plastics in the Makrolon^® RE series have bio-waste and other residual materials as well as renewable energies attributed to them during their production, they can reduce the carbon footprint compared with traditional material solutions. This also applies to the Bayblend^® RE series: the polycarbonate content in these blends is also mass-balanced, so the carbon footprint of these products is reduced by up to 70 percent compared to fossil-based blends. In some cases, renewable energies are also used in production, for example at the Antwerp site of Covestro, where the company is supplied with energy from wind power.

Another important aspect is the dissipation of heat, which is released during battery operation. The thermally conductive polycarbonate Makrolon^® TC (TC stands for "thermally conductive") offers new options for cooling the battery module. Here, for example, Covestro is investigating the effects on battery life. Depending on the design of the battery system, this could also enable faster charging. Battery modules made with this material can be used in electric vehicles, in stationary energy storage systems and in replaceable batteries for two-wheelers.

Stronger, lighter and more sustainable plastics for charging stations

The number of electric vehicles and plug-in hybrids is growing significantly, and with it the need for charging stations. There is a wide range of charging equipment on offer, from fixtures in parking lots to wall-mounted charging points in private homes.

Charging stations require materials that meet a number of often very specific requirements. They have to withstand all types of weather and also withstand attacks of vandalism well. Added to this are the wishes of the operators of charging stations, for example manufacturing by means of mass production as well as high functionality, lightness, toughness and good electrical insulation of the materials. And last but not least, they must be easy to shape in order to offer as much design freedom as possible.

Polycarbonates from the Makrolon^® range and polycarbonate blends from the Bayblend^® series meet all these requirements. Together with the mass-balanced products of the Makrolon^® RE series, they play their part in further reducing the carbon footprint of this more sustainable form of propulsion.

The new committee has a lot of plans for the next term of office. In particular, it wants to breathe even more life into the three guiding principles of the society with a focus on digitization, diversity and internationalization, and thus also continue the course it has taken in recent years to drive forward the modernization of the GDCh. "We can be truly proud of what the GDCh has achieved and what it represents, but we also want to support the changes in society and science and thus play an active role in shaping the future of the GDCh," Danielmeier emphasizes.

Karsten Danielmeier, born in Werl in 1967, studied at the University of Bonn where he received his doctorate in synthetic organic chemistry under Professor Dr. Eberhard Steckhan in 1995. The following year, he joined Bayer AG where he was active in numerous positions of increasing responsibility in raw materials research for coatings and adhesives in Germany and the United States. Most recently, he headed research for the Functional Films division in Leverkusen and was Senior Vice President for Research and Development in the Coatings, Adhesives, Specialties segment at Covestro from 2015 to 2021.

Danielmeier has been a member of the GDCh board since July 2020 and had previously served for several years on the scientific planning committee of the Coatings Chemistry division.

The new products are produced using bioattributed raw materials and have a reduced carbon footprint in comparison to their fossil-based counterparts. At the same time, the mass-balanced products boast the same impressive quality and properties and can be integrated directly into manufacturing processes in downstream industries without technical modifications. In this context, the products are to be certified according to the ISCC Plus standard.

"I am thrilled that we will soon be able to help our customers in the electronics, footwear, automotive and other industries reduce their carbon footprint with this drop-in solution," said Dr. Andrea Maier-Richter, global head of the TPU business at Covestro. "With the ISCC Plus certification, we aim to achieve more transparency from raw material purchasing to our production and distribution to customer use. This is an important step in achieving our vision of becoming fully circular."

Extensive range of more sustainable TPU plastics

Covestro has already launched various TPU products based on alternative resources over the past few years, as more and more consumers prefer more sustainable products. Covestro is offering a webinar on this topic on October 28 as part of its CE Days event series. Outdoor outfitter VAUDE, for example, plans to use a foam midsole made partly from bio-based TPU in its new Lavik Eco hiking boot. Other product types contain a component that has been manufactured proportionately using CO₂ instead of fossil raw materials. Covestro's range of Desmopan® brand TPU plastics also includes a range of fully recycled products. They are used, for example, in smartphone cases from the Dutch manufacturer Fairphone.

Thermoplastic polyurethanes are very versatile plastics. They come in a variety of hardnesses, are flexible yet impact resistant, and are therefore highly suitable for a wide range of applications.

