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.

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.

The so-called People Mover, which will be tested on public roads this year at speeds of up to 50 km/h, is the result of a project funded by the Federal Ministry for Economic Affairs and Energy (BMWE) and the European Union.

"The People Mover is more than just a vehicle – it's a showcase for the future of mobility," explains Jochen Hardt, Head of Global Marketing Mobility at Covestro. “It also vividly demonstrates the 'Material Effect,' for example in the 381cm large windshield made of polycarbonate. Additionally, we considered recycling during the design process and worked with three fully recyclable monomaterials Arfinio^®, TPU and Polycarbonate that can be found either in interior or exterior.”

Material Effects for the Major Trends in Mobility

The materials used in the People Mover demonstrate Covestro's Material Effects and include, for example, Makrolon^® AG for the 381cm panoramic glazing. Covestro can offer this innovative polycarbonate solution based on mass-balanced raw materials from post-consumer waste.

For the autonomous driving systems, opaque but sensor-transparent Makrolon^® AX ST is used for multi-sensor system covers. This innovative solution enables seamless and invisible integration of sensor technology while providing resistance to vandalism and stone impacts.

In the interior, the lightweight, high-quality, and fully recyclable monomaterial Arfinio^® is used in a vehicle for the first time. The material combines a stone-like appearance and feel with high resistance to mechanical stress, UV radiation, and wear.

A consistent monomaterial approach with recycling in mind was also pursued for the seat upholstery. Printed TPU-based solutions made of Desmopan^® AIR provide high seating comfort combined with high abrasion resistance and easy cleaning – a crucial factor for vehicles in continuous public transit operation.

Monomaterials Facilitate Recycling

The use of monomaterials also facilitates recycling at the end of the lifecycle and supports SUE's claim to consider sustainability not only in the propulsion system but throughout the entire vehicle architecture.

"With SUE, we pursued a user- and design-centered approach from the beginning," says Alexander Uedelhoven, founder and project manager of SUE and authorized signatory at UE | STUDIOS. "We wanted to develop not just a technologically advanced vehicle, but one optimally aligned with passenger needs in terms of service, information, ergonomics, and aesthetics. The materials and extensive technical expertise from Covestro gave us the freedom to implement this vision without compromises."

The project was realized in collaboration with renowned partners, including the Institute for Automotive Engineering of the Lower Saxony Research Centre for Automotive Technology (NFF), TÜV Nord, the Fraunhofer Institute EMFT, and Deutsche Bahn (DB Regio).

As initiator, project manager and vehicle manufacturer, UE | STUDIOS are responsible for the overall concept, complete development, design and production of the SUE People Mover.

The capacity expansion at Covestro Integrated Site Shanghai (CISS) comes in response to growing customer demand for TDI, a key component used primarily in flexible foams for furniture, mattresses and automotive applications. The debottlenecking project was completed on schedule and will enable Covestro to provide more reliable supply to customers throughout the region.

Commitment to supporting customer growth

"This investment demonstrates our commitment to supporting our customers' growth in Asia Pacific, particularly in China and the broader region," said Xiaobin Zhong, Covestro's Head of Performance Materials Sales in the Asia Pacific region. "By expanding our TDI capacity in Shanghai, we ensure reliable supply to meet increasing market demand while reinforcing our position as a preferred partner for the furniture and automotive industries."

The site, located in the Shanghai Chemical Industry Park, is one of Covestro's largest production facilities worldwide. The successful debottlenecking project involved optimizing existing production processes and infrastructure rather than building new production lines, resulting in a more resource-efficient approach to capacity expansion.

Disciplined investments in growth areas

"This achievement reflects our strategy of growing through smart, efficient investments that deliver maximum value to our customers," said Hermann-Josef Doerholt, Head of Performance Materials at Covestro. “It also further strengthens Covestro's global TDI production network, which includes world-scale plants in Dormagen, Germany and Baytown, Texas, ensuring that we can reliably serve customers across all major regions.”

TDI is an essential component for producing flexible polyurethane foams, which provide comfort in furniture, mattresses, and car seat

Across industries, companies must increasingly demonstrate sustainability progress to meet market requirements, Scope 3 reporting needs, and comply with growing regulatory requirements. ”The CQ-Configurator supports these needs by enabling rapid, data-based environmental performance assessments and by improving transparency along the polyurethane value chain.”, said Patrizia Wegner, VP Sales Flex Foam EMLA, Covestro.

“Companies can now compare material choices and reach their desired product sustainability profile in just a few clicks — eliminating the need for time-consuming calculations and lengthy alignment processes”, said Dennis Wagner, Marketing Manager Soft Furniture, Covestro.

From data to decisions: Making sustainability tangible

The CQ-Configurator intuitively allows users to select between flexible or rigid foam applications — such as mattresses, insulation panels, or even special formulations — define technical properties and specify shares of mass-balanced isocyanate and polyol options. The tool then calculates the associated CO₂ impact and sustainable material share of each formulation scenario.

By translating formulation choices into clear, application-specific sustainability results, the CQ-Configurator provides companies with a transparent fact base to support internal decision-making. It enables rapid comparisons of different material options with exportable results that facilitate cross-functional alignment and customer discussions. At the same time, the tool links material choices to market-relevant sustainability benefits, supporting both product development and marketing strategies.

Designed for broad industry use

The tool supports various professional roles involved in product development, including R&D specialists, procurement teams, sales managers, marketing professionals, and sustainability experts. Its intuitive interface ensures that both technical and non-technical users can leverage the insights effectively.

“As sustainability becomes a key differentiator across markets such as bedding, furniture, construction, and appliances, the CQ-Configurator helps companies to make informed choices that align product performance with economic considerations,” added Dennis Wagner.

With the launch of the CQ-Configurator, Covestro is the first European PU materials supplier to offer a comprehensive digital sustainability assessment tool focusing on multiple polyurethane foam applications. Built on third-party verified raw material LCA data¹ and long-standing PU expertise of Covestro, the tool provides transparent and credible sustainability metrics that support informed decision-making across the value chain. The company continues to expand its digital portfolio to support customers in meeting their sustainability targets.

For more information and to request a demo, please visit the CQ-Configurator landing page.

_{1 Methodology for LCA data calculation certified by TÜV Rheinland}

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 ›

Latest info on Covestro’s K fair presence:

• Experience “The Material Effect” at K 2025 at Covestro | Covestro AG

Additional Press Releases:

• From Materials to Solutions: Covestro Brings "The Material Effect" to K 2025
• Digital Material Twins in Automotive Design: Imagio^® of Covestro Now Integrated into Autodesk VRED
• Covestro deepens collaboration with Ausell to advance end-of-life automotive plastics recycling
• More speed from design to series production
• From old tires to new car parts: Covestro, Neste and Borealis aim at closing loop for automotive industry 
• Covestro and Deloitte jointly develop Monetization Framework for Circular Economy
• Life Cycle Assessments digitalized: boosting transparency

Covestro at a Glance:

Are you looking for more information? Here you could find further facts about Covestro.

Monique Buch, Chief Commercial Officer at Covestro: "The chemical industry and many of its key customer industries face profound transformations – on the path to circular economy, through AI and digitalization, or due to geopolitics and the realignment of global markets. With our expertise in high-performance materials, process and application development, we remain part of the solution and support our customers in achieving their goals."

The solutions presented at "K" are organized across the booth in the areas of Automotive, Electronics, Healthcare, Sports and Leisure, as well as Sustainable Future. They showcase "The Material Effect" in application across various industries and underline the company's long-term vision of a complete alignment with the circular economy. This vision remains the North Star for Covestro and the industry – despite short-term challenges and overlapping crises that require resilience and adaptability.

Materials with Impact: "The Material Effect" in Practice

Jochen Hardt, Booth Manager and Vice President Global Marketing Mobility in the Engineering Plastics business entity at Covestro: "At our booth, visitors can experience first-hand how 'The Material Effect' becomes reality in concrete applications. We deliberately present not only materials and products but showcase well-designed system solutions that offer real added value to our customers. My team and I at Covestro look forward to engaging with visitors throughout the fair!"

Sustainable Future

In the "Sustainable Future" area, Covestro demonstrates its comprehensive commitment to the circular economy. This includes the "CQ" portfolio, which marks products containing at least 25% alternative raw materials. Another example is the technology developed by Covestro and partners for producing plant-based aniline. Also featured are several car-to-car recycling projects that advance circularity in the automotive industry. For example, the NALYSES project, where Covestro works together with partners like HELLA and BMW on the circularity of headlights. Or a pilot program with NIO, VW, and GIZ for recycling polycarbonate parts. For the latter, visitors will find materials labeled "RE", "RP", and "R" at the booth – these are partly made from alternative raw materials.

Automotive

Highlight in the automotive area: The SUE "People Mover" – a prototype vehicle for public transportation. The autonomous e-shuttle was designed and developed by UE | STUDIOS. It features large-scale, curved 3D polycarbonate glazing as well as seamless integration of driver assistance systems and sensors, also using polycarbonate. The lightweight, highly durable monomaterial Arfinio® is used in the interior, along with a recyclable TPU monomaterial seat. The IMAGIO® tool for digital, photorealistic material twins will also be on display. It is now implemented in Autodesk VRED and makes design processes faster and more efficient.

Electronics

In the electronics area, Covestro showcases innovative NIA-PFAS (not intentionally added PFAS) polycarbonates with flame retardancy for laptop covers and IoT device housings. Additionally, a recyclable antenna housing made of Makrolon® monomaterial will be on display, combining optimal signal transmission with weight reduction.

Healthcare

In the healthcare booth area, Covestro presents material solutions that combine sustainability with performance and reliability: From medication delivery with particularly thin-walled, more easily recyclable monomaterial injectors to resistant housings for diagnostic devices that withstand disinfectants. Such devices can furthermore be made with NIA-PFAS material types for flame retardancy, and support the seamless integration of functionality such as touch operation and signaling in an attractive design.

Sports and Leisure

In the sports and leisure area, visitors will find applications such as the e-surfboard by Awake. Covestro materials can be found, for example, in the easily and quickly replaceable battery, with thermally conductive and flame-retardant polycarbonate for improved battery performance. Durable TPU-based materials on the grip of the replaceable battery additionally provide pleasant haptics and comfort.

Press Tour for Media Representatives

Media representatives are cordially invited to experience Covestro's exhibition booth at K 2025 in person. A press tour will take place on the first day of the fair, October 8, 2025, at 3:00 p.m. at booth A75 in Hall 6.

The tour offers a comprehensive overview of all focus areas as well as the opportunity for discussions with technical experts about "The Material Effect" and the implementation of the circular economy strategy in concrete applications. There will also be opportunities for individual interviews.

For more information about Covestro at K 2025, please visit Experience “The Material Effect” at K 2025 at Covestro | Covestro AG

The announcement aligns strongly with this year’s World Green Building Week¹ motto, “Business goes better when you're bold on buildings,” as partners Covestro, Recticel and Brightlands all work towards bold, more sustainable solutions that do not compromise on technical performance but enable the building industry to reduce its ecological footprint and accelerate its transition to circularity.

“The construction sector is responsible for about 37% of global CO₂ emissions, with around a quarter stemming from embodied carbon², e.g. emissions associated with the building materials before a building is even in use,” says Fernando Resende, Marketing Manager Building & Construction EMEA-LATAM at Covestro. “This urgently needs to change. Through our collaboration with Recticel, we’re able to offer a compelling alternative.”

Brightlands Circular Space: Platform for circular collaboration

The 7,500 m² Circular House will serve as a living lab for demonstrating, co-creating and piloting zero-waste plastic technologies. It integrates sustainable design at every level, using innovative materials to reduce both operational and embodied carbon. As part of its mission, Circular House aims to share best practices in circular solutions in its Experience Space and host events in which Covestro and Recticel could share knowledge about circular building materials with students and peers as well.

“In the Circular House, we chose insulation boards that incorporate more sustainable raw materials, meeting both performance and sustainability requirements,” states Lia Voermans, chair of the Steering Board at Brightlands Circular Space. “This way, we apply the same circular principles driving Brightlands Circular Space by embedding them into the design of our demonstration facility for circular plastics, showing how circular and low-carbon materials can be integrated into real-world building projects.”

The building, located on Brightlands Chemelot Campus in Sittard-Geleen, the Netherlands, is part of the Brightlands Circular Space. The facility is the first of its kind: an open-access, circular plastics demonstration hub where R&D can be scaled and integrated with real-world industrial infrastructure.

