Automotives are resource-intensive. Currently, over 60 different raw materials are used to manufacture car components.

If the circular economy model is adopted in manufacturing processes, several components, such as tires, don’t have to be discarded after a single cycle.

The automotive sector must go beyond simple tire recycling to reduce its dependence on virgin materials and fossil fuels. In a circular economy, industries can keep several materials in circulation and enjoy the benefits of lower production costs, assured local resource supply, and increased operational sustainability.

In this article, you will learn:

• The various car components and materials that can be recycled,
• How automotive recycling contributes to a European circular economy, and
• The advantages and disadvantages of recycling car components.

Subscribe to the Contec Monthly on our LinkedIn Page and gain relevant insights into circularity and sustainable business models.

The importance of car recycling in the circular economy

A vehicle’s environmental impacts start before it’s ever used due to the extraction, transport, and processing of raw materials during production.

Vehicles also produce vast amounts of waste during and after use, a significant part of which is toxic. However, many materials in end-of-life vehicles (ELVs) still have value. According to the Alliance for Automotive Innovation, nearly 86 per cent of the materials in ELVs are recyclable. 

According to the European Parliamentary Research Service (EPRS), the automotive sector is responsible for 19 per cent of steel and 10 per cent of plastics demand in the European Union (EU). However, the unreliability of global supply chains for steel, critical raw materials, and fossil fuels poses serious challenges for the automotive sector. These problems can be resolved by adopting a circular economy. Considering the entire life cycle of materials, circularity is the most economical and environmentally conscious method of material use.

Recycling is crucial to keeping materials in circulation and supporting the circular economy. Currently, car materials from ELVs are reused and recycled but also incinerated for energy. Incineration destroys resources and should be avoided when possible. Instead, materials that would otherwise be incinerated should be diverted for recycling. 

Local and regional recycling centers in the EU can become sources of valuable, high-quality secondary raw materials and reduce outside dependence on resources. Recycling also conserves reserves of natural resources and reduces the portion of ELVs that are landfilled or burnt. 

Car parts with recycling potential

Vehicles have several components and materials that can remain in circulation beyond tires. Metals, plastics, glass, electronic appliances, oil, batteries, etc., are all recyclable.

However, dismantling ELVs requires the collection and sorting of various car parts. This poses several technological and economic challenges which the automotive sector must tackle. According to the EPRS, 6.5 million vehicles in the EU reach the end of their life annually. Instead of becoming a waste problem, adopting circularity can help meet the EU sector’s demand for raw materials. 

Plastic car parts

Plastics are the second most common material used in vehicles, after metals. According to the EPRS, plastics make up 50 per cent of car waste by volume and 10 per cent by weight, but only 19 per cent is recycled.

To meet the EU target of recycling 30 per cent of plastics from ELVs, the automotive sector can focus on polymers with mature recycling technology, such as polypropylene (PP), polystyrene (PS), and acrylonitrile butadiene styrene (ABS).

The items with recyclable plastic types that are easy to dismantle before shredding ELVs are as follows:

• Car exterior: Vehicle components like the bumper, fender, car body, bonnet, and wing mirrorcasingcan be used for new car parts like mud and splash guards. Tire recycling in various ways can close the loop.
• Interior Plastics: Several recyclable interior items, such as dashboards, door panels, car mats and carpets, seat polyurethane foam, and door panels, are useful for furniture and building material production.
• Plastic Fuel Tanks: The fuel tanks made of high-density polyethylene (HDPE), are highly recyclable and dismantled easily. 

Plastics may not be as valuable as metals, but recycling them still reduces waste and fossil fuel extraction. 

Other recyclable car components beyond plastics

To meet EU targets of reusing and recycling 85 per cent of the material in cars, other materials must also be considered.

• Metals: The automotive sector uses a large percentage of EU steel (19 per cent), aluminum (42 per cent), and critical raw materials (50 per cent). Steel and iron make up 65 per cent of a car by weight and the material has a 90 per cent recycling rate. All metals can be indefinitely recycled to produce high-quality non-downgrading secondary material.
• Glass: Windshields and windows are recyclable ifdismantled in time. However, currently, only 10 per cent are removed before shredding vehicles, making recycling challenging.
• Hazardous material: Batteries and catalytic converters are also recyclable. The rising demand for lithium-ion batteries due to increased electric vehicle production can be met by reusing, refurbishing, and repurposing old batteries. It´s also possible to recover valuable metals like lithium from used batteries. Lead-acid batteries are recycled, and most of the hazardous lead is recovered, reducing the environmental risks of improper disposal.