Mass balancing creates transparency

Supplying mass-balanced products is part of Covestro's comprehensive global program designed to fully align itself with the circular economy. In doing so, the company is focusing on increasing the use of alternative resources such as bio-based materials, plastic waste and CO₂, as well as renewable energies. The company is also collaborating with partners to develop innovative recycling technologies.

In mass balancing, fossil and alternative raw materials are mixed in production but treated separately in accounting. The chain-of-custody method enables materials to be tracked along the entire value chain and allows alternative resources, such as bioattributed components, to be allocated to selected end products. To date, a total of three Covestro production sites in Europe and Asia-Pacific have been certified in compliance with the ISCC Plus standard, with further sites to follow.

ISCC ("International Sustainability and Carbon Certification") is an internationally recognized system for the sustainability certification of biomass and bioenergy. The standard applies to all stages of the value chain and is recognized worldwide.

In the German cities of Überlingen and Stuttgart, climate-neutral residential quarters are being realized as part of the STADTQUARTIER 2050 project – with a special focus on socially responsible rent development –, which are already intended to serve as a lighthouse for the climate targets to be achieved by 2050 at the latest. The project includes both new buildings and the renovation of existing buildings. See the video.

Highly efficient insulation material

At the subproject in Überlingen, the focus is on very good thermal insulation of the around 170 residential units distributed over 14 new buildings. It is achieved by means of an efficient high-performance insulation material from project partner puren. "Our insulation panels make an important contribution to ensuring that the buildings in Überlingen meet the top energy standard KfW 40 Plus," explains Dr. Andreas Huther, Managing Director of puren. KfW Efficiency House 40 Plus means that a building requires only 40 percent of the primary energy of a reference building in accordance with the Energy Saving Ordinance. "But the insulation boards offer even more sustainability, as they are manufactured in a resource-friendly way and are also durable and recyclable."

"The insulation boards are based on polyurethane raw materials from Covestro and offer the best insulating effect of commercially available insulation materials," adds Fernando Resende, Marketing Manager Building and Construction in the Europe, Middle East and Africa region at Covestro. "Therefore, they can be designed thinner compared to other materials to achieve the same insulating effect. The result is a gain in usable space in the home, but also less resource consumption in the manufacture of the panels."

Affordable housing

The socially responsible rental concept of the investor, Baugenossenschaft Überlingen (BGÜ), also ensures a plus in sustainability. Low energy costs due to thermal insulation, a gain in living space due to slim facade insulation, and an innovative and efficient local heating supply all contribute to this. In addition, there is a new type of neighborhood app tailored to the residents with a bonus system for conscious energy consumption of the Project Group Business Informatics of the Fraunhofer Institute for Applied Information Technology (FIT). The socially compatible and rent-neutral renovation of the neighborhood on the outskirts of Überlingen also contributes to this.

STADTQUARTIER 2050 is supported by the Federal Ministries of Education and Research (BMBF) and Economics and Energy (BMWi) as a flagship project at the neighborhood level (funding code: 03SBE116). It is part of the interdepartmental funding initiative “Solar Building/Energy Efficient City” within the framework of the 6th energy research program of the Federal Government.

Individual city quarters such as the one in Überlingen serve as real-world laboratories in which, with the involvement of all relevant stakeholders, innovative concepts for the heating and energy revolution can be researched and implemented simultaneously, but also quickly transferred to other municipalities.

"The Expo in Dubai is a unique opportunity to show the world how we can tackle the many global challenges and shape a truly sustainable future. This will succeed if society and business consistently adapt to the circular economy," says Markus Steilemann, CEO of Covestro. "The chemical industry is contributing to this by making its processes and products even more environmentally compatible. With this in mind, we at Covestro are developing more and more ways to produce high-quality plastics using CO₂ instead of petroleum."

Science and industry discuss future topics

To accompany Expo 2020 in Dubai, Covestro and the Institute of Biological and Earth Sciences 2: Plant Sciences at Forschungszentrum Jülich are hosting #IndustryMeetsScience Talks, a virtual talk series highlighting and discussing current issues and global challenges such as endangered biodiversity, future mobility and the expansion of renewable energies. The talks feature high-profile opinion leaders from the fields of science and business.

