Covestro and the Fraunhofer Institute for Environmental, Safety and Energy Technology UMSICHT announced an agreement to develop a pilot plant for chemical recycling of rigid polyurethane foam using smart pyrolysis technology.

The facility is expected to have an annual capacity of 2 kt and is scheduled to begin operations in 2028. The process will convert end-of-life polyurethane insulation materials into high-purity aniline, which can be reused in the production of methylene diphenyl diisocyanate (MDI).

According to the companies, the recycled aniline can achieve approximately 99% purity and enable production of MDI with a reduced carbon footprint compared to conventional fossil-based routes.

The project builds on prior research and aims to scale the technology toward industrial implementation, addressing challenges associated with recycling rigid polyurethane foam due to its crosslinked structure.

The partners said the initiative supports broader efforts to develop circular solutions for polyurethane materials, particularly in insulation applications where demand continues to grow.

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