Despite the challenges, several vehicle manufacturers are already committing to recycling materials in their automobiles. 

Circular economy in the automotive industry: Real-life examples

Some excellent examples of recycling in the automotive industry in the EU are as follows:

• Car manufacturers Skoda, Stellantis, and Volkswagen have joined the EU project “ZEvRA (Zero Emission electric vehicles enabled by haRmonised circulArity),” aiming to achieve 100 per cent recycling of steel and aluminum.
• Mercedes-Benz has opened a battery recycling plant in Germany to recover over 95 per cent of lithium, cobalt, and nickel in automotive batteries for reuse in ELVs produced by the brand. 
• Contec uses a proprietary pyrolysis process to turn end-of-life tires into new commodities. Learn more about our process.

What are the advantages and disadvantages of recycling car parts?

The global automotive industry accounts for 5 per cent of industrial waste, so recycling car parts can have environmental and economic benefits for everyone.

However, recycling car parts also has challenges impacting its effectiveness that must be resolved.

Advantages of recycling car parts:

Recycling ELVs supports circularity by using fewer virgin materials and energy. The benefits are discussed below: 

• Environmental benefits: The main ecological benefits include less pollution and increased resource conservation.
  • Recycling car parts reduces waste and pollution. It also reduces landfill space, for example, by shredding tires. 
  • Keeping materials in circulation conserves natural resources by limiting the extraction and processing of new materials. For example, using one ton of recycled plastic instead of new plastic saves oil (16.3 barrels), energy (5,774 kWh), and landfill space (22.9 m3). 
  • Alternate feedstocks can be produced from chemical recycling to make new plastic.
• Energy savings: Recycling car parts cuts energy use and can reduce 90 per cent of greenhouse gas emissions and mitigate climate change.
  • Producing secondary materials is not as energy-intensive as new material production. Recycling polypropylene plastic generates 42 per cent fewer carbon emissions than producing new plastic.
  • Recycling metals saves 20 times or between 60-95 per cent of energy compared to extraction from ores.
• Economic opportunities: Recycling involves various functions such as collection, dismantling, sorting, shredding, and processing.
  • The automotive recycling industry is expected to grow at an anticipated CAGR of 7.2 percent between 2024 and 2031. In the EU, net revenues of €1.8 billion, after considering costs, are expected.  
  • Recycling is labor-intensive and can create job opportunities. In the EU, it could add over 22000 jobs, most in small and medium enterprises.
  • The market for remanufactured products is increasing and can soon become economic for consumers.
  • ELV recycling can diminish the EU’s dependence on imported resources, as most of the raw materials needed for making cars are unavailable in the region.

Disadvantages of recycling car parts:

Some challenges in recycling car parts are complexity, economic viability, and insufficient recycling processes. 

Complexity of recycling processes: The number of materials and composite nature of car parts complicates recycling. Currently, only 19 per cent of the plastic components recovered from ELV are recycled. Of the nearly 200 polymers used in cars, around 39 are commonly used either individually or in combination with other polymers and materials. 

Several plastic polymers lack recycling technology, capacity, or sufficient quantities of waste to make circularity feasible. Another problem is the difficulty of dismantling car parts. Innovative product designs that plan for easy disassembly can help improve recycling. 

Many of these challenges can be solved by evaluating the entire creation of car parts and designing them from the beginning with circularity in mind.

Economic viability: Though new mined resources are not needed, recycling costs can sometimes be higher than new production costs. The market and prices for recycled materials also fluctuate, which influences the profitability of recycling. Materials that need special handling equipment and conditions can be expensive for small recyclers. As EU regulations favor increased recycling, secondary materials will likely become more abundant and cost-effective.

Insufficient Infrastructure: ELV recycling also suffers due to supply chain management problems. Several regions lack the infrastructure and efficient networks for collection and recycling. Required recycling centers may not be available nearby, which can reduce recycling efficiency or increase costs due to transport. Recycling technology for specific parts may also not be economical. The sector requires more R&D efforts within the industry and in collaboration with research institutes to fix this problem.