"The #IndustryMeetsScience Talks are an exciting virtual talk series that highlights exemplary solutions to global challenges. Together, we want to highlight Germany's innovative solutions to key issues. I am pleased that we have been able to attract renowned experts for this purpose," says Professor Ulrich Schurr from Forschungszentrum Jülich. The first virtual talk on the topic of plant life and biodiversity will take place on October 15. This will be followed on October 21 by the topic of alternative raw materials with Covestro CEO Markus Steilemann.

The #IndustryMeetsScience Talks will be broadcast live on Covestro's popular social media channels, including LinkedIn, Twitter, Facebook und Youtube.

Part of the German Pavilion with focus on sustainability

Covestro and Forschungszentrum Jülich are partners in the German Pavilion consortium at Expo 2020 Dubai. The exhibit on the circular economy is part of the German Pavilion, which is located on the grounds in the sustainability area and is organized by Koelnmesse GmbH on behalf of the German Federal Ministry for Economic Affairs and Energy. In total, the German Pavilion showcases 36 innovative and creative exhibits designed to encourage guests to interact and raise awareness of the importance of sustainability in the present and future.

The exhibits are divided into the core themes of energy, city of the future and biodiversity, each of which represents a so-called lab. The Covestro exhibit on the circular economy will be located in the Lab City of the Future, which is divided into a series of innovative ideas and approaches that take a look at the mobility, buildings and life of tomorrow.

Expo 2020 will start on October 1, 2021 and run for a total of six months, until March 31, 2022.

From November 2021, Adient will be integrating cardyon^®, a polyol made using Covestro’s CO₂-technology, as a sustainable feedstock for the production of hot cure molded polyurethane foam. Adient deploys these foams as cushioning in its cutting-edge automotive seating systems.

This supply chain-related sustainability milestone helps to further reduce Adient’s scope 3 emissions as calculated by the Greenhouse Gas protocol. Based on the principle of the circular economy, the CO₂-technology by Covestro reuses carbon dioxide as a valuable material source by integrating up to 20 percent of CO₂ into polyol production. The smart contribution helps to preserve fossil resources and close the carbon loop.

David Nash, Vice President Components EMEA at Adient: “Adient is pursuing multiple ways to reduce its CO₂ footprint, further raising sustainability, and this is especially true for the production of polyurethane foam. By choosing cardyon^® by our partner Covestro, we have made another valuable step towards more sustainable production of our high-class seating systems. In addition to the high quality of our products, this means further differentiation and added value for our customers.”

Flexible CO₂ technology enables sustainable solutions

“We feel very pleased that, together with Adient, we are taking a further step towards the circular economy. The fact that our CO₂-technology is now also available for premium car seats confirms the great potential of this unique innovation, realizing high-quality sustainable solutions for the automotive industry”, says Dr. Persefoni Hilken, cardyon^® Venture Manager at Covestro.

By integrating enhanced polyol solutions into the production of polyurethane foam, Adient supports the reuse of CO₂ from chemical processes as an alternative raw material. Thereby the company follows the path of moving away from fossil resources to recycled ones, avoiding CO₂ being emitted to the atmosphere. The CO₂-technology itself can be also used for further applications, such as sports flooring, mattresses, and textile fibers.

The newly-developed foams fulfil all stringent OEM specifications, having the same properties as those produced from fossil-based polyols. Additionally, the new solution can be easily applied within existing production processes, with only a minor modification of equipment.

"I am fascinated by the creativity and entrepreneurial spirit with which the students are developing and optimizing new ideas for solar cars," says Sucheta Govil, Chief Commercial Officer of Covestro. "That’s why we’re sponsoring this project: with our commitment to sustainable future mobility and building a Circular Economy, we want to encourage young people from top universities to use their talents to work with us to develop advanced materials and technologies."

"After two years of hard work, we finally reveal our new Sonnenwagen," says Simon Quinker, vice chairman of Team Sonnenwagen Aachen. "By using innovative technologies, the Covestro Photon is the most efficient Sonnenwagen. We are looking forward to the cooperation with Covestro and together we are taking a further step towards sustainable mobility."

