Evonik's new hydrolysis technology for PU foam recycling receives state funding

The company received a grant from Hesse's Ministry for Economic Affairs, Energy, Transport, Housing and Rural Areas during a visit by state economics minister Kaweh Mansoori to Evonik's Wolfgang Industrial Park in Hanau, where the technology is being developed.

The process is designed to tackle one of the largest waste streams for polyurethane product: thousands of tonnes of PU foam from discarded mattresses, automotive seats and furniture are generated each year in Germany.

Using a newly developed hydrolysis process, the company says the foam can be broken down into its chemical building blocks, allowing the recycled materials to be fully recovered and reused in the manufacture of new, high-quality products.

Following successful laboratory trials, Evonik has established a continuously operated pilot plant at its Hanau site to demonstrate the technology. The next objective is industrial-scale deployment, with the aim of replacing fossil-based raw materials, reducing the carbon footprint of polyurethane production and supporting a circular economy.

The company also plans to establish a technology centre in Hanau dedicated to the chemical recycling of plastics. The centre will investigate feedstock pre-treatment processes, including shredding, pelletising and grinding, as well as purification technologies such as filtration and centrifugation. It will also explore the recovery of additional waste streams.

Thomas Wessel, Evonik's chief human resources officer and labour director, said: "Especially in the current economic situation facing the chemical industry, it is crucial to support innovation in a targeted way. The support from the state of Hesse comes at exactly the right time and will help us bring sustainable technologies into industrial application more quickly. We are sincerely grateful for this support!"

Hesse's economics minister Kaweh Mansoori added: "The recycling of PU foam is an outstanding example of how industrial value creation and climate protection can go hand in hand. Hesse is specifically supporting projects that transfer innovation from research into practical application while strengthening the region's industrial base."

Evonik says the project also has strategic importance for the Hanau site.

Kerstin Oberhaus, site manager at Hanau, said: "With the PU foam recycling process, we are developing a practical solution here that enables the main constituents of polyurethane foam to be recovered to virgin-material quality. At the same time, we are further strengthening our role as a centre for innovation, technology development and scale-up."

Photo: Kaweh Mansoori (third from right), Hesse's minister for economic affairs, toured the pilot plant for the recovery of polyurethane foam additives with Evonik chief human resources officer and labour director Thomas Wessel (second from right) after receiving the funding award. Credit: Evonik Industries

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