Carbon Dioxide as an Alternative Raw Material for the Automotive Industry

Covestro has opened another application area for the use of CO2 in plastic production, in addition to mats, sports flooring and textile fibers:

Foams for the automotive industry can now be produced partly using carbon dioxide instead of fossil raw materials like crude oil. For this purpose, the innovative pioneer cardyon® is being used, and Swiss company FoamPartner is using it to produce foams for various areas in vehicle interiors. Covestro Chief Commercial Officer (CCO) Sucheta Govil states, "We are currently taking another important step toward using carbon dioxide on a larger scale as an alternative raw material in the chemical industry." "In doing so, we are accelerating the transition to a circular economy and supporting our positive momentum for growth in recent weeks. FoamPartner CEO Michael Riedel adds, "New materials such as cardyon® are extremely important for the development and responsible production of sustainable foams." "As one of the innovation leaders in the use of alternative raw materials, we are pleased to work with Covestro." Sustainable foams that FoamPartner will market in the future as a new product series under the name OBoNatureTM will be laminated with a textile in the next step and thus used in vehicle interiors. They will initially be processed in ceiling linings, as well as in door panels and armrests and car seat covers. In addition to their resource-conserving production, the particularly low-emission foams are characterized by longer service life and material resistance. Moreover, thanks to optimized lamination behavior, they enable faster lamination processes while being processed with reduced material thickness. This saves both material and production costs.

Strategic alignment drives profitable growth

Technologies such as these make an important contribution to promoting the circular economy, with which Covestro is fully aligned. CO2, biomass and waste materials such as alternative raw materials, as well as the development of innovative recycling technologies and the use of clean energy sources such as wind energy in production, are all areas of focus. This long-term strategic alignment, combined with innovation and sustainability trends, drives Covestro's profitable growth. Despite the significant impact of the coronavirus pandemic in the first half of 2020, the company experienced a steady upward trend in global demand from mid-May onward. In July, sales volumes returned to the prior-year level, and the positive trend continued in August. Therefore, Covestro expects EBITDA of around EUR 350 million in the third quarter, compared to EUR 125 million in the previous quarter.  

Versatile applications accelerate circular economy

Covestro has developed a new technology in which up to 20% CO2 can be incorporated into known polyols. These are base components for polyurethanes, a widely used and versatile plastic type. By using them instead of fossil raw materials in this way, Covestro makes an important contribution to resource conservation. Since the carbon contained in CO2 is recycled, the new process also supports the circular economy.   CO2 polyols under the cardyon® brand are already being used in many other applications. In addition to foams in mats and upholstered furniture, they are currently being used as specialty adhesives for sports floor coverings. In a more advanced research project, it has also been possible to produce elastic textile fibers based on cardyon®. For example, they can be used as a replacement for conventional oil-based elastic fibers in socks and medical textiles. Covestro is working with various textile manufacturers, among others, to bring fiber production to industrial scale and new fibers to market maturity.