Jointly furthering sustainability

Covestro has enabled Recticel to use Desmodur^® CQ MS into its Recticel’s “Eurothane^® Silver Impact” insulation boards, which are now used to insulate the roof of the Circular House at Brightlands. Desmodur^® CQ MS is based on climate-neutral³ methylene diphenyl diisocyanate (MDI), produced using bio-circular feedstocks, certified via the mass balance approach. As a result, the “Eurothane^® Silver Impact” boards used in the Circular House contain 43%⁴ less embodied carbon compared to standard versions, while maintaining the trusted technical and thermal performance.

“The buildings of tomorrow must be measured by more than just energy efficiency. They must address embodied carbon, material circularity and long-term environmental impact across their entire lifespan,” says Benedikt van Roosmalen, Commercial Manager at Recticel. “The collaboration with Covestro allowed us to create Eurothane^® Silver Impact insulation boards, which have a reduced carbon footprint compared to conventional insulation boards.”

About Recticel:

Recticel is a Belgian insulation Group with a strong presence in Europe and the USA. It offers smart insulation solutions that advance a carbon-free economy and a better quality of life.
Recticel delivers upon a portfolio of Insulation Boards, Insulated Panels and Acoustic Solutions.
Recticel Insulation designs polyurethane thermal and thermo-acoustic boards for optimal building comfort and energy efficiency. This includes vacuum insulation panels (VIP) by Turvac.
Trimo enables the highest aesthetic standards and extends architectural capabilities with its mineral wool insulated panels and modular space solution, primarily in non-residential applications. With the recent acquisition of REX Panels & Profiles, the portfolio now includes PIR insulated panels.
Soundcoat provides acoustic solutions used in some of the world’s leading technological innovations.
At the end of 2024, Recticel employed 1,275 people and had achieved sales of EUR 610.2 million. Its operations are spread over seven countries.
The Science Based Targets initiative (SBTi) approved Recticel’s near-term targets for the reduction of scope 1, 2 & 3 greenhouse gas emissions by 2030 (from base year 2021) and net-zero targets for 2050.
CDP added Recticel to its 2024 A list for Climate Change.
Recticel is listed on Euronext in Brussels (Euronext: RECT - Reuters: RECT.BR - Bloomberg: RECT:BB).

About Brightlands Circular Space:

Brightlands Circular Space (BCS) is in Sittard-Geleen (NL) and is a cooperation between Brightlands Chemelot Campus, Maastricht University and TNO (the Dutch Organization for Applied Scientific Research).
BCS is part of the Brightlands ecosystem of 30.000 innovators and 350 companies and addresses sustainability by advancing the circular reuse of plastics, transforming them into raw materials for new products and closing the loop on an industrial scale. Currently BCS is building a first of a kind open innovation R&D demonstration center, designed with sustainability and circularity as priorities and with the aim to foster the development and scaling of circular plastic solutions in fields as packaging, automotive and electronics. From here, BCS facilitates collaboration across the entire plastics value chain.

_{¹ World Green Building Week is an annual global campaign organized by the World Green Building Council (WorldGBC) to accelerate sustainable buildings for everyone, everywhere. The 2025 edition takes place from September 8–12, with activities coordinated by Green Building Councils and partners worldwide.}

_{² According to the Global Alliance for the Building and Construction from United Nations Environment Programme}

_{³ Climate neutrality is the result of an internal assessment based on the TÜV reviewed EcoPAss LCA method (ID No. 0000083440), 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 calculation takes into account biogenic carbon sequestration based on preliminary data from the supply chain. No compensation measures were applied.}

_{⁴ Internal LCA calculation according to EN15804+A2 standard, for modules A1 - A3 (cradle to gate), based on the mass balance method.}

In qualifying, the Covestro Æthon secured pole position with a time of 1:52.50 minutes, setting a new team record. Never before has a Team Sonnenwagen solar race car been faster on the circuit in Darwin. After five days of racing, the new Sonnenwagen Covestro Æthon finished in fourth place – a world-class performance in a strong field of 37 teams from 18 countries, made possible in part by Covestro products.

“Regardless of the outcome of the race, Team Sonnenwagen has done a great job in my opinion,” says Dr. Thorsten Dreier, Chief Technology Officer at Covestro. “What these students from Aachen have achieved with the design of their solar car is a demonstration of innovative strength, team spirit, and determination. They deserve nothing but congratulations. And I am always delighted that we are able to support this extraordinary team with our innovative and sustainable technologies and our expertise.”

“We are incredibly proud of what we have achieved,” says Leonie Brandt, Chair of Team Sonnenwagen Aachen. “Just finishing this race is an enormous achievement – and with Æthon, we made it into the ranks of the world’s best teams. Our vehicle proved itself under extreme conditions, and we are taking away many important insights.”

Covestro has been supporting Team Sonnenwagen since its founding in 2017 and has been its main sponsor and technology partner since 2018. The company is convinced that more sustainable high-performance plastics are key to climate-neutral and circular mobility. Together with customers and partners, Covestro is continuously developing new material solutions and recycling technologies for this purpose.

As with previous vehicles, the Æthon also relied on more sustainable high-performance plastics from Covestro – this time even more than ever before: over ten different materials from the company were used in the car.

One example of the application of our raw materials is chemically recycled car seat foam, which offers comfort while conserving resources. Sustainable mass-balanced Vulkollan^®, a particularly resilient elastomer that absorbs shocks between the battery and the chassis, was also used to protect the structure. For the cell holders, the team used Makrolon^® TC, a thermally conductive polycarbonate that helps to reduce the temperature during battery charging and discharging, thereby increasing the battery's service life. The coating cures at room temperature and contains a binder with a high proportion of sustainable Covestro raw materials. In addition, other Covestro raw materials were used as materials in the cockpit hood, outer shell, headlights, seat, and steering wheel, for example.

The more than 20 innovation stories that Covestro presents at its booth are closely linked to this guiding idea and the company's long-term vision of becoming fully circular. This vision is gaining additional importance under the current circumstances – short-term challenges and overlapping crises that require resilience and adaptability.

Covestro’s CEO Markus Steilemann emphasized this at the traditional K pre-press conference: "The world seems to have gone off track, and the chemical industry is feeling the full force of the current multiple crises. At the same time, the future will be ever greener and smarter. At Covestro, we are paving the way for that for many sectors with our recyclable, climate-neutral high-performance plastics – whether in e-mobility and autonomous driving, efficient buildings, or digitalization. We are excited to showcase the diverse and beneficial effects of our materials for our customers and partners at this year's K trade fair."

Covestro's Guiding Idea: "The Material Effect"

At booth A75 in Hall 6, Covestro will place special emphasis on progress and innovations in the areas of Sustainable Future, Automotive, Electronics, Healthcare, and Sports & Leisure. Among the highlights at the booth will be a new concept vehicle for public transportation: The SUE "People Mover". The self-driving urban e-shuttle has been developed by UE | STUDIOS. It features full polycarbonate glazing, polycarbonate for lidar sensors, as well as the lightweight and highly durable mono-material Arfinio^® and TPU. Also among the exhibits is the digital sampling tool IMAGIO^®, which enables realistic digital visualization of product designs, thereby replacing physical samples with digital material twins in early development phases.

With these and many other stories and exhibits at the booth, Covestro demonstrates under this year's guiding idea "The Material Effect" what role high-performance materials play in a sustainable world. "The Material Effect" combines best in class materials with process and innovation expertise, enabling the leap from laboratory to industry. "It is precisely this unique combination of material science, process- and application development that makes the decisive difference," said Jochen Hardt, K 2025 project lead and Vice President Global Marketing Mobility in the Engineering Plastics business entity at Covestro, at the press conference. “'The Material Effect' enables our customers and partners to achieve more – in terms of sustainability, circularity, and performance of their products.”

Progress Towards Corporate Vision and Strategy

Covestro pursues a clear strategic vision: to become fully circular and make the circular economy a global guiding principle. This includes the use of alternative raw materials, switching to green energy, and developing advanced recycling technologies. The company has set a goal to become climate-neutral in its own operations (Scope 1 and 2) by 2035 and to achieve complete climate neutrality along the entire value chain (Scope 1-3) by 2050. To this end, Covestro has already signed eleven power purchase agreements (PPAs) and now covers around 16 percent of its global electricity needs from renewable sources.

Furthermore, Covestro is consistently expanding the use of alternative raw materials – with the goal of largely avoiding the use of fossil primary raw materials in the long term. The company is to that end currently developing and testing novel recycling technologies for polyurethanes, polycarbonates, and elastomers.

The commitment to the circular economy is furthermore reflected in the product portfolio: Products with the brand suffix "CQ" – which stands for Circular Intelligence – contain at least 25 percent alternative raw materials. For polycarbonates, Covestro differentiates its offering with specific labels: "RE" stands for products based on renewable raw materials and produced with renewable electricity.^* "RP" identifies products with chemically recycled post-consumer waste.^* "R" designates products with mechanically recycled material content.

Such products aFor more information about the trade fair presence, visit:

For more information about the trade fair presence, visit:
Experience “The Material Effect” at K 2025 at Covestro | Covestro AG

_{* attributed via mass balancing}

Latest info on Covestro’s K fair presence:

• Experience “The Material Effect” at K 2025 at Covestro | Covestro AG

Additional Press Releases:

• Covestro deepens collaboration with Ausell to advance end-of
• More speed from design to series production
• From old tires to new car parts: Covestro, Neste and Boreali
• Covestro and Deloitte jointly develop Monetization Framework
• Life Cycle Assessments digitalized: boosting transparency

Covestro at a Glance:

Are you looking for more information? Here you could find further facts about Covestro.

"What the students from Team Sonnenwagen have achieved here, alongside their regular studies and exams, is really impressive," said Dr. Thorsten Dreier, Chief Technology Officer at Covestro, during the unveiling. "The collaboration between our experts and the students has been and continues to be a great inspiration. Together with all the other strong partners, we're demonstrating what tomorrow's mobility can look like. We’re proud that we can contribute innovative materials and know-how to help shape a more sustainable future."

"Æthon" is the result of twelve months of intensive development. Over 40 students from RWTH and FH Aachen designed, tested, and built the vehicle alongside their studies – supported by Covestro as main sponsor and technology partner. The Leverkusen-based materials manufacturer contributes more expertise than ever: More than ten different Covestro materials have been incorporated into the vehicle – a record in the project's history. The solar car thus provides the company with the additional opportunity to test materials for series vehicle production under extreme conditions.

"We are very proud of Æthon. The entire team has put their heart and soul into this project," explains Leonie Brandt, Chair of Team Sonnenwagen. “The same goes for our partners, especially Covestro, who have been involved in the project for so long. Without this expertise and support, there would be no Sonnenwagen, and we wouldn't have been as successful as we've been. This year, we want to repay everyone involved with a victory in Australia. We're looking forward to it!”

Material Solutions for Future Mobility

Like its predecessors, the new Sonnenwagen relies on sustainable and innovative materials. The highlights: chemically recycled foam in the driver's seat – proving that comfort and circular economy can go hand in hand. Chemically recycled Vulkollan®, an extremely durable elastomer, is also used. It dampens impacts between battery and body, contributing to the structure's longevity. Covestro materials are also used in the battery cell holders, aerodynamic outer shell, interior trim, headlights and turn signals, as well as in the coating.

New Rules, New Challenges – New Opportunities

Such high-tech materials are more important than ever this year, as new rules apply at the World Solar Challenge: The allowed battery capacity has been halved, and the development time shortened by two months. At the same time, cars are allowed to be longer – an opportunity Team Sonnenwagen consistently utilizes with "Æthon": At 5.80 meters, it's longer and features six square meters of solar cells – a full two square meters more than its predecessor "Covestro Adelie." Additionally, the racing calendar brings a new challenge: This year, the race takes place at the end of the Australian winter - and thus earlier than usual. For the team, this meant less time for development and testing.

The official unveiling of Æthon marks the beginning of the intensive testing phase. In July, Team Sonnenwagen will depart from Aachen to Australia to compete against over 50 teams from 24 countries – including numerous leading international universities. Covestro continues to support the project on its journey – with the shared goal of advancing sustainable mobility and bringing the world championship title to Aachen with the power of the sun.

"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.

