Porsche, BASF, and BEST Successfully Complete Pilot Project for Chemical Recycling of End-of-Life Vehicle Waste

Porsche AG, BASF SE, and BEST Bioenergy and Sustainable Technologies GmbH have successfully completed a pioneering pilot project focused on the chemical recycling of automotive shredder residue (ASR)—a mixed waste stream generated from end-of-life vehicles. According to reports from the companies, the project demonstrates the potential of transforming complex waste, including foams, plastics, films, and paint particles, into valuable raw materials through advanced gasification technology.

This collaboration aims to tackle one of the automotive industry’s most pressing challenges: improving recycling rates and enabling a more sustainable circular economy. Currently, ASR can only be thermally recovered, making it difficult to recycle the high-performance plastics contained within. However, this new chemical recycling method, which involves converting mixed waste into synthesis gas at high temperatures, could serve as a viable alternative, enabling the reuse of materials that are otherwise difficult to process.

According to the pilot project’s findings, gasification has proven to be an effective method for converting mixed waste into valuable raw materials. These materials can then be used in the production of high-performance plastics, which can be employed in automotive components such as steering wheels. The project also utilized bio-based raw materials, such as wood chips, alongside automotive waste, completely eliminating the need for fossil-based inputs. This shift toward bio-based inputs is reported to be a significant step in reducing the carbon footprint of recycling operations.

Dr. Robert Kallenberg, Head of Sustainability at Porsche AG, commented, “Pilot projects like these allow us to evaluate how we can further develop the circular economy as a sustainability field at Porsche and how we can anchor chemical recycling in our strategy in the long term.” He added that the company is testing these new recycling technologies in order to increase recyclate quotas and evaluate new processes for waste streams that are currently being thermally utilized.

Martin Jung, President of BASF’s Performance Materials division, shared his insights on the importance of integrating various recycling technologies to achieve global sustainability goals. “BASF offers a wide range of recycling solutions and we strongly believe that different recycling technologies have to add up to a wide spectrum to achieve recycling targets,” he explained.

The raw materials produced through gasification were found to meet the quality standards for high-performance plastics, making them suitable for safety-critical automotive components. This outcome marks a key milestone in the development of sustainable materials for the automotive industry.

As global regulatory pressure on waste management and recycling intensifies, industries are increasingly turning to innovative technologies to meet sustainability targets. The success of this pilot project is expected to play a pivotal role in advancing the adoption of chemical recycling as part of the automotive sector’s broader circular economy strategy. According to experts, chemical recycling could complement existing methods like mechanical recycling, providing a more comprehensive solution to the growing challenges of plastic waste management.

The successful completion of this pilot project marks a significant step forward in the automotive industry’s pursuit of more sustainable manufacturing practices. As Porsche, BASF, and BEST continue to explore new recycling technologies, the industry as a whole moves closer to achieving its sustainability goals. By integrating chemical recycling into their circular economy strategies, these companies are setting a new benchmark for how end-of-life vehicle waste can be processed and reused, contributing to a more sustainable future for the automotive sector.

Source: Porsche AG

SUNSHINE Spotlight: This pilot project demonstrates how chemical recycling can transform complex automotive waste, such as plastics and foams, into high-performance plastics, furthering Porsche’s circular economy goals and reducing reliance on fossil fuels.