Circularity and recycling car parts

A significant portion of car part material is recycled, reducing waste and environmental impacts and saving natural resources. However, recycling efficiency can be higher for recyclable materials if the challenges in the availability of suitable and economical recycling technology are addressed.

Contec, with its innovative and protected pyrolysis process, provides much-needed and scarce green and safe solutions and capacity for recycling tires. Contec can recycle 100 per cent of the materials in end-of-life tires to reduce waste and produce feedstocks like recovered Carbon Black (ConBlack®), recovered Tire Pyrolysis Oil (ConPyro®), and recovered Steel (ConWire®) as sustainable alternatives to current industrial production.

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• What is tire pyrolysis and how does the process work?

We’re excited to announce the completion of our third and fourth pyrolysis lines, marking a significant milestone in the company’s growth and execution within budget.

The milestone was reached from last year’s strategic investment including installing and commissioning our third and fourth pyrolysis lines. These new lines, which are already operational, are a step forward in our mission to provide sustainable, circular products to the automotive and tire industries.

At Contec, sustainability is at the heart of everything we do. That’s why we’re thrilled to announce that we have achieved the ISCC EU and ISCC Plus certifications, reinforcing our commitment to responsible resource management and reducing greenhouse gas emissions.

ISCC – International Sustainability and Carbon Certification is a globally recognised system that sets high standards for sustainable practices across various industries, including biofuels, chemicals, plant-based materials, and recycling.

These certifications confirm our alignment with rigorous sustainability standards, build trust with our customers, partners, and communities, and demonstrate our dedication to a greener future in tire recycling.

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The countdown to the completion of our plant expansion work in Szczecin is well underway!
Wojciech Paruzel Joins Contec S.A. As COO

The global tire market, of which the European Union has a 30 per cent share, is estimated at USD 34512.2 million and will grow at a CAGR of 2.5 per cent from 2024 to 2031.

Sustainability is increasingly important for the tire industry as it generates a challenging amount of post-consumption waste. Its raw materials are derived from limited, non-renewable, and polluting fossil fuels. The circular economy model, where end-of-life tires are considered raw materials for further production cycles, can solve both these problems and ensure the industry’s growth. 

This article will cover the various circular economy approaches that manufacturers can use to become sustainable, such as: 

• Tire production and raw material extraction,
• Current collection and management of used tires, and
• Strategies guided by the 10Rs to bring circularity to the tire industry.

Subscribe to the Contec Monthly on our LinkedIn Page and gain relevant insights into circularity and sustainable business models.

What are the current circularity challenges in the tire industry?

Most tires are currently produced using the linear economy model, which is stressful for the environment and society at every stage of “extract-manufacture-consume-dispose” products.

The linear model currently used in the tire industry extracts resources continuously, depleting fossil fuels, whose reserves are shrinking and will become very expensive. Oil is expected to run out by 2052, gas by 2060, and coal by 2090.

The circular economy recognises that the materials in end-of-life products retain value and can be used several times if post-consumption items are collected.

They can be first repaired, reused, or refurbished. When the product can no longer be used, it is recycled to recover materials for the next cycle of products. This way, materials remain in circulation longer, saving natural resources and reducing waste and environmental impact. 

According to a 2022 report from the European Recycling Industries’ Confederation (EuRIC), currently, only 60 per cent of collected ELTS were used for material recovery as part of the circular economy. Over 30 per cent of the remaining ELTs were incinerated for energy recovery following a linear model, meaning their raw materials were lost after one cycle of tire production.

Using secondary materials in a circular economy model has many sustainability benefits, including:

• Stopping the loss of materials after one cycle of tire production and use can ensure a steady and regional/local supply of components to stabilise tire production and make it economically efficient.
• Using secondary recycled materials reduces the energy used to make one tonne of new tires from 1019 kWh to 770.5–800 kWh. It also reduces water consumption.
• Incorporating recycled materials from ELTs to make new tires can reduce environmental impact. Using 4 per cent or 10 per cent of secondary material in truck tires reduces ecosystem impacts by 4.60 per cent or 4.65 per cent, respectively.
• Reducing carbon emissions by 700 kg of CO2 per tonne of tire produced.