Hanno Bruemmer, Head of Supply Chain and Logistics EMLA at Covestro, stated: “The entire value chain must be involved to achieve our joint goal of climate neutrality by 2050. Reliable, efficient and sustainable logistics for our ever more sustainable products are integral to this effort. We collaborate with our customers and transport companies to optimize the supply chain. This includes improving load capacity, selecting the best transport modes and routes, and introducing using sustainable and future-oriented energy sources like green electricity or HVO to replace fossil fuels.”

As part of the collaboration, DB Cargo BTT provides Covestro with an end-to-end transport solution that combines several sustainable approaches: First, the chemicals are transported in tank containers from the production sites of Covestro in Germany to a nearby railway terminal using bio-fuel (HVO 100)-driven trucks. The tank containers are then transported to a distribution center in Poland via rail, keeping trucks off the road and saving respective emissions. From there, bio-fuel (HVO 100)-driven trucks are again deployed to distribute the chemicals to end customers in Poland to ensure on-time delivery. This particular bio-fuel is one of the most sustainable alternatives to fossil diesel. Altogether, the combination of these modes of transport saves at least 70% of CO₂ emissions compared to conventional road transport methods.

Torsten Lüders, Managing Director of DB Cargo BTT GmbH, points out: “At DB Cargo BTT, we also rely on working with external partners across all modes of transport in order to arrange traction or first and last mile services as efficiently as possible for our customers. For Covestro, we have recently transported essential chemical products to Poland and we’re now happy to combine our rail expertise with bio-fuel-driven trucks for the first and last mile. This collaboration exemplifies our commitment to enabling more sustainable supply chains and supporting the transformation of the chemical industry. Projects like these demonstrate how we, as part of the DB Cargo group, offer our customers a significant degree of added value and are an essential part of European supply chains.”

The collaboration is designed to be flexibly scaled in the future to accommodate growing business needs. It also sends an important signal to customers of Covestro, such as the Polish Selena Group, a global manufacturer of construction chemicals and materials, who benefit from the delivery of MDI with a lower carbon footprint, as it helps to reduce their Scope 3 emissions.

Bernd Hennig, Head of Trading Cluster MDI at Covestro remarked: “Together with Selena Group, we are committed to advancing sustainable solutions across the entire value chain, offering our valued customers not only more sustainable materials but also sustainable transportation solutions.” Michal Specjalski, Member of the Management Board of Product and Innovation at Selena Group added: “Today, sustainable business no longer means having to compromise between efficiency and quality. In Selena Group we are constantly increasing our commitment to the development of sustainable construction. We carefully follow trends and changes in the world around us. We are constantly working on minimizing our environmental impact and rational resource management. That’s why we are delighted to have Covestro and DB Cargo BTT at our side as strong partners who share our commitment to reducing emissions and achieving climate neutrality targets in Europe and worldwide.”

Selena Group and Covestro are already collaborating in multiple ways to advance the circular economy. For instance, they are developing polyurethane (PU) foams for improved thermal insulation in buildings which are based on MDI of the Desmodur^® CQ product range. It is ISCC Plus-certified, using plant-based raw materials through mass balancing. As a result, these products have a lower carbon footprint compared to those derived from fossil raw materials—and now, thanks to the transport solution, they will also be delivered to Selena in a more sustainable way.

¹ _{The reduction in CO₂ emissions is based on a comparison between the use of HVO100 renewable diesel and conventional fossil diesel}

For the highly competitive construction sector, the product sold by Selena offers clear advantages: It can be used with various types of blocks (ceramic, silicate, ACC) with high accuracy and allows for a higher yield compared to traditional cement mortars. The product also improves construction efficiency by curing twice as fast as traditional cement mortars. Additionally, it can be used in a wide range of operating temperatures from -5 degrees Celsius to +30 degrees Celsius, which helps reduce temperature-induced work stoppages.

“Materials play a decisive role for an ever more climate neutral and circular economy”, said Bernd Hennig, Head of Trading Cluster MDI EMEA at Covestro. “If materials providers early in the value chain join forces for climate neutrality, the impact on end products will be significant. In this spirit, we are therefore very happy to deepen our collaboration with our like-minded partner Selena to help the construction sector bring down emissions and meet its climate neutrality targets in Europe and worldwide.”

Buildings are responsible for over one third of greenhouse gas emissions in the EU alone. As about 75% of the buildings in Europe do not meet energy efficiency requirements, the building sector faces a wave of renovations over the coming years. In fact, the EU has just recently updated the Energy Performance of Buildings Directive (EPBD). It states that by 2050, all buildings in the EU should be net-zero emission buildings².

More sustainable adhesive instead of cement

“With existing and upcoming climate neutrality regulations for the construction sector, we expect a steeply rising demand for sustainable building materials”, said Miroslaw Truchan, Senior Category Development Manager, Selena Group. “With a great partner like Covestro, we jointly drive innovation in the construction materials industry. We both believe that innovative products can play a vital role in achieving climate neutrality targets and put us ahead of the curve.”

The Tytan Professional^® Adhesive for Bricklaying uses Desmodur^® CQ MB of Covestro, a bio-based MDI (methylene diphenyl diisocyanate), of which the plant-based feedstock is mathematically attributed to the final product via the mass balance approach certified by the ISCC Plus standard.

Tytan Professional^® Adhesive for Bricklaying is the third product launched from the collaboration between Selena and Covestro. The partnership was deepened in 2023, aimed at collaborating to craft a more sustainable range of polyurethane (PU) foams for enhancing thermal insulation of buildings. Bio-attributed methylene diphenyl diisocyanate (MDI) of the Desmodur^® CQ MB-series of Covestro is already being used in an enhanced version of Selena’s Ultra Fast 70 one-component foam, primarily applied in the installation of windows and doors. Also, this product is ISSC Plus certified to include plant-based feedstocks through mass balancing and allows for an up to 45% reduced carbon footprint compared to fossil-based products.

_{¹Comparison of 1 can of Tytan Adhesive for Bricklaying (750ml) with the data for generic cement mortar for 1,5 x 25 kg bags.
²https://www.consilium.europa.eu/de/infographics/fit-for-55-making-buildings-in-the-eu-greener/#:~:text=Mit%20der%20%C3%9Cberarbeitung%20der%20Richtlinie,in%20der%20EU%20Nullemissionsgeb%C3%A4ude%20sein}

Covestro will supply Carlisle with methylene diphenyl diisocyanate (MDI) that is based on ISCC PLUS certified mass balanced bio-circular raw materials and features up to a 99%¹ lower product carbon footprint than fossil-based MDI. It specifically has a CO₂ reduction potential of 2.4 KG per KG of MDI produced.² This will enable Carlisle to produce its high-performance polyiso insulation boards with lower embodied carbon.

The collaboration between Covestro and Carlisle extends a legacy of joint innovation in the construction industry that spans decades. As sustainability targets for the built environment stand to increase, the two companies are prepared to develop and introduce the next generation of insulation materials.

“Covestro’s vision to become fully circular requires R&D advancements that directly support the scope 3 goals of our customers, like Carlisle,” said Hermann-Josef Doerholt, global head of the segment Performance Materials at Covestro. “Covestro has some of the most aggressive sustainability and climate targets in the chemical industry, and the further we progress in developing solutions to achieve them, the more the effects resonate along the supply chain.”

Covestro will supply its Mondur^® CQ 489 MS isocyanate to Carlisle. The CQ, or “Circular Intelligence” designation represents a broad family of Covestro’s circular products with an attribution of at least 25 percent alternative raw materials derived from biomass or recycled plastics.

Carlisle Construction Materials, a global leader in building envelope solutions, aims to be net zero by 2050. Carlisle will produce its bio-based rigid foam insulation, which contains 5% bio-circular content, for the SynTec, Versico, Hunter Panels and WeatherBond brands. This state-of-the-art bio-based insulation is the latest addition to Carlisle Construction Materials' portfolio of sustainable building products.

"Carlisle Construction Materials has always been at the forefront of developing high-performance construction products that lead the way in sustainability," said Steve Schwar, President of Carlisle Construction Materials. "With our new bio-based rigid foam insulation, we are demonstrating our unwavering commitment to environmental responsibility while ensuring that our customers have access to the most advanced building materials available. Our partners play a pivotal role in the realization of our bio-based isolation," added Steve. "Together, we're not only pushing the boundaries of material science, but also supporting the construction industry's transition to a more sustainable future."

“At Covestro, we have long understood the unparalleled performance attributes of polyurethane insulation,” said Julia Rubino, head of sales for Performance Materials at Covestro North America. “The ability to provide an innovative, bio-circular raw material solution to a long-time partner and a leader in the construction industry, like Carlisle, shows that future-focused sustainable solutions are available today.”

Covestro has ISCC PLUS certified facilities in every major global market, including its manufacturing facility in Baytown, Texas. In support of its vision to be fully circular, Covestro aims to be operationally climate neutral (scope 1 and scope 2) by 2035 and climate neutral for scope 3 by 2050. The company currently has hundreds of circular CQ products and is continuously expanding its product portfolio.

_{¹ Exact percentage depends on the amount of allocated raw material. 
² Bio-circular attributed MDI contains ~60% ISCC PLUS certified feedstock. The calculation is based on Covestro-specific production and supply chain data, replacing fossil raw material with ISCC PLUS certified renewable feedstock via the mass balance approach.}

“Circularity requires cooperation, and this cooperation with our partners Neste and Borealis is testament to the possibilities at our disposal,” says Guido Naberfeld, Senior Vice President, Head of Sales and Market Development Mobility at Covestro. “We are creating options to turn old tires into new car parts again. With that, we are supporting our automotive customers and addressing an increasingly prominent question discussed across the value chain: How to match high-performance materials with recycled content? Projects like this can be the answer.”

As part of the collaboration, Neste turns liquefied discarded tires into a high-quality raw material for polymers and chemicals manufacturing and supplies it to Borealis. Borealis will then process the Neste-produced raw material into base chemicals phenol and acetone, which are supplied to Covestro. Covestro can use these materials to make polycarbonates. The share of recycled content is attributed via the mass balancing approach all the way to the final products using ISCC Plus certification.

The first products based on the collaboration are already available as each party has manufactured the first batch of their respective contribution to the project. Aside from polycarbonates, the project partners may also consider polyurethanes as a possible end product, which could also find its way into parts of the interior of a car. The companies emphasize that the potential to scale-up these types of developments should be considered when setting ambitious targets for future EU regulations, such as the End of Life Vehicles Regulation.

“We are demonstrating the importance of value chain cooperation to give new value to waste,” says Thomas Van De Velde, Senior Vice President Base Chemicals at Borealis. “We are proud that Borealis, in collaboration with Neste, is able to play a role in this project, providing more sustainable solutions for polymer applications for Covestro and its customers.”

“This project can serve as a blueprint when it comes to establishing circularity in the field of plastics in cars,” says Jeroen Verhoeven, Vice President Value Chain Development for polymers and chemicals at Neste. “It shows how low-quality waste materials can be turned into very high-quality plastics. This is good news for the polymers and automotive industries as well as for the environment.”

The collaboration will be presented during the PIAE in Mannheim on June 19-20, 2024.

The aim of the partners is to recycle the sorted polyurethane foams as efficiently as possible by combining mechanical and chemical technologies after careful sorting by foam type in the mattress cutting plants.

Collaborations leveraging own expertises with like-minded partners are key: In addition to Ecomaison and Covestro, the French dismantling company Secondly and Federal Eco Foam, a Belgian specialist in the mechanical recycling of flexible foams, are involved as partners in the project, which is planned to run for a maximum of 24 months. The project is called Foam Recycling Ecosystem Evolution (FREE) and coordinated by Covestro and half-funded by Ecomaison.

For the FREE consortium, the motivation lies in the added value of the material that can be recovered from the used foams and the opportunity to enter a more sustainable circular economy. The partners want to explore all possibilities in a future-oriented foam recycling ecosystem and are convinced that chemical and mechanical recycling will complement each other in a meaningful way. As dismantler and sorting actor, Secondly is interested in empowering its sorting processes to be able to supply to recyclers a specified quality of foam.

At the same time, the project will provide a good picture of how the foam recycling market in the coming years may look like. The partners truly believe that chemical and mechanical recycling can be complementary given different specifications of inlet materials being sorted already at dismantlers. To provide added value to the PU foam material, the consortium will investigate all possibilities in a future oriented eco-system of foam recycling.

The research and development project includes the foam sorting at the dismantling step, as well as a comparative feasibility study for two recycling processes for the sorted foams covering economic and ecologic value co-creation.

