Insulation industry news from Global Insulation

Germany: BASF has completed a pilot, with Frankfurt-based housing society ABG and external thermal insulation composite systems producer Sto, testing an insulation board based on expandable polystyrene (EPS) containing recycled material. Around 10% of the polystyrene was replaced with a recycled substitute during the test. The results showed that the newly developed board met the same quality standards as standard market products. The sustainability targets of ABG was one of the key impetuses for the project.

BASF used its Neopor F 5 Mcycled product in the test. It is a graphite-containing expandable polystyrene granulate that contains 10% recycled material. The recycled material comes from mechanically recycled EPS waste. The aim is to other byproducts for the production of Neopor Mcycled in the future, such as EPS off-cuts from construction sites.

Austria: Multiple actors across the Austrian insulation, construction and environmental management sectors have launched a nationwide expanded polystyrene (EPS) recycling pilot. Initiative leader Fraunhofer Austria Research aims for the project, entitled EPSolutely, to establish a circular economy for EPS insulation based on its on-site collection service. Participants include insulation producers Austrotherm, Hirsch Porozell and Steinbacher Dämmstoff. The Kleine Zeitung newspaper has reported that the service provides reuseable bags and manages workflows via an app. The pilot will conclude in December 2024, with the outcomes informing a possible industrial-scale roll-out. Insulation producers have reportedly invested in new separation equipment to meet the requirements of the materials.

Steinbacher Dämmstoff head of research and development Maximilian Bernard said "The biggest challenge is the varying quality of the material delivered. The differences range from different colours to different raw materials such as extruded polystyrene (XPS) to various foreign substances such as screws and plaster residues. Despite these differences, a consistent quality of the new EPS panels must be guaranteed."

France: Saint-Gobain subsidiary Isover has begun construction of a prototype glass wool recycling plant in Chemillé-en-Anjou. Contractor Eiffage Génie Civil is executing the project, which is scheduled for commissioning in 2023.

Isover France and Switzerland technical director Jérôme Saulnier saud "The realisation of this revolutionary industrial prototype with fusion by immersed burners will make it possible to recycle glass wool in industrial quantities, transforming it into cullet. This cullet will be used in the manufacturing process of our insulating products and will also reduce our energy consumption, our carbon emissions and improve the life cycle of our products."

Netherlands: Germany-based Knauf has rolled out a waste glass mineral wool insulation recycling pilot project across the Netherlands. At a small cost, a Knauf partner company will take back leftover insulation from customers’ projects, which is remotely quantified and scheduled for collection by Knauf’s software system. The partner company recycles the insulation for use in bricks and tiles. Knauf Western Europe circular economy manager Marc Bosmans said, “The scheme saves our customers costs, gives them peace of mind that waste is being dealt with responsibly and lowers the environmental impact of their projects.”

Knauf has also launched a pallet pick-up pilot project. Under the scheme, customers can contact a Knauf partner company in order to have the pallets on which Knauf products were delivered collected for reuse, in line with the principles of the circular economy. Bosmans said, “Customers, particularly those on large sites, see a huge added value in this service and appreciate that it is a one-stop solution that is good for business and good for the environment.”

Germany: BASF is developing a pilot project to make insulation panels from plastics waste as part of its ChemCycling project. The company is making ethylene and propylene from the waste to use as raw material for further chemical manufacturing. Other projects the company is testing using waste plastics with include mozzarella packaging and refrigerator components.

“With our ChemCycling project, we are using plastic waste as a resource. In this way, we create value for the environment, society and the economy. We have joined forces with partners throughout the value chain to establish a working circular model,” said Martin Brudermüller, chairman of the board of executive directors and chief technology officer of BASF.

BASF feeds oil derived from plastic waste by an oiling process into the Production Verbund process. BASF gets this feedstock for the pilot products from Recenso in Germany. As an alternative, syngas made from plastic waste can also be used. The first batch of this oil was fed into the steam cracker at BASF’s site in Ludwigshafen in October 2018. The steam cracker is the starting point for Verbund production. It breaks down or ‘cracks’ this raw material at temperatures of around 850°C. The primary outputs of the process are ethylene and propylene. Under the mass balance approach, the share of recycled raw material can be mathematically allocated to the final certified product. Each customer can select the allocated percentage of recycled material.

BASF is working with its customers and partners, which range from waste management companies to technology providers and packaging producers, to build a circular value chain. Its next step is to make the first products from the ChemCycling project commercially available. However, technological and regulatory conditions need to be met on a regional basis before the project is market-ready.