Covestro, Fraunhofer Plan to Build Chemical Recycling Pilot Plant

Covestro (Pittsburgh, Pennsylvania) and Fraunhofer UMSICHT (Germany) have signed an agreement to build and operate a pilot plant for the chemical recycling of rigid polyurethane foam waste using smart pyrolysis technology. Scheduled to begin operations in 2028, the facility will process 2 kilotons of end-of-life foam annually and convert the material into high-purity recycled aniline for the production of MDI (methylene diphenyl diisocyanate).

The resulting recycled MDI is expected to meet conventional quality standards while reducing the carbon footprint by up to 40% compared to fossil-based production methods. The technology targets rigid polyurethane insulation foam from appliances and construction materials, which has traditionally been difficult to recycle.

The project builds on research conducted through the EU-funded CIRCULAR FOAM initiative and represents a major step toward commercial-scale chemical recycling solutions for polyurethane materials as demand for sustainable insulation products continues to grow.