A few years ago, Covestro and its partners developed a chemical recycling process that is the only one of its kind capable of ultimately recovering both main raw materials of flexible PU foams in high purity. The company also operates a pilot plant at the Leverkusen site for this purpose. Together with the waste management industry, the company wants to drive the process forward to industrial use.

To make its vision of a fully circular economy a reality, Covestro is making the development of innovative recycling technologies a priority and calls the evolution of recycling Evocycle^® CQ. The chemolysis of PU mattress foam is the first initiative of Covestro of its kind and is called Evocycle^® CQ Mattress.

At its booth (C20), Covestro will present materials and solutions that support the corporate vision of achieving a circular economy. Climate neutrality¹ is a core element of that, for which the company just recently announced its “Scope 3 emission” targets, encompassing anything from the raw material base of products to their transport, the performance during their lifetime and the end of their life. By 2035, Covestro intends to reduce 30% of those emissions, while being entirely climate neutral across all scopes by 2050. Working towards that goal, the company’s product portfolio will become ever more sustainable.

“As provider of polyurethane raw materials and solutions, including for example systems for Elastomers, we are at the forefront of circularity and climate neutrality. We take that responsibility seriously and develop recycling technologies, switch to renewable energy and already started the switch to an alternative raw material base,” says Thomas Braig, Head of Elastomers at Covestro. "All the while we ensure maximum quality and performance of our products and to enable our customers to be successful to meet the needs and demands of the market. At our booth at UTECH Europe, customers and interested parties can get a glimpse of how we combine circularity and climate neutrality with product and innovation quality.”

To achieve full circularity, collaborations across value chains in and beyond core industries such as Automotive, Building and Construction or Furniture and Appliances will be key. The motto of Covestro’s booth therefore is “Crafting Solutions For You”, inviting for in-depth exchanges and discussions. It is divided into three core areas:

Crafting Sustainability

In the area dubbed “Crafting Sustainability”, Covestro will be showcasing innovative products and solutions from the fields of alternative raw materials, innovative recycling and renewable energies that tile the way to circularity. One example among the exhibits is Desmodur^® CQ MS. This climate-neutral MDI (cradle-to-gate assessment) is a key component in the production of low-carbon PU insulation boards, specifically designed for thermal insulation purposes.

Crafting Innovations

In the area “Crafting Innovations”, Covestro shows that innovative materials and solutions will be key to answer an ever more demanding market in terms of properties and reliability while striving to cope with the commanding challenge of a more circular and climate neutral world. At the booth, the company will for example showcase a Baulé^® alpha low pressure dispensing machine for cast PU processing. This machine is notably equipped with catalyst and pigment direct injection and allowing an output up to 10 kg/min. To demonstrate automated production capabilities, the company will also showcase a 3-axis robot equipped with sensors and camera allowing automatic mould detection and casting frame selection as well as safety alarms to improve and secure the casting process.

Covestro will furthermore give a glimpse on the latest in terms of recycling with its Evocycle^® CQ program. The goal of the Evocycle^® CQ Mattress initiative is to bring end-of-life polyurethane (PU) mattress foam back to its building blocks polyether polyol and toluene diamine (TDA), a key precursor of toluene diisocyanate (TDI), via chemical recycling. These shall then again be used just like virgin materials.

Crafting Performance

Circularity won’t happen unless sustainable products provide at least equal value and quality for customers and industries. Covestro aims to provide its customers with exactly that – and will showcase some examples how it “crafts performance” during UTECH Europe. For example several products made with Desmodur^® 15 prepolymer based systems. On top of improving safety and comfort in the railway sector, these cost-effective and safe solutions can also boost the sewing process in the loom shuttle or reduce maintenance costs in the offshore wind industry.

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 (of Covestro), also known as cradle-to-gate assessment. The methodology of our LCA, for which an external audit and certification will soon be available, is based on the ISO 14040 and 14044 standards. The calculation takes into account biogenic carbon sequestration based on preliminary data from the supply chain. No compensation measures were applied.}

Building upon previous sustainable sourcing efforts, this marks the first major procurement agreement involving chemically recycled, circular-based raw materials for Covestro, a major step in the company’s journey towards full circularity. It also helps reduce scope 3 emissions for Covestro and its customers.

"The ability to source raw materials from used plastics for the manufacture of our products makes a decisive contribution to realizing our vision of a circular economy," said Thorsten Dreier, Chief Technology Officer at Covestro. "This is because such raw materials not only enable the reuse of used plastics, but also have a lower carbon footprint, which leads to more sustainable end products."

Benzene and toluene are important raw materials in Covestro’s manufacturing processes used for the production of methylene diphenyl diisocyanate (MDI) and toluene diisocyanate (TDI), respectively. MDI and TDI are critical raw materials used to produce rigid and flexible polyurethane foams, which are used in applications such as household appliance and building insulation as well as furniture and car seats.

Benzene can also be used for the synthesis of phenol and acetone – raw materials for making polycarbonate plastics such as Makrolon^®, which are used in high-quality applications for the automotive, electronics, IT and other industries.

Encina’s proven proprietary catalytic technology produces circular feedstock with a lower carbon footprint when compared to those based on fossil fuels and an exceptionally high yield.

"Encina is proud to be working with Covestro, a company with a long track record of innovation and commitment to sustainability. This agreement represents the beginning of what we hope to be a long-standing partnership between our companies as we work to create a truly circular economy and realize a future in which nothing is wasted," said David Roesser, Chief Executive Officer of Encina.

Covestro’s vision to become fully circular is predicated on four key drivers: the use of alternative raw materials, innovative recycling and renewable energy, as well as engaging in joint solutions. The agreement with Encina represents a pioneering milestone for incorporating innovative recycling technologies, in this case chemical recycling of end-of-life plastic, into Covestro’s production.

As part of this collaborative effort, the initial phase involves the introduction of the first electric heavy-duty truck to replace the existing diesel truck for transporting polymeric diphenylmethane diisocyanate (pMDI) from the Shanghai site to nearby warehouses. This transition is set to cover part of the annual pMDI shuttle volume at Covestro’s largest production site, resulting in a projected reduction of 43 tons of CO₂ equivalent in well-to-wheel emissions (CO₂ emissions over the entire life cycle of fuels) in 2024 compared to the 2022 baseline – a 22 percent decrease. The future use of green power to charge the trucks will further contribute to the goal of achieving net zero in logistics.

Both companies will consistently evaluate the electric truck’s performance and efficiency, aiming for continuous optimization of the total cost of ownership associated with the vehicle. Based on these evaluations, decisions will be made regarding potential scalability.

"As a pivotal route toward achieving net zero, green logistics is poised to deliver sustainable solutions for mitigating scope 3 emissions. We look forward to working with Covestro to advance the exploration and adoption of sustainable logistics solutions in the chemical industry and contribute to the ultimate goal of net-zero emissions from the logistics side," said Fu Peng, Executive Vice President of COSCO Shipping Logistics & Supply Chain Management.

"The supply chain plays a crucial role in the chemical industry’s journey to achieve climate neutrality, demanding collaboration beyond individual company boundaries. The commercial deployment of this groundbreaking electric truck for chemical shuttling is poised to act as a catalyst, propelling our site and company towards climate neutrality and a circular economy," stated Dr. Yun Chen, General Manager of CISS.

Contributing to scope 3 emissions reduction

Approximately 80 percent of Covestro’s total emissions stem from scope 3 emissions, or indirect emissions resulting from upstream and downstream processes, including supply chains, material transport, and raw material processing.

In the Asia Pacific region, where around 70 percent of Covestro’s products are transported by truck, concerted efforts to reduce emissions within the logistics framework are specifically targeted at trucks. In light of this, the green logistics program was launched last year with the objective of devising more sustainable methods for road transportation via trucks. Collaborators in this endeavor include customers, logistics solution and infrastructure partners, and industry organizations, with the network steadily expanding.

The program is designed to rigorously assess the viability of specific strategies under distinct scenarios. Among the explored solutions is the utilization of subsidized biodiesel in Shanghai for long-haul transport of dangerous goods, as well as the integration of hydrogen fuel cell-powered trucks.

"We are committed to expanding our network of partnerships to actively seek, pilot, and scale up sustainable, low-carbon logistics solutions that meet both environmental and commercial needs. We anticipate continued progress in introducing new solutions aimed at significantly reducing our scope 3 emissions, thereby propelling us towards a climate-neutral future," said Marius Wirtz, Senior Vice President, Supply Chain & Logistics Asia Pacific, Covestro.

Covestro has said that it is aiming to become operationally climate neutral – this includes reducing both direct emissions from its own operations (scope 1) as well as indirect emissions from purchased energy (scope 2) to net zero – by 2035. The company is poised to unveil its reduction targets for scope 3 emissions soon.

Thanks to its long history in polyurethanes chemistry, Covestro boasts a portfolio of insulation material solutions renowned for exceptional thermal and weather resistance. Initially used in refrigeration, they have great potential to enhance energy efficiency in construction.

“Covestro is devoted to becoming fully circular. At the same time, we help our customers and major industries to achieve climate neutrality through our material innovations.¹ The construction industry, particularly in China, is central to this mission. With our new partnerships we will expedite the adoption of more sustainable construction practices in China and jointly play a vital role in mitigating climate change,” said Dr. Markus Steilemann, CEO of Covestro, during the signing of agreements with named companies at the China International Import Expo (CIIE), an event dedicated to promoting imports and international trade.

One key collaboration involves PDG Group and insulation integration specialist Collodin, working on an innovative polyurethane exterior wall insulation system designed to be thinner and lighter than conventional alternatives. This system, named the ‘carbon-optimized composite wall insulation structural integration system’, combines polyurethane insulation with low thermal conductivity and a lightweight non-combustible layer, further reinforced by composite tie bars, ensuring superior insulation. A comprehensive study will evaluate its energy efficiency, safety, and economic viability before implementation on the developer’s future projects, provided it meets all compliance conditions.

“We look forward to partnering with sustainable material expert Covestro in promoting this innovative solution, which could also set new standards in the industry. We believe this collaboration will facilitate the transformation and upgrade of the construction sector, promoting low-carbon, high-quality development in line with China’s dual carbon goals,” emphasized Li Junlan, Chairman of PDG Group.

Another groundbreaking partnership involves Lujiazui Group and Chinese composite profile maker Deyilong. Together, they are developing a low-carbon, energy-efficient window and door system tailored to meet Shanghai’s requirements on ultra-low energy buildings. This system will leverage Covestro’s Baydur^® Pultrusion, a composite material with exceptional thermal insulation, mechanical strength, and durability. The whole window system thereby can be made thinner for better aesthetics.

“We look forward to working with partners including Covestro, which has a proven track record in the field of efficient insulation in windows and doors. We aim to leverage Lujiazui Group’s property development strengths in Pudong, Shanghai to promote these excellent window and door systems and help elevate the industry’s energy efficiency level,” said Xu Erjin, Chairman of Lujiazui Group.

“We are excited to be connected by the CIIE with Chinese property developers, which provides us with new opportunities that will last long. We intend to promote more sustainable and low-carbon solutions for the construction industry, enhance market penetration of energy-saving building solutions, and make efforts towards China’s infrastructure development and dual carbon goals,” said Holly Lei, President of Covestro China.

For a closer look at Covestro’s solutions for a fully circular future at the CIIE, visit us at booth 3B6-05, at the National Exhibition and Convention Center (Shanghai) from November 5 to 10, 2023.

^{1 Carbon neutrality of Covestro products is the result of 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, for which an external audit and certification will soon be available, is based on the ISO 14040 and 14044 standards. The calculation takes into account biogenic carbon sequestration based on preliminary data from the supply chain. No compensation measures were applied.}

“In the face of global challenges such as climate change, innovative materials like plastics are needed more than ever to drive progress towards a truly sustainable future ,” says Dr. Markus Steilemann, CEO of Covestro. “China, with its ambitious climate targets, is a leader in dynamic markets like electric vehicles and renewable energy. We are eager to contribute our material expertise to aid the nation’s transition, while driving fresh business momentum.”

Under the banner of “Becoming Fully Circular and Climate Neutral,” Covestro’s CIIE booth features dedicated areas, including “Beyond Mobility”, “Green Home”, “Renewable Energy” and “Fully Circular”. Several showcases will highlight the pivotal role of sustainable materials in these sectors. Additionally, a dedicated “Covestro Story” area shall engage visitors, particularly those outside the chemical industry.

