Porsche, BASF, and BEST Forge Ahead with Chemical Recycling for Automotive Plastics

Porsche, in collaboration with chemical giant BASF and technology partner BEST, has successfully concluded a pilot project focused on the chemical recycling of mixed waste from end-of-life vehicles. This initiative explores the potential of transforming automotive shredder residue (ASR), a complex mix of materials, into valuable new resources, aligning with Porsche's commitment to a circular economy.

Key Takeaways

• Successful pilot project demonstrates chemical recycling of mixed automotive waste.

• Aims to increase the proportion of recycled materials in future Porsche vehicles.

• Utilizes advanced gasification technology to convert plastic waste into synthesis gas.

• New plastics produced are of high quality, suitable for demanding applications.

Advancing the Circular Economy

Porsche is actively pursuing a circular economy strategy, with the goal of incorporating more recycled materials into its vehicle production. This pilot project is a significant step in evaluating the viability of chemical recycling for materials that are difficult to process through traditional mechanical methods. The project specifically targeted automotive shredder residue (ASR), a challenging waste stream primarily derived from end-of-life vehicles, which currently is mostly thermally recovered.

Innovative Recycling Process

The pilot project employed an advanced gasification process, a form of chemical recycling. This method converts plastic waste into synthesis gas at high temperatures. Notably, this trial utilized bio-based raw materials, such as wood chips, alongside automotive waste, completely eliminating the need for fossil-based inputs. The synthesis gas produced was then integrated into BASF's production network to create new polyurethane formulations.

From Waste to High-Performance Components

As part of the project, these newly created recycled plastics were used to manufacture steering wheels for new vehicles. The recycled content was tracked and attributed using a mass balance approach, ensuring transparency and traceability. The resulting materials meet the stringent quality requirements for high-performance plastics, making them suitable even for safety-critical components.

Future Outlook

Dr. Robert Kallenberg, Head of Sustainability at Porsche AG, highlighted the importance of such pilot projects in developing Porsche's circular economy strategy. He stated, "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." Martin Jung, President of BASF’s Performance Materials division, added, "We are convinced that complementary technologies like chemical recycling are needed to deal with the remaining waste that is still incinerated today."

This collaboration underscores a shared commitment to innovation in sustainable material use and waste management within the automotive industry.