Becoming fully circular

Global challenges such as climate change and increasing resource consumption require new concepts for future mobility. Covestro has been developing material solutions for electromobility for some time, but is also focusing on the increased use of renewable energies such as solar and wind power. Together with the use of alternative raw materials and the development of innovative recycling concepts, it is part of a comprehensive program with which Covestro is fully gearing itself to the Circular Economy. To achieve this, the company cooperates with many partners along the value chain as well as with universities and institutes.

In the solar cars of the Sonnenwagen team, Covestro is testing innovative and sustainable materials under the extreme climatic conditions that typically prevail on such race tracks: very high UV radiation, high temperatures and mechanical vibrations while driving. The company thereby underscores that its innovative and sustainable materials can be used in cutting-edge technologies, for example for cars. In addition to partially biobased raw materials, the company also plans to launch recycled plastics in the next vehicle.

With the environmental impact of fossil-based products becoming increasingly clear, recent years have seen an unprecedented demand for sustainable products and brands. Across the global paints and coatings industry, regulatory bodies are setting higher and higher sustainability and transparency standards, while consumers are increasingly applying their spending power to choosing eco-friendly solutions. For example, a recent European Painter Insight Monitor¹ report found that environmentally friendly paints are now the number-one desired innovation among painters, with 36 percent of France’s professional painters selecting this as a desired innovation/ranking this as their most desired innovation.

Market insights from artificial intelligence and Big Data

To address these changes in the market landscape and help shape more sustainable high-performance paints and coatings industries, Covestro is launching a new plant-powered approach marked by transparency, dialogue and collaboration – called ‘Paint with Nature’. Leveraging its proprietary market insights gained through artificial intelligence and big data, Covestro will work closely with partners across the value chain to provide education and support on biobased raw materials. Additionally, it will implement a ‘Sign the Sustainability Pledge’ initiative.

Through these initiatives and its Decovery® family of resins, whose biobased content is verified to C14 standards, Covestro will drive awareness of biobased solutions as an alternative to fossil-based products and accelerate their adoption across the paints and coatings industries.

Tim Gratzke, Marketing Manager Decovery®: “At Covestro, we are very excited and proud to be launching a new approach to further drive plant-based resins for paints and coatings, and better connect the needs of end-users and manufacturers to environmentally friendly technologies. Using our market leadership in biobased solutions, we’ll be able to provide education and support to accelerate our customers’ sustainability journeys. This will help them to better address market needs, as well as protect the environment.”

No compromise on performance

He continues, “More than ever, the transition from fossil-based paints and coatings to biobased ones is within reach and involves no compromise on functional performance. And we’re committed to continuing to push the boundaries on sustainability – as such, a new, exciting plant-powered paints and coatings age awaits!”

To learn more about Decovery® paints and coatings, and Covestro’s new approach, please visit the dedicated landing page here: Paint with Nature

¹ https://www.usp-mc.nl/files/painter-insight-monitor-2020-report-impression.pdf

The objective is to explore the use of carbon monoxide (CO) from steel industry metallurgical gases for the production of high-quality polycarbonates. Covestro has now commissioned a mini-plant for this purpose at its Dormagen site. This is where it is tested whether the quality of the CO from metallurgical gases is sufficient for further processing.

The innovative process has great sustainability potential: Initial life cycle analyses show that around 0.48 kilograms of CO₂ equivalent can be saved per kilogram of CO provided in the steel industry-chemical industry alliance. This means savings of more than 80 percent.

Industrial symbiosis as the key

The lighthouse project proves how important industrial symbiosis is on the path to climate-neutral production in Germany. Covestro has been working closely with thyssenkrupp since 2016. RWTH Aachen University and the Max Planck Institute Mühlheim are also involved in the project. Among other things, they do life-cycle analyses for the processes and test and develop new catalysts.

Dr. Stefanie Eiden heads the Carbon2Polymers subproject at Covestro. She is confident that the knowledge gained could also be helpful for other research projects: “Coke oven gases have the advantage that they bring with them many accompanying substances. If we succeed in processing the CO in such a way that we can use it to produce our high-performance plastics, we can also do the same with other non-fossil-based CO sources.” By the end of the year, it will be evaluated whether the innovative process is economically and ecologically viable.