Chemical recycling of polyurethane foams

The “Fully Circular” zone will for example demonstrate advancements in recycling technologies and in the use of alternative raw materials. Notably, it will showcase a recycled foam created through Covestro’s proprietary chemical recycling process. This groundbreaking process is capable of transforming end-of-life mattress foam directly into its core building blocks, breathing new life into old foam.

At the center of “Beyond Mobility” stands Chinese EV maker HiPhi’s latest luxury SUV – the HiPhi Y. It extensively incorporates Covestro’s advanced and sustainable material solutions in interior and exterior components. This includes the use of high optical performance polycarbonate in LiDAR lenses, taking advantage of the material’s temperature resistance up to 115 degrees Celsius along with its excellent infrared transmittance, ensuring the reliable and stable operation of the entire system. The strengthened partnership builds upon a cooperation agreement signed between the two sides at last year’s CIIE.

Covestro also aims to foster collaborations for ultra-low energy buildings (ULEB). The company’s materials can support making buildings more energy efficient and causing less emissions – key to the sector, which is one of the major contributors of global emissions. Covestro will for example show polyurethane pultrusion composites for window frames, and highly efficient building insulation solutions at the “Green Home” zone. At this year’s CIIE, the German materials manufacturer will sign agreements with Chinese real estate developers and value chain partners, forming multi-party business collaborations in this vital domain to expedite the adoption of sustainable solutions.

“The CIIE has consistently proven to be a highly rewarding endeavor for Covestro. It offers a unique platform to strengthen partnerships and promote our approach to becoming circular and how we can support downstream industries to do the same,” says Holly Lei, president of Covestro China. “We are committed to delivering versatile solutions and exploring innovative business models in collaboration with value chain partners both within and beyond the CIIE venue, in support of China’s sustainable development.”

The CIIE stands as the world’s first national-level import-themed exhibition, an annual event since 2018. This year, it draws over 3,400 international exhibitors and is expected to host hundreds of thousands of visitors. The CIIE serves as a platform that fosters international procurement, investment promotion, cultural exchange, and open cooperation. China’s ambitious climate goals, including reaching peak carbon emissions by 2030 and attaining carbon neutrality by 2060, carry global significance to meet the Paris’ agreement and remain a consistent focal point in the exhibits and activities at the CIIE.

For a closer look at Covestro’s solutions for a fully circular future at the CIIE, visit us at booth 3B6-05, at the National Exhibition and Convention Center (Shanghai) from November 5 to 10, 2023.

Selena Group, a pioneering figure in construction chemicals since its establishment in 1992, is leading the way by introducing their enhanced Ultra Fast 70 one-component foam, primarily used for window and door installations. This product, with its remarkable yield of up to 77 liters per can and a very short cut time of just 20 minutes, is already recognized for its efficiency.

What makes this innovation even more remarkable is the incorporation of a bio-attributed MDI (methylene diphenyl diisocyanate) from Covestro in its production process. The sustainability aspect lies in the mathematical assignment of plant-based feedstocks to MDI through mass balancing, resulting in a 60 percent reduction in carbon footprint compared to fossil-derived counterparts, after all.

Same quality and properties as fossil counterparts

This pioneering collaboration highlights that sustainability doesn't necessitate compromises in quality. The new-generation foams, despite their bio-based content, boast the same good quality and properties as their fossil counterparts due to their identical molecular composition.

This allows customers to seamlessly integrate them into their existing operations without any loss of quality. The sustainability of these products is validated by the globally recognized ISCC PLUS standard, certifying the use of plant-based raw materials and their precise allocation in the manufacturing process. The products retain their excellent quality, but at the same time meet the requirements of today's environmental protection and correspond to the trends of the future. This action is proof of the effectiveness of building cooperation through innovation.

Selena also offers bio-based polyols

Selena doesn't stop at foam innovation – their commitment to a sustainable future is embodied in their line of BIOSELENOLS^®, own-produced bio-based polyols that complement their foams.

This commitment extends to also including recycled polyethylene terephthalate (PET) as a formulation component for every foam variant. Their Environmental Product Declaration (EPD), verified by the German Institut Bauen und Umwelt e.V. (IBU), leverages life cycle analysis to assess the environmental impact of buildings and serves as a benchmark for Selena's environmental stewardship.

Covestro focuses on circular economy and climate neutrality

Covestro is committed to a circular future, underscored by an unwavering focus on alternative raw materials, innovative recycling technologies, renewable energies, and strategic collaborations, and plans to achieve climate neutrality by 2035 (scope 1 and 2). The company is methodically expanding its portfolio of alternative products, extending invaluable support to its partners in their climate protection pursuits.

Their commitment to creating a circular and sustainable world is also tangibly demonstrated through the "CQ" concept – a testament to "Circular Intelligence". The "CQ" label on the mass-balanced MDI of the Desmodur^® CQ grade utilized by Selena solidifies Covestro's dedication to alternative raw materials and their pivotal role in sustainable innovation. This innovative spirit is a reflection of Covestro's role as a global leader in manufacturing high-quality polymer materials that significantly contribute to sectors such as mobility, construction, electronics, and more.

"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."

"Thanks to this new milestone, Covestro will soon be able to serve even more customers around the world with an easily accessible, more sustainable product portfolio," says Sucheta Govil, Chief Commercial Officer of Covestro. "Customers in North America can now reduce their carbon footprint and Scope 3 emissions with drop-in, mass-balanced materials derived from recycled and bio-attributed products."

Learn more about Covestro’s ISCC PLUS certification in the US: https://www.covestro.com/en/company/covestro-worldwide/united-states/covestro-in-the-united-states/sustainability-and-innovation/iscc-plus-certification

Covestro is the first manufacturer of polyurethane and polycarbonate raw materials to receive this certification in the United States. The certification is an important milestone for both Covestro and the industries it serves, including the automotive, construction, comfort, electronics and appliance industries, which will now have access to ISCC PLUS-certified products made from more sustainable raw materials in North America.

To underscore how the products support both the company’s vision to become fully circular and its customers' journey to greater sustainability, Covestro has introduced a specially branded product line with the suffix "CQ". CQ, which stands for ʺCircular Intelligenceʺ, is a portfolio of products with attribution of at least 25 percent alternative raw materials derived from biomass or recycled plastics. 

Covestro is also introducing the name Evocycle^® CQ for all evolutionary recycling processes. The first project of this kind is called Evocycle^® CQ Mattress and denotes an innovative chemical recycling technology for polyurethane mattress foam. Covestro currently has more than hundreds of CQ products and is continuously expanding this portfolio.

The ISCC PLUS certified products produced at Covestro’s Baytown facilities will include: 
• Methylene diphenyl diisocyanate (MDI) – used primarily in the production of rigid polyurethane foam for efficient insulation of refrigeration equipment and buildings
• Toluene diisocyanate (TDI) – used in the production of flexible foam for the automotive and furniture industries
• Makrolon^® RE – polycarbonate, a high-grade plastic used in the automotive, electronics and medical industries, among others
• Hexamethylene diisocyanate (HDI), isophorone diisocyanate (IPDI), Desmodur^® W and Desmodur^® Z – used in various coatings and adhesive applications

Covestro expects to begin supplying select ISCC PLUS-certified products from its Baytown facility in the second half of 2023.

The products will be produced using a mass-balance approach. Sustainable raw materials will be accounted for throughout both the value chain and production process, allowing for an accurate attribution in the end products. The existing production infrastructure will be utilized while reducing the carbon footprint of the final products.

ISCC is an internationally recognized sustainability certification for biomass and bioenergy. The standard applies to all stages of the value chain and is recognized worldwide.

"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).

The chlorine is used on site as a raw material for the production of MDI, a precursor for the manufacture of rigid polyurethane foams as used for producing energy-efficient insulation solutions for buildings and refrigerating devices. In 2019, the global MDI market had a volume of around 7,500 kilotons and is expected to further grow in the long term. In addition to chlorine, the plant will also produce caustic soda for the Iberian and European markets. Both chlorine and caustic soda are two indispensable basic chemicals for the chemical industry, and are also key raw materials for many other strategic sectors. 

Andrea Firenze, General Manager of Covestro in Spain, added: "The arrival of this plant allows us to significantly strengthen Covestro's MDI production in Tarragona. Being able to have our own, independent supply of chlorine gives us the ability to further increase the efficiency and competitiveness of our MDI plant. Moreover, the new plant also strengthens Tarragona’s position as the benchmark for chemistry in southern Europe, promotes the economic and social development of the area and both directly as well as indirectly generates new jobs. I would therefore like to sincerely thank all my colleagues who have contributed to the success of this project with their work."

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.

According to a memorandum of understanding (MoU) signed at Covestro’s booth at the China International Import Expo, the company will work with customers like Sherwin-Williams and Changzhou Changtu Chemical Co. Ltd, logistics solution and infrastructure partners such as Sinotrans Chemical International Logistics and Harbour New Energy Technology Shenzhen, as well as industry organizations such as Smart Freight Center China to devise new green logistics solutions to further reduce greenhouse gas (GHG) emissions across the industry ecosystem.

Truck transport in focus

In the Asia-Pacific region, around 70 percent of Covestro's goods are transported by truck, while in Europe and North America only around one-third is transported by road in each case, with inland waterways and railroads otherwise being used more frequently.

As such, the new partnership will focus on designing more sustainable means of road transportation by truck, and evaluate the viability of certain solutions under specific scenarios.

This includes the experiment of using electric trucks, which are prohibited for the road transport of dangerous goods under Chinese and European laws, for the short-distance shuttling of non-dangerous chemicals – free of limitations regarding the range. The team is also trying biodiesel, whose prices are subsidized in Shanghai, in long-haul transport of dangerous goods. Other solutions the program is looking at include hydrogen fuel cell-powered trucks. Some of the experiments will be adopted in real cases with cost and benefit estimation in the first half of 2023 under the partnership.

"The idea is to pilot, adopt and scale up low-emission fuels, vehicles and more sustainable logistics solutions with optimal costs and even financial benefits through an open platform," says Samir Hifri, Senior Vice President, Supply Chain & Logistics Asia Pacific, Covestro. "We believe the supply chain could be an essential part for the chemical industry to achieve climate neutrality, and it’s crucial for us to find a balance between economics and emission reductions through such collaboration."

Under the partnership, efforts will also be made to standardize calculations and reporting of GHG emissions. Through these efforts, Covestro and its partners hope to create a transparent and reliable certification mechanism that promotes green logistics as a widely applicable business model in the industry.

Jason You, Senior Supply Chain Director of Sherwin-Williams Asia, said: "Sherwin-Williams is committed to satisfying customer needs through quality products, excellent service and a highly trained and professional workforce and is constantly seeking ways to become more sustainable. We are excited to work with Covestro and other leading partners on this challenge. We look forward to continuing to innovate and introduce more sustainably advantaged product solutions to our customers in China and across the globe."

Key to scope 3 emissions target

Earlier this year, Covestro announced that it is aiming to become operationally climate neutral – this includes reducing both direct emissions from its own operations (scope 1) as well as indirect emissions from purchased energy (scope 2) to net zero – by 2035. The company will be reporting its scope 3 emissions target next year.

"The MoU marks an essential step in Covestro’s planned announcement of the scope 3 emission target in 2023," says Zhong Xiaobin, Senior Vice President of the Coatings and Adhesives segment of Covestro in Asia Pacific. "We expect to provide an integrated offering that combines more sustainable products and logistics services, thus supporting our customers to meet their sustainability and climate-neutrality targets and moving towards a circular economy."

The unveiling of the EcoFoam mattress at Covestro’s booth during the fifth China International Import Expo (CIIE) builds on a deal reached late last year, when Covestro signed its first commercial contract for supplying mass-balanced TDI to Hong Kong-based Sinomax.

“We are honored to stage the world debut of our new low-carbon sleep system products together with Covestro at the CIIE,” said Sinomax President Eric Cheung. “This marks a major step towards sustainable development at Sinomax Group, amid growing market demand for low-carbon products in China and around the globe. We look forward to further cooperation with Covestro on a global scale for more sustainable products.”

TDI is a key building block of flexible polyurethane foams, which are widely used in the furniture, automotive, and shoe industries. It can also be used in the production of polyurethane coatings and adhesives.

Under the mass balance method, bio-based or recycled raw materials are fed in at an early stage of extraction and mathematically assigned to the purchasers of downstream products. Mass-balanced products are in the same good quality as their fossil-based counterparts, and they can help customers reduce CO₂ emissions without the need to change their production procedures.

