BASF, Porsche, and BEST collaborate on chemical recycling!
On September 29, 2025, Porsche AG and BASF SE, along with their technology partner BEST Bioenergy & Sustainable Technologies GmbH, successfully completed a pilot project for the recycling of mixed end-of-life vehicle waste.
The project demonstrated the recyclability of high-performance plastics and renewable raw materials from automotive shredder residue (ASR). ASR, a complex composition consisting of plastics, films, coatings, and foam residues, is currently only thermally recycled. The pilot project demonstrated that ASR can be recycled through gasification, a chemical recycling process, and reused within the automotive supply chain.
The project demonstrated the potential of new plastic sources and chemical recycling technologies for automotive parts, with the goal of reducing the use of virgin materials and increasing the proportion of recycled content in vehicles. As part of the project, chemically recycled materials were used in steering wheel manufacturing.
Dr. Robert Kallenberg, Head of Sustainability at Porsche, stated that projects like these help the company assess how to further promote a circular economy and integrate chemical recycling into its long-term strategy. Porsche is working with partners to test new recycling technologies to increase the proportion of recycled materials, develop new recycling sources, and explore novel treatment processes for waste streams.
Porsche is committed to using recycled materials in its vehicles and closing the resource loop. It has set a goal to increase the proportion of traceable secondary materials in vehicle production. This project is evaluating the potential of ASR as a future recycling source, complementing mechanical recycling with the potential for large-scale application in conjunction with a mass balance approach.
Defossilization: A fully fossil-free gasification process produces new plastics
In this project, the research team, for the first time, recycled a mixed waste stream of pure automotive waste and biomass through gasification. The resulting recycled raw materials (syngas and its derivatives) replace fossil raw materials within BASF's integrated value chain. BASF uses a mass balance approach to produce the polyurethane formulation for its steering wheels.
This recycling innovation utilizes modern gasification technology from BEST, which converts plastic waste and other residues into syngas at high temperatures.
Dr. Matthias Kuba, Technical Manager of the Syngas Platform at BEST, explained that the company previously focused on converting biomass into chemical feedstocks. However, in this pilot project, gasification technology was applied for the first time to convert complex plastic waste streams with biomass to produce "synthetic crude oil." This chemical recycling method has the potential to transform complex mixed waste streams into high-value feedstocks, offering an alternative to incineration.
Maintaining Technological Diversity
Dr. Martin Jung, President of BASF's High Performance Materials division, stated that BASF's actions focus on sustainable development across the plastics value chain, encompassing the three key links of production, use, and recycling. BASF offers a diverse range of recycling solutions and firmly believes in the complementary nature of various technological approaches. BASF prioritizes mechanical recycling and continuously improves its efficiency. At the same time, it selects the most appropriate technology based on the type and level of waste sorting. BASF believes that complementary technologies, such as chemical recycling, are crucial to promoting a circular economy and reducing the amount of plastic waste sent to landfill or incineration. A sound regulatory framework is crucial to fully utilize waste recycling pathways and advance technological development.