Setting the course for a climate-neutral circular economy

Dr. Markus Steilemann, CEO of Covestro, sees the Carbon2Polymers project as a further milestone in the development of a global circular economy: “We can only succeed in the fight against climate change if we enter into profitable cooperations. The collaboration with thyssenkrupp illustrates once again the enormous contribution industry can make on the path to greenhouse gas-neutral production. By using coke oven gases, we are further advancing the repeated use of raw materials and thus closing the cycle.”

The industry is receiving support from politicians: the German government is funding the Carbon2Chem project with an additional 75 million euros until 2024. In this way, around 20 million tons of the steel industry’s annual CO₂ emissions in Germany are to be made economically viable in the long term.

The CO₂-technology makes it possible to use harmful carbon dioxide as a valuable raw material for sustainable plastics. The process uses chemical catalysts to drive reactions between CO₂ and a conventional raw material. This process creates so-called polymers in a more sustainable and economically viable way. CO₂ is tightly bound during the process.

Recognition "for the entire team"

"We are overwhelmed and enormously happy for the entire team, which collectively deserves this recognition. The participation in the inventor award for the CO₂ technology is an important sign for all scientists, process engineers, application engineers and patent attorneys that years of research and development and professional patent management pay off - to create a more climate-friendly future in this case," says Christoph Gürtler.

"Our efforts to make chemistry more sustainable are once again bearing fruit. The fact that the contributions of basic research are being recognized as part of the development of such a process is an extraordinary recognition that would never have been possible without the interdisciplinary team behind it," adds Walter Leitner.

With its CO₂-technology, Covestro has taken an important step toward the Circular Economy. Proportionally, up to 20 percent of fossil raw materials can now be replaced in products. The carbon from the CO₂ then remains in the cycle without being released into the atmosphere. At the same time, initial studies suggest that this technology can also be used to produce more recyclable plastics, whose components could be more easily recycled.

Markus Steilemann, CEO of Covestro, is convinced of the future-oriented technology: "We need to save fossil resources and make industry climate-neutral. With sustainable CO₂-technology, we have set a leading light on the path to a circular economy. We are leaving the era of petroleum behind and driving the circular economy with alternative raw materials. I am proud of the team that has made this development possible."

"To curb climate change, all sectors of society and the economy must reduce their carbon footprint. This cannot be done without far-reaching technical innovations, which in many areas require fundamental findings in chemistry. CO₂ utilization, made possible by the team led by Walter Leitner and Christoph Gürtler, is an excellent example of this. And also of how fruitful cooperation between basic and applied research can be," says Martin Stratmann, President of the Max Planck Society.

Joint solution from industry and science

The pioneering research and development work for the Inventor's Award began in 2007 in joint BMBF-funded research projects ("Dream Reaction/ Dream Production"), which primarily involved Covestro and the CAT Catalytic Center as a joint research facility of Covestro and RWTH Aachen University, along with other partners. Once significant new findings on the effect of the catalyst were available, rapid further development of the innovative process became possible: an excellent example of the potential of partnerships between basic research and research-oriented industry. These developments were scaled up in other fields of application in two additional BMBF-funded projects („Dream Resource/ Dream Resource Conti“) and form the basis for the CO₂-technology of Covestro.

CO₂ generally only forms chemical compounds at great expense and only with the right partners under conditions optimized for this purpose. “The use of CO₂ requires a 'chemical matchmaker,' so to speak: the catalyst," Leitner explains. It was this problem that the team had to solve. The combination of industrial and academic expertise, creativity, perseverance and many experiments finally culminated in success. The breakthrough was achieved by precisely controlling the reaction between CO₂ and the petroleum-based alkylene oxide in the presence of a suitable catalyst system. "Working together, we found the right way to proceed, which can now be readily used for a large-scale chemical process," says Gürtler.

The next step was taken in 2016: an industrial plant was installed in Dormagen, Germany. The reaction of CO₂ with alkylene oxide produces so-called polyols. They are marketed by Covestro under the product name cardyon®. The polyols are already being used to produce soft foam for mattresses, for adhesives in sports flooring, padding in shoes and in car interiors. Elastic textile fibers are currently on the threshold of market maturity. Other Research projects have successfully demonstrated that CO₂ can also be deployed for insulating materials made of rigid foam and for surfactants, for example in detergents.