Covestro’s mass-balanced bio-attributed TDI can reduce the carbon footprint by 36 percent. For Sinomax, it means a reduction of about 10 kilograms of CO₂ equivalent emissions for a single EcoFoam mattress, without compromise to breathability, hardness and durability of the space cotton.

Lars Phillips, Head of Sales for TDI and Polyol in Asia Pacific at Covestro’s Performance Materials segment, said: “Covestro and Sinomax have invested in bio-based feedstock to offer more sustainable products to consumers. That shows that the upcoming mega trends of sustainability and carbon reduction play a gradually more important role for buying decisions and increasingly become a commercial reality.”

Mass-balanced products including TDI offered by Covestro are certified to the internationally recognized ISCC PLUS standard, which is already joined by many big multinational companies. Certified members can pass on certificates documenting the sustainable share of their products along the value chain.

The largest import themed expo in the world, the CIIE gathers a myriad of companies from across industries every year. This is Covestro’s second appearance following its debut in 2021.

"The world is increasingly facing enormous challenges. It is in our hands to meet them and set the course for a green, smart and safe future. Many ideas, concepts and technologies are there, they now need to be realized with determination," says Dr. Markus Steilemann, CEO of Covestro. "At CIIE, we want to raise awareness for building a circular economy and for climate neutrality by presenting particularly innovative and sustainable material solutions. At the same time, we want to strengthen relationships with our partners in China and around the world."

A leading example of Covestro’s successful partnerships comes from Hong Kong-based Sinomax, a manufacturer of polyurethane-based comfort products, which will make the global debut of its first low-carbon mattress at the Covestro booth.

"We are honored to stage the world debut of our new low-carbon sleep system products together with Covestro at the CIIE," says Sinomax President Eric Cheung. "This marks a major step towards sustainable development at Sinomax Group, amid growing market demand for low-carbon products in China and around the globe. We look forward to further cooperating with Covestro on a global scale for more sustainable products."

The mattress uses bio-attributed mass-balanced TDI (toluylene diisocyanate), a key component for the production of flexible foams, purchased from Covestro. This can reduce CO₂ equivalent emissions by about 10 kilograms for a single mattress.

Materials with lower carbon footprint

Covestro offers renewable TDI, among other materials, using the mass-balanced method, under which alternative raw materials are allocated to the products as certified by ISCC PLUS. They uphold the same high quality as their fossil-based counterparts without customers having to change their processing operations, while enabling them to reduce CO₂ emissions.

Other solutions featuring the mass-balanced method at CIIE include low-carbon coatings applied to the wood structure on Covestro’s booth. The coatings, made by Chinese company Baichuan, are based on the Desmodur^® CQ hardener from Covestro. The hardener contains more than 30 percent of biomass according to ISCC PLUS and reduces CO₂ emissions by more than 20 percent from cradle to Covestro’s factory gate.

"We believe mass-balanced solutions, among other low-carbon materials, are crucial to support the sustainable development and climate-neutral future of various industries and society. But to broaden this impact, we rely on the strength of more partnerships, and that’s why we are here at the CIIE," says Covestro China President Holly Lei.

In another example, Covestro and Chinese premium smart EV brand HiPhi are deepening their partnership to create next-generation solutions to make mobility smarter and greener. Under a new agreement to be inked during the CIIE, an array of Covestro’s CO₂-reduced polycarbonates, coating and adhesive solutions are expected to be applied in HiPhi’s future models, enabling new functions while reducing their carbon footprint.

Broad portfolio to promote circular economy

Covestro will showcase its cutting-edge materials, solutions, technologies and collaborative ties at several exhibition areas: Future Mobility, Clean Energy, Green Building and Sustainable Living, on top of a Branding & Culture corner designed to improve visitor engagement.

"We look forward to further advancing our sustainable development agenda in China through advocacy and collaboration with our customers, partners and other key stakeholders here," Lei adds.

To learn more about Covestro’s solutions for a climate-neutral future at the CIIE, visit its booth, 3C3-01, at the National Exhibition and Convention Center (Shanghai) from November 5 to 10, 2022.

¹ Renewable TDI is produced using the mass balance approach using renewable feedstocks – from virgin biomass as well as biowaste and residuals – which are mathematically assigned to the product.

"Plastics are a must to drive the shared global vision of the circular economy and achieve climate neutrality. At K 2022, we want to highlight the huge potential of these advanced materials to solve global challenges and showcase promising developments," says CEO Dr. Markus Steilemann. "The show will also play an important role in bringing together partners in the value chains and from other sectors. The task now is to move forward together with rapid, major steps toward implementation."

Sucheta Govil, Chief Commercial Officer, adds: "We have set ourselves ambitious targets and want to become carbon neutral by 2035 for CO₂ emissions from our operations and renewable energy supply, so that our customers can achieve their climate and sustainability goals. To achieve this, we are relying on close cooperations with them and many other partners," says Govil. "At the show, we will be showcasing innovative products and solutions from the fields of alternative raw materials, innovative recycling and renewable energies that pave the way to full circularity at Covestro."

Covestro will use K 2022 from October 19-26 for a multimedia appearance to network: At the booth, an exciting program of talks will be streamed live throughout in the "Talk Arena" with prominent guests. The Backstage area is a multifunctional space for hybrid events and interactive formats. An extensive digital platform – called "Space" – provides a lot of background information about the developments shown. Innovators and their developments for the circular economy are presented as part of the video series "Meet The Innovators".

Crafting Circular Economy

In this important area, Covestro shows how it is driving the transformation to a circular economy and aims to achieve climate neutrality in its own production and in its supply of renewable energy. With the introduction of the "CQ" label for products based on alternative raw materials, Covestro aims to create greater transparency and make it easier for customers to distinguish them from conventional, fossil-based products.

Another focus is on innovative recycling technologies. The "Recycling Technology Wheel" provides information on current developments. Chemolysis in particular holds great potential for the quantitative recovery of raw materials. Covestro is now introducing the name "Evocycle^® CQ" for all evolutionary recycling processes as an extension.

Crafting Electrification

The shift from fossil to renewable energy sources is also linked to electrification of the important sectors of transport and buildings: The mobile and stationary future is electric. Plastics from Covestro will play an important role in all of these in the future – from power generation and storage to use in vehicles and at home.

Renewable energy also plays a role in a special exhibit: The "Photon," a prototype solar race car, is on display in the outdoor area of Hall 7A. This "Sonnenwagen" was designed and built by a dedicated team of students from Aachen, Germany, who have set themselves the task of developing and racing high-tech vehicles for a particularly sustainable form of mobility. Covestro is the main sponsor of the project.

Crafting Smart Designs

This exhibition area is dedicated to the possibilities of digitalization and open innovation approaches to work in a more connected and sustainable way along the entire value chain.

At K 2022, Covestro will present, among other things, new charging stations and wall charging stations (wallboxes) for future mobility, including the first wallbox produced by partner EVBox using more sustainable polycarbonates. These plastics from the Makrolon^® RE range are produced proportionately from biowaste and residual materials, in part using renewable electricity, and therefore have a very low carbon footprint.

Crafting Sustainable Living

How can urban spaces be made more sustainable without compromising on consumer preferences? Covestro provides answers to this question in this exhibition area. The aims of the developments presented are greater comfort and design freedom, enhanced functionality, more sustainable and circular solutions, and energy-efficient living.

Covestro and Arcesso Dynamics, a custom polyurethane parts manufacturer, will introduce Arfinio^® at K 2022, a breakthrough manufacturing solution for furniture, bathroom fixtures, electronic parts, housings and other applications based on reaction injection molding (RIM) of aliphatic polyurethanes.

All journalists are cordially invited to visit Covestro's booth A 75 in Hall 6. There you will have the opportunity to talk about the innovations and topics on display, and you can obtain the Covestro press kit for K 2022. If you wish, we will also be happy to give you a tour of the booth or arrange interviews.

"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.

Product and process design is heavily dependent on the engineer’s experience with customers. Trial and error in setting up the final process is time consuming and costly. That is why simulations have played an important role in the planning of new products for quite some time. In car interiors, however, it has long been a question not only of simulating structure and form, but of creating a digital twin of the possible manufacturing process. To this end, those involved are relying on the science of materials modeling to simulate the foaming process.

This can be explained using the example of an instrument panel. In this application, semi-rigid PU foams based on Bayfill^® have become well established, as they enable the economical and reliable production of components with complex contours. In addition, the foams provide a pleasant feel and noise insulation.

"Thanks to Covestro's digital twin for Bayfill^® foams, suppliers and automotive manufacturers receive detailed information about the processing behavior of the material as early as the design phase, before real experiments or trials are necessary," says Dagmar Ulbrich, Head of Automotive Systems R&D at Covestro. "This helps identify potential challenges early on, when product and tooling changes can still be made at low cost."

Polyurethane foams can meet the requirements for instrument panels and other interior parts well, but the foam must be processed within a specific process window. Simulated foaming based on Covestro’s material models helps to optimally adjust the process window.

PU rigid foams with MDI provide very efficient thermal insulation in buildings and refrigeration equipment. The soft foams using TDI provide a lot of comfort in mattresses and upholstered furniture, as well as in car seats and shoes. And with these polyols, Covestro is now able to offer selective prepolymers for various adhesive applications. The introduced mass balance approach enables the gradual substitution of fossil-based raw materials by bio-circular alternatives, which further improves the sustainability in these applications.

Covestro produces the polyether polyols in Dormagen, Germany, using the mass-balanced precursor propylene oxide from the shared site with LyondellBasell in Maasvlakte, The Netherlands. There, the two partners produce propylene oxide and styrene monomer as part of a joint venture. Both of the above-mentioned sites are certified according to the internationally recognized ISCC PLUS standard.

"With the introduction of both main components for polyurethanes based on alternative raw materials, we have reached another important milestone on the road to climate neutrality," says Sucheta Govil, Chief Commercial Officer of Covestro. "We can now help customers in a variety of industries meet their climate goals and drive the transition to a circular economy. At the same time, we are reducing the CO₂ footprint in various value chains."

Customers can use the more sustainable polyether polyols and isocyanates as a drop-in solution, meaning the raw materials can be quickly and easily integrated into existing production processes without the need for technical modifications. The products offer the same good quality as their fossil-based counterparts and meet the demands from various industries looking for alternative raw materials. They can be easily distinguished from their fossil counterparts through the CQ suffix in the product name. CQ stands for Circular Intelligence and highlights Covestro´s products and initiatives around circularity.

 ¹ _{The more sustainable polyether polyol as well as the renewable TDI are produced with the help of the mass balance approach using renewable raw materials – from biowaste and plant residues – which are mathematically attributed to the product.}

² _{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 the 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 the uptake of biogenic carbon. The calculation was based on preliminary data from the supply chain. No compensatory measures were applied.}

The new MDI enables Pearl to help its downstream customers reduce their carbon footprint by offering a broader portfolio of more sustainable raw materials as part of its newly rebranded EcoPearl product range. The new MDI grades from Covestro can be used in numerous construction, cold chain and automotive applications.

Pearl is the first system house in the EMEA region to receive the carbon-neutral¹ MDI from its former joint venture partner and long-time supplier Covestro. The latter has already received ISCC-PLUS certification for five of its 16 main sites and is able to supply climate-neutral MDI from its sites in Uerdingen, Germany, and Caojing, China.

Following a comprehensive ISCC audit to trace the supply chain and assess raw material sustainability requirements, Pearl became the first local polyurethane systems house to be ISCC certified in March 2022, enabling it to verify the various sustainability credentials for its product formulations and raw materials used. The certification followed an internationally recognized five-step process and allows end users to measure the sustainability performance of the ISCC-certified products they use.

In the context of commercial building insulation, ISCC PLUS certification allows end users and tenants of such buildings constructed with Pearl-supplied insulation products to easily measure and verify the sustainability performance of the buildings they occupy. This is a factor that is becoming increasingly important to businesses as consumer interest in the environmental impact of companies grows.

"This mass-balanced carbon neutral MDI further enriches our broad portfolio focused on the circular economy and responds to the growing demand for more sustainable products," says Sucheta Govil, Chief Commercial Officer of Covestro. "By working with multipliers such as Pearl Polyurethane and helping a growing number of downstream users in various industries achieve their sustainability goals, together we are accelerating the transition to the circular economy." Covestro plans to further expand its portfolio of carbon-neutral products.

