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Mechanical Recycling

As part of its ChemCyclingTM project, BASF invested €20 million into Quantafuel, a start-up headquartered in Oslo, Norway. Quantafuel is specialized in the pyrolysis of mixed plastic waste and the purification of the resulting oil. BASF feeds the pyrolysis oil from Quatanfuel’s plant in Skive in its production Verbund in Ludwigshafen and further processes it into new chemical products by using a mass balance approach. The products have the same quality as products from fossil raw materials. BASF and Quantafuel are also working closely together to further develop and optimize Quantafuel’s technology.

Mechanical recycling moves the circular economy

Mechanical recycling is an essential component of the circular economy. It can be applied to various material classes like plastics, lithium-ion batteries for electric vehicles, or metals. End-of-life materials can be processed via collecting, sorting, shredding, melting and transforming it into secondary raw materials for a new application. Manufactured from recycled material, the article enters its new use-phase before the next end-of-life management.

Mechanical recycling of plastic waste has priority over chemical recycling in the waste hierarchy if ecologically beneficial, technologically possible, and economically feasible.

BASF has developed tailor-made materials and processes for mechanical recycling solutions. Some examples:

But there is more than plastics: BASF also engages in the recycling of precious metals and lithium-ion batteries for electric vehicles. Find out more below.

Mechanical recycling of plastics

Sustainable engineering develops mechanical recycling to design a true circular economy

Mechanical recycling of plastic – improving feedstock

Expert design and material development now make it easier than ever to incorporate mechanical recycling into engineering and manufacturing processes. Now is the time to integrate post-industrial and post-consumer waste materials into your designs with our recycle-based and recyclable plastics portfolio.

More about mechanical recycling that improves feedstocks

Due to the repeated use and processing of the plastics the polymer chains will be damaged so much that the plastic becomes brittle or yellowed. Additionally, the plastic waste is often made up of a mixture of different plastic types which cannot be separated from each other. Such mixtures of incompatible plastics have a significantly negative impact on quality.At BASF’s research scientists are working on developing additives that can specifically stabilize recycled plastics and improve their properties. This enables plastics to be mechanically recycled multiple times and and material loops can be closed more effectively and more often.Daniel Santoro, lab technician at the Application Center for Plastic Additives in Kaisten (Switzerland), compares the optical properties of a recyceld film with and without a stabilizer package.

Additives for mechanical plastics recycling

As the market leader for plastic additives, BASF supports the industry with solutions for mechanical recycling. One big challenge for the use of mechanically recycled plastic in demanding applications is the often lower and/or fluctuating technical properties of previously used materials. Additive solutions designed for the diverse problems encountered when using recyclates can improve the material properties in order to fulfil the requirements of different applications. In many cases, using the appropriate additive package can restore the quality and subsequent performance of the recycled material to nearly that of virgin plastic. BASF is developing these additives to enable the plastics industry to create more value from recycled content and thus increase plastics circularity in general.

Mechanical recycling of EPS packaging waste

Mechanical recycling of expandable polystyrene (EPS) packaging waste is still largely unknown to the public. Collected and clean EPS packaging waste is recycled by medium-sized companies in Germany. They process EPS waste into secondary products that are returned to the economic cycle. The shred produced from this waste is used as an additive for the plaster and mortar industry, as a filling material for seat cushions, as a pore-forming agent for the brick industry or as a thermally insulating levelling compound in the construction of flooring. The so-called “polystyrene regranulate” goes to the insulation industry.

Recycling of lithium-ion batteries for electric vehicles and catalytic converters

Catalytic Converter Recycling

As a market leader, with state-of-the-art resources and a highly experienced team, BASF provides exceptional value for recovering PGM (Platinum Group Metals) from discarded automotive catalytic converter and other scrap containing PGM. Thanks to unparalleled transparency in our sample, assay, and processing, global trading and hedging services, as well as our world-renowned, independent assay lab, BASF provides the best total return on precious metal materials.

More about Automotive Catalytic Converter Recycling

Complementary solutions for circularity of plastics

ChemCycling^TM

To increase overall recycling rates of plastics and avoid incineration or landfill, mechanical recycling can be complemented by chemical recycling. It is a recommended solution for plastic waste streams which are not recycled mechanically for technological, economic or ecological reasons.

How ecovio® contributes to closing the nutrient cycle towards a Circular Economy With the certified compostable plastic ecovio®, BASF has developed a material portfolio for a variety of applications which can be used throughout the entire food cycle and thus support Circular Economy – from production via packaging and transport to the waste collection of food. Photo: BASF 2019

Biopolymers

Biodegradable plastics close the nutrient loop in special applications. Read more about how certified biodegradable plastics contribute to Circular Economy.

Empty road surrounded with tree and green field on either sides

Biomass balance approach

BASF’s biomass balance approach contributes to the use of renewable raw materials in BASF's integrated production system and can be applied to the majority of BASF's product portfolio.