Martin Kruczinna, CEO of Pearl Polyurethane Systems, commented, "rigid polyurethane foam, as a superior insulating material, plays an important role in meeting the Paris Agreement to limit the rise in global temperature to 1.5 degrees Celsius at best. Just as Covestro is leading the way among PU raw material producers to achieve carbon neutrality by 2035, Pearl is acting as an agent of change in the PU systems industry, giving its customers a competitive advantage by helping them adapt to greener technologies and improve the thermal insulation performance of their products. The addition of carbon neutral¹ MDI-based solutions to our newly named EcoPearl product range helps our customers achieve their emission reduction and circular economy goals."

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 was critically reviewed by TÜV Rheinland, is based on ISO standards 14040 and ISO 14044. The calculation takes into account biogenic carbon sequestration based on preliminary data from the supply chain. No compensation measures were applied.}

This is reason enough for Covestro to further increase the sustainability and insulating performance of its foams and develop innovative solutions for more effective production. At the K 2022 plastics trade show, the company will present promising results that support its vision to become fully circular.

Climate-neutral raw material for insulation

For example, Covestro now offers one of the two main raw materials for PU rigid foam, methylene diphenyl diisocyanate (MDI), in a version that is climate-neutral¹ from the cradle to the factory gate: On balance, no CO₂ emissions are generated in the aforementioned part of the value-added cycle. This increase in sustainability is due to the use of alternative raw materials based on plant waste and residual oils, which are allocated to the products with the help of certified mass balancing according to ISCC PLUS. With such climate-neutral¹ solutions, Covestro helps its customers achieve their own sustainability goals and master the transition to a circular economy. The products can be incorporated into existing process technology at construction, refrigeration and automotive industry customers without any significant changes.

Small refrigerators with plenty of interior space

In the cold chain, too, rigid PU foam has been the insulating material of choice for decades to keep food from spoiling efficiently and permanently. In the future, it will be important to not only further increase the insulation performance, but also to have the largest possible interior space in which to store a lot of refrigerated goods, and yet limited external dimensions of the refrigerator. Here, PU vacuum insulation panels (VIPs) offer an advantageous solution: they take up little space but provide efficient insulation with low energy consumption and CO₂ emissions. Even at the end of their useful life, PU VIPs still reduce the carbon footprint: Thanks to their use, refrigerators are made from only a few different materials and can be recycled more easily.

More effective and sustainable production of insulation elements

For the production of rigid foam insulation boards and metal sandwich elements, customers have to spread a PU reaction mixture on a top layer. Covestro has developed an innovative technology using casting rakes that enables more uniform distribution of the liquid mixture, simplifying the production process but also increasing the quality of the insulation elements. Insulation Board Fastline (IBF) technology also reduces out-of-spec batches and production waste – waste that would otherwise have to be disposed of or recycled. The casting rakes can be easily integrated into the existing production.

Efficiently insulated windows

The efficient thermal insulation of doors and windows naturally makes another important contribution to reducing energy consumption and CO₂ emissions from buildings. While multi-pane windows made of insulating glass have proven themselves in practice, for a few years now, composite materials made of polyurethane resins in combination with glass fibers using pultrusion technology have been providing excellent insulation of window and door frames. They also give them good strength and fire resistance.

_{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 ISO 14044. The calculation takes into account biogenic carbon sequestration based on preliminary data from the supply chain. No compensatory measures were applied.}

The goal of a new collaboration with the Zurich-based bag company FREITAG is the unlimited recycling of truck tarps, based on thermoplastic polyurethanes (TPUs) from Covestro. At the end of their useful life, the tarps are to be recycled mainly chemically and used for new tarps or other products. It is important for the success of the project that the tarps are similarly robust, durable and water-repellent as the previous products. FREITAG expects it to be a few years before bags made from the tarps are mass-produced, but plans to put a first prototype on a truck as early as this year.

Sorting of plastics by type

At the K 2022 trade show, Covestro will present these and a number of other developments for the unmixed recycling of used plastics. The company’s focus to date has been on proven mechanical recycling, in which the plastic is chemically preserved, and more recent chemical recycling processes, in which the polymer molecules are broken down chemically. Other technologies of such raw material reprocessing – specifically enzymatic and pyrolytic – are under development.

Mechanical recycling is particularly suitable for polycarbonates. Numerous corresponding products from Covestro are already on the market, including polycarbonate blends for IT applications with up to 75 percent recycled material – besides products based on mass balanced raw materials. To facilitate recycling, the company is increasingly relying on monomaterial solutions for end products that feature simplified material separation. In addition, new plastic products are designed from the outset to be easier to recycle at the end of their useful life.

Chemical recycling on the rise

Polyurethanes (PU) and other thermoset products usually cannot be mechanically recycled. Chemical processes are the obvious choice here. Covestro has developed an innovative technology for recovering both core raw materials PU mattress foam as part of a research project with partners. These are polyols and the isocyanate TDI, which are used in the production of mattress foam. The precursor is recovered from the TDI, and both raw materials can be reused for the production of new foam after reprocessing. The results achieved to date are being tested in a pilot plant at the Leverkusen site. 

To drive the project forward and close recycling cycles, Covestro is cooperating with partners from the chemical and recycling industries. Together with Interseroh, an ALBA Group company, opportunities are to be developed for the collection and processing of the recyclables so that they can ultimately be supplied to Covestro for chemical recycling. Covestro is pursuing a similar goal in its cooperation with the French environmental protection organization Eco-mobilier, which specializes in the collection and recycling of old furniture.

Used PU rigid foams, which provided efficient thermal insulation for buildings and refrigeration equipment, should also be able to be broken down into their constituent parts again by means of chemolysis or even pyrolysis. This is the goal of the CIRCULAR FOAM research project with 22 industrial partners from nine countries, coordinated by Covestro. Over the next four years, experts from science, industry, and society want to develop a comprehensive solution model for the waste management and recycling of such foams.

Here, too, the aim is to recover both raw materials originally used – polyols and an amine used as a precursor for the isocyanate MDI. If the material cycle is successfully closed, up to one million metric tons of waste, 2.9 million metric tons of CO₂ emissions and 150 million euros in incineration costs could be saved in Europe every year from 2040.

"Mankind is facing enormous challenges. In addition to acute crises, we need to overcome long-term challenges such as protecting the climate, nature and resources and thus safeguarding our livelihoods," said CEO Dr. Markus Steilemann. "This can be achieved if business and society consistently orient themselves towards the circular economy. Plastics are indispensable on this long journey, and Covestro is pleased to contribute particularly sustainable new products and materials to this end, tailored to the customer needs of today and tomorrow. Together with our partners, this is how we intend to seize the immense opportunities for sustainable growth."

"Crafting Connections With You"

Under the motto "Crafting Connections With You", Covestro intends to establish new collaborations with customers and partners and strengthen existing ties at booth A 75 in Hall 6 at K 2022 from October 19 to 26, as well as on a digital platform. "Collaboration along key value chains in particular is of great importance for the vision of a full circular economy to succeed," said Dr. Andrea Maier-Richter, Global Head of the TPU Business Entity. "With our more sustainable developments, we support our customers and partners in facilitating their transition to the circular economy and achieving their own climate goals."

To make circular solutions in the product portfolio even more recognizable to customers in the future, Covestro has developed the "CQ" concept. The brand suffix stands for "Circular Intelligence" and indicates the alternative raw material base for the company's products if it is at least 25 percent. Among the first "CQ" products is Desmodur^®CQ. Polyurethane foams based on Desmodur^®CQ are used, for example, in upholstered furniture, mattresses and thermal insulation.

Moving away from fossil resources

Covestro primarily uses mass-balanced, renewable precursors and plastic waste as alternative raw materials, as well as green electricity. To realize its vision of a circular economy and achieve its ambitious climate targets, the company is also focusing on the future supply of "green" hydrogen and the development of innovative recycling technologies.

All these measures help conserve fossil resources and avoid CO₂ emissions. In the long term, Covestro aims to offer all its products in a climate-neutral¹ version. By 2030, the company plans to invest around one billion euros in circular economy projects. To achieve net zero emissions, Covestro also expects to invest between EUR 250 million and EUR 600 million by 2030.

The high-performance plastic polycarbonate and the important polyurethane (PU) raw material methylene diphenyl diisocyanate (MDI) are already available in larger quantities as climate-neutral products. Like the renewable PU raw material toluene diisocyanate (TDI), they are manufactured using renewable² raw materials such as new biomass and biowaste and residual materials, which are allocated to the products by calculation using the mass balance approach. According to a common calculation model¹, no net CO₂ emissions are generated during production from the cradle to the factory gate.

For its own raw material supply, Covestro cooperates with a number of industrial partners who provide renewable precursors such as mass-balanced acetone, phenol and benzene. Suppliers such as Borealis, Total, Mitsui Chemicals and Mitsui & Co. produce these raw materials at sites certified to the internationally recognized ISCC PLUS standard. At the same time, Covestro is gradually converting its production sites to this standard, which is already the case in Leverkusen, Dormagen, Krefeld-Uerdingen, Antwerp and Shanghai.

Most recently, Covestro announced a collaboration with Neste and South Korean petrochemical company SK geo centric to supply mass-balanced benzene for its MDI production in China. MDI is an important raw material for rigid PU foam, which provides efficient insulation for buildings and the cold chain. Certified polycarbonate, in turn, plays a role in the automotive, electrical and electronics, and medical industries, among others. And TDI is a precursor for PU flexible foam, which is used to make mattresses and upholstered furniture.

Covestro has also signed contracts with energy suppliers such as Ørsted, EnBW, ENGIE, Datang Wuzhong New Energy and others to supply sites in Germany, Belgium and China with electricity from renewable sources.

Innovative technologies for chemical recycling

Hermann-Josef Dörholt, Global Head of the Performance Materials segment, emphasized the great importance of recycling technologies in order to really close loops: "Covestro is taking a committed approach here: using various approaches, we can specifically recover the raw materials we need for the production of our plastics. In addition to the established mechanical recycling of polycarbonate and thermoplastic polyurethane, we are focusing primarily on chemical recycling for this purpose." The aim, he says, is to recycle materials completely in order to save fossil raw materials and CO₂ emissions, while at the same time offering recycled products in virgin material quality.

As examples, Dörholt cites innovative processes for the chemical recycling of mattress foam waste and used rigid PU foam. Together with partners, Covestro has developed a process to chemically recover the two main components from PU mattress foam: the polyol and the precursor to the isocyanate TDI used. The results of the tests conducted to date are promising and are currently being tested in a pilot plant at the Leverkusen site. The project is now to be extended to the industrial processing of flexible foams.

Covestro is also coordinating the EU project CIRCULAR FOAM with 22 partners from nine countries, which is dedicated to the chemical reprocessing of rigid polyurethane foam from building insulation materials and used refrigeration equipment. The products make an important contribution to saving CO₂ emissions and reduced energy consumption, but recycling processes and systematic waste management have been lacking until now. The project aims to save up to one million tons of waste and 2.9 million tons of CO₂ emissions annually in Europe by 2040.

_{¹ This climate neutrality is the result of an internal assessment of part of the product life cycle, from raw material extraction (cradle) to the factory gate of covestro. It is also referred to as "cradle-to-gate" assessment.}

_{² Renewable TDI is produced using the mass balance approach using renewable feedstocks – from virgin biomass as well as biowaste and residuals – which are mathematically assigned to the product.}

SK geo centric will process this feedstock into benzene at the company’s facilities in South Korea and supply it to Covestro to use as raw material for methylene diphenyl diisocyanate (MDI) at its site in Shanghai, China. MDI is a key raw material for the manufacture of rigid polyurethane foam, which is a well-proven insulating material for buildings and used in the cold chain helping to save CO₂ emissions and reduce energy consumption during its product life.

The cooperation marks the start of possible future collaborations between the three companies, aiming at replacing fossil feedstocks by more sustainable ones in the production of polymers and chemicals in the APAC region and beyond.

"With renewable solutions available, we are now entering the phase of scaling up their usage in the chemical industry," says Mercedes Alonso, Executive Vice President Renewable Polymers and Chemicals at Neste. "This will be crucial in replacing the vast amounts of fossil resources the industry is currently depending on. To make this ramp-up a success, we’ll need to establish collaborations along the value chain – and this one between three sustainability-minded partners is a prime example of how the industry can do just that."

Replacing the common crude oil-based fossil feedstock with Neste RE provides a significant reduction in greenhouse gas (GHG) emissions, thereby improving the carbon footprint of the polyurethane raw materials produced by Covestro and of downstream industries. Neste RE is produced with renewable raw materials such as waste and residue oils and fats.

"I am much pleased that through this collaboration we continue to ramp up the market for sustainable alternative materials. This enables us to supply our customers in Asia-Pacific with more sustainable MDI based on mass-balanced raw materials," says Sucheta Govil, Chief Commercial Officer of Covestro. "Using such materials is attractive because it will also help them achieve their climate goals. Another core benefit of this line of products is that it is a technical drop-in solution that our customers can use immediately without a major changeover in their plants."

"We are delighted to ship and export our first renewable Benzene produced with 100 percent renewable Neste RE feedstock," says Woohyuk-Choi, Vice President of SK geo centric’s Aromatic Business Unit. "SK geo centric will actively work with Covestro and Neste as we mark the first collaboration of this kind in the Asia-Pacific region. We remain committed to expanding this cooperation."

Under the strategy of "Green for Better Life", SK geo centric announced its ambitious target to become "Net-Zero" before 2050. To fulfill its responsibility, the company will drive its business transformation by expanding its high-quality renewable products portfolio. SK geo centric will respond to increasing global demands in the market by leveraging the strong synergies between collaboration partners.

Covestro intends to focus entirely on the Circular Economy. The company is driving the development of innovative and resource-saving processes to make its products recyclable to meet this goal. That is why Covestro intends to offer more material solutions based on sustainability and circularity in the markets in which it is active. Covestro's own technological development is focused on four recycling approaches. In addition to mechanical recycling, which is already used for the high-performance plastic polycarbonate and thermoplastic polyurethane (TPU), Covestro is developing chemical recycling processes: These include chemolysis, smart pyrolysis and enzymatic recycling. The aim of these processes is to produce recycled plastics in virgin material quality while significantly reducing the environmental footprint compared to the conventional fossil-based production of polymers and polymer raw materials. Covestro applies its core competence in chemistry to process development.

"We see ourselves as the driving force behind the Circular Economy industry that is currently being developed, where the chemical and waste management industries will have to grow closer together in perspective and synergies will have to be created," explains Markus Steilemann, Chairman of the Board of Covestro. "We are moving forward here with vigor for the entire industry: with various recycling approaches, we can systematically recover the different raw materials we need for the production of our plastics. Our goal is to fully circularize materials from end-of-life products to save fossil raw materials and greenhouse gas emissions, while offering recycled high-performance materials in virgin quality." The company plans to invest around one billion Euro in Circular Economy projects by 2030. In Leverkusen, Covestro already operates a pilot plant for the chemical recycling of flexible polyurethane foams.

In addition, Covestro will showcase how circular solutions in the product portfolio can be made even more visible to customers at IFAT in Munich. With the "CQ" concept, in the future Covestro will highlight the alternative raw material base in products if it is at least 25 percent. "CQ" here stands for Circular Intelligence. Among the first "CQ" products is Desmodur^®CQ. Polyurethanes based on Desmodur^®CQ are deployed, for example, in upholstered furniture, mattresses and thermal insulation. They are used, for example, as coatings for cars or household appliances.

 "In order to take meaningful climate protection measures, we need a change, a paradigm shift, for us, our customers and everyone else in the entire value chain. At the same time, the benefits must be clear in the application of such solutions. The chemical industry must fundamentally change as a central part of the value chain - toward alternative raw materials and renewable energies," says Sucheta Govil, Chief Commercial Officer at Covestro. "We have set ambitious targets to make our production fully circular and ultimately independent of fossil resources. In doing so, we are supporting a wide range of industries to reduce the carbon footprint of their own products," Govil said.

Cooperations provide contribution to full Circular Economy

New recycling processes and cooperation with partners from industry and research are making an important contribution to achieving full circularity. For example, Covestro is coordinating the EU project "CIRCULAR FOAM" with 22 partners from nine countries. The aim of the project is to develop innovative chemical recycling processes for rigid polyurethane foams. As an insulating material, rigid polyurethane foams contribute to the energy efficiency of refrigerators and buildings - but coordinated waste management and suitable recycling processes are still lacking for a sustainable life cycle. Chemical recycling could save up to one million tons of waste and 2.9 million tons of CO₂ annually from 2040.

Markus Steilemann and Sucheta Govil at IFAT

To kick off IFAT on Monday, May 30, 2022, Sucheta Govil will be a guest on the show's opening session. The topic will be the role of environmental technologies for a more sustainable future. Participants will include founder Mikela Druckman, an expert on AI in recycling and a member of the WEF Global Future Council; Prof. Dr. Erich Zahn, co-author of the Club of Rome report "The Limits to Growth"; Dr. Johannes Kirchhoff, Board of Management of the Circular Economy Initiative from the Federation of German Industries; and Ren Xiaoyuan, (UNEP) Young Champions of the Earth 2020 and founder of the water information network MyH2O.

CEO Markus Steilemann will discuss the topic "Global Value Creation in the Crisis? The Circular Economy as Europe's Response" on a BDI panel on Tuesday, May 31, at 2:15 p.m. with Delara Burkhardt, environmental policy spokeswoman for the Socialists and Democrats delegation in the European Parliament, Dr. Christoph Epping, head of the Circular Economy subdivision at the German Federal Ministry for the Environment, Nature Conservation, Nuclear Safety and Consumer Protection, and Wolfgang Niedermark, member of the BDI's Board of Management. On Wednesday, June 1, Markus Steilemann will give an introduction at 12:15 p.m. to the panel discussion "Chemistry for circular mobility: Chemical recycling as a building block of circular value creation for automotive?" with experts from Audi, Covestro and TU Dortmund University.

Covestro at IFAT 2022 in Munich, Germany

• DGAW booth (Hall/Booth: A6 125/224) and VCI booth (Hall/Booth: A6 231)
• Monday, 30 May, 11:50 a.m. - 1 p.m.: Opening panel "How to create change?" - From activism and politics to environmental solutions and impacts" with Sucheta Govil (Forum Water Hall C3. 139/238)
• Tuesday, May 31, 2:15 p.m., (Hall C6, Room C62a, BDI Initiative Circular Economy), and Wednesday, June 1, 2022 (12:15 p.m., Hall A5 | 317/416 | Waste / Secondary Materials Forum): Markus Steilemann visits IFAT

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.}

According to a common calculation model¹, on balance no CO₂ emissions are generated in the aforementioned part of the value-added cycle. The climate neutral MDI and its precursors are manufactured at the ISCC PLUS-certified Covestro sites in Krefeld-Uerdingen, Antwerp and Shanghai.

"With the launch of our climate neutral MDI, we are now further expanding our portfolio of climate neutral products," says Sucheta Govil, Chief Commercial Officer of Covestro. "I am pleased that this will enable us to even better support our customers in large parts of the world in meeting their own sustainability goals and transitioning to a circular economy." Only last December, the company announced the launch of its climate-neutral polycarbonate.

Hermann-Josef Dörholt, Head of the Performance Materials segment, adds: "Climate neutral products are an important factor in achieving our sustainability goals. Our climate neutral MDI has another major advantage: it is a drop-in solution – so our customers can use it immediately in their production without any changeover and without compromising on quality."

Even more sustainable building insulation

This is the case, for example, in building insulation. MDI is an indispensable raw material for the production of polyurethane (PU) insulation boards and sandwich panels, among other products. These have proven their value for many years as highly efficient elements in the thermal insulation of buildings. The heating or cooling requirements of buildings can be reduced by up to 70 percent through the use of PU insulation. This saves CO₂ emissions and is good for residents' wallets. Because PU insulation elements can therefore be designed thinner to achieve good insulation performance already, they save resources and make more usable space accessible than other insulation materials.

In addition to the good thermal insulation properties of PU insulating materials, Covestro's climate neutral MDI now provides a further sustainability benefit: It even helps reduce embodied carbon and energy consumption over the life cycle of a building. The use of PU insulating materials made from it in new buildings as well as in the renovation of older real estate can thus make an important contribution to the responsible use of primary resources and to significantly reducing CO₂ emissions.

"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.

The first batch of the bio-attributed TDI via mass balance is expected to be delivered from Covestro Integrated Site Shanghai in the first quarter of 2022, and be applied to Sinomax’s medium and high-end product lines for mattresses, pillows and mattress toppers. Both partners signed an agreement to this effect at the Hong Kong office of Covestro on December 15. Covestro and Sinomax, based in Hong Kong, China, also agreed to extend their regional partnership to a global scale, with Sinomax scaling up their operations in the United States.

TDI (toluene diisocyanate) is a key building block of polyurethane flexible foams, which are widely used in the furniture, automotive, and shoe industries. It can also be used in the production of polyurethane coatings and adhesives.

Eric Cheung, President of Sinomax said, "We have been working hard to reduce carbon emissions, and Covestro’s mass-balanced TDI products can effectively help us meet emissions reduction goals. With a global footprint, Covestro has sufficient, stable and fast delivery capacity in major markets, which is crucial to our global development."

"With this mass-balanced lower-carbon-footprint TDI, we are further enriching our broad portfolio focused on the circular economy, in response to the rising demand for more sustainable products," said Sucheta Govil, Chief Commercial Officer of Covestro. "By helping an increasing number of customers and value chain partners across industries meet their sustainability targets, we are accelerating the transition to the circular economy together."

Mass balance is a chain of custody method that allows fossil and alternative feedstock to be mixed in production, but separated in bookkeeping. It is able to track materials through the value chains and allows attribution of alternative feedstock, like bio-based raw materials, to selected end products.

"With this new approach of incorporating sustainable raw materials into our TDI, the reduction of CO₂ footprints in the flexible foam industry can be accelerated immediately and also become easily scalable. We are excited to take this first step globally here in Asia Pacific with our partner Sinomax that shares our vision and commitment towards the circular economy," outlines Marius Wirtz, Head of Sales in the Performance Materials segment of Covestro in the Asia Pacific region.

Covestro earlier received the ISCC Plus certification for its Shanghai production site. Now the site is able to offer Asia Pacific customers large volumes of TDI, in addition to polycarbonate and MDI with alternative feedstock attributed via mass balance. These products are of the same good quality as their fossil-based counterparts and can be used as a drop-in solution, meaning they can be implemented in existing production processes without the need for technical modification.

Year after year, large quantities of used furniture are generated worldwide that have to be disposed of. Covestro and Eco-mobilier want to keep it out of landfill and minimize incineration, thus reduce its environmental impact and give it a new life. For this purpose, they want to combine their expertise and jointly develop a new solution and a business model for the chemical recycling of polyurethane foam from post-consumer mattresses and upholsteries.

Eco-mobilier has extensive experience in the collection, logistics and processing of used furniture, such as mattresses and upholsteries. This mainly concerns the dismantling of used furniture and presorting materials in order to obtain pure foam parts as raw materials for recycling. A key topic of the collaboration is to further develop the decentralized dismantling process of mattresses to avoid ecologically unfavorable transport of the foam parts to the chemical recycling plant. At a later stage, the partners also plan to evaluate possibilities and develop a corresponding process for recycling upholstered furniture with polyurethane foams.

"For ten years, Eco-mobilier has been acting to set up and improve a specific scheme for End of Life PU foam collecting and recycling. The partnership between Eco-mobilier and Covestro will allow to increase and to diversify the existing solutions for the chemical recycling of PU foam and to extend the perspectives for a material which had been considered, yet recently, as non recyclable. Especially, by experiencing padded furniture recycling with Covestro, Eco-mobilier is delighted to start a new stage of development of its strategy targetting of ´zero landfilling´ for furniture," said Dominique Mignon, President of the French organization.

Innovative process to recover both main PU components

As part of its new collaboration with Eco-mobilier, Covestro intends to make use of a novel process compared to other chemical recycling approaches, which it has developed for recycling the foam chemically. The technology has competitive advantages as it allows the recovery of both core raw materials originally used. To this end, the company also operates a pilot plant for flexible foam recycling at its site in Leverkusen, Germany, which is used for test purposes.

"We are thrilled to complement Eco-mobilier´s unique expertise in furniture recycling with our chemical recycling technology in this powerful partnership," says Dr. Christine Mendoza-Frohn, Executive Vice President & Head of Sales EMLA for Performance Materials at Covestro. "The strategic intent of our collaboration is to design and validate a joint pilot model to encourage and make real an accelerated adoption of recycling and reusing polyurethane foams from used furniture in Europe and beyond."

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