According to a 2021 research paper, globally, 20 million tonnes of ELTs are generated, but only 70 percent are recovered—52 percent for materials and 19 percent for producing tire-derived fuel. So, there is scope for more material recovery and circularity in the tire industry to enhance sustainability.  

Contec uses a proprietary pyrolysis process to turn end-of-life tires into new commodities. Learn more about our process.

The Circular Economy in action: Tire industry innovations

The current 3Rs of reduce, reuse, and recycle only support a linear economy model.

Industries can develop a circular economy in manufacturing to become sustainable by using one of the 10Rs instead. The aim of the 10Rs is to reduce the extraction of natural resources and waste and maximise materials’ utilisation and lifetimes.

According to a 2022 research publication on circular manufacturing, the 10 Rs relevant to circularity are refuse, rethink, reduce, reuse, repair, refurbish, remanufacture, repurpose, recycle, and recover. 

 1. Refuse

Refuse refers to a refusal to use harmful, non-recyclable, or/and non-renewable materials in manufacturing. In manufacturing, this would mean using recycled raw ingredients that reduce environmental impact instead of harmful materials.

For example, using recovered secondary products from recycled ELTs instead of fossil-fuel-based vCB, rubber, or textiles.

2. Rethink

This step involves rethinking several stages and product usage. It includes rethinking product design to make the product circular, using recyclable, renewable, and sustainable materials in production, and developing circular innovations where necessary.

“Manufacturers can invest in new innovative tire designs that produce modular individual components for simpler disassembly for recycling, repair, and reuse in manufacturing new tires. Similarly, modular components in new car designs will allow for more replacement and repair, decreasing demand for new vehicles and lessening the use of new raw materials to build cars,” says Krzysztof Wróblewski CEO of Contec.

3. Reduce

This involves improving manufacturing efficiency to reduce the utilisation of virgin raw materials, energy, chemicals, fuel, packing materials, and water while also reducing environmental impacts like waste production, greenhouse gas emissions, and pollution of air, water, and soil.

One means to achieve reduction is by using lean manufacturing principles. Various tire brands are using different strategies to achieve reduction.

4. Reuse

This strategy involves reusing a product or resource while retaining its original abilities. In the case of tires, consumers can reuse worn tires after retreading with recycled rubber instead of buying new tires.

Retreading is a cost-effective method of improving product lifetime and limiting the environmental impacts from tire production by reducing the use of new materials, energy, and water. High-quality used tires can also be resold for use on vehicles or other purposes.

5. Repair

Repairing products to facilitate proper functioning can also extend their lifetime.

Instead of replacement, minor tire problems can be fixed by repair, service, and maintenance. Developing and promoting service-based repair facilities will be crucial to achieving this goal and could require policy intervention. Consumers can also use kits and information guidance to make basic tire repairs.

6. Refurbish

Refurbishing is like repair but goes further to restore the product to its original condition. The process can involve buy-back schemes and reuse of product components.

The quality of refurbished products is comparable to new ones. Establishing a second-hand market for refurbished components and refurbishing experts will be necessary to support this goal. For example, older tires can be retrofitted with advanced technology to extend their lifetime and improve performance.

7. Remanufacture

Remanufacturing involves dismantling end-of-life products and reusing their parts to make new products with the same functions and abilities. It supports circularity by reducing reliance on new natural resources, the production of components, and associated environmental impacts. 

Circularity examples through remanufacture already exist in the tire industry. Industrial leaders like Michelin and Bridgestone use recycled content like recovered Carbon Black (rCB) to close the material loop and remanufacture new tires. Nokian’s concept green tires aim to use rCB, recovered steel wires, and belts from ELTs. 

8. Repurpose

Repurpose involves using an end-of-life product or its components for a new purpose. When it is no longer possible to recirculate materials in a closed loop, they can be used in an open loop with or without processing.

For example, all ELTs are used without processing to dampen shock and noise vibrations. Shredded tires are used for several civil engineering purposes, such as eco-friendly paving materials, playground surfaces, bases for construction, etc. 

9. Recycle

Recycling involves processing end-of-life products to obtain secondary materials to make new products.

Recycling waste is also crucial. The standard tire recycling method is mechanical processing to produce shreds, chips, and granules. Shreds and chips are used in civil engineering like making athletic tracks, paving blocks, or asphalt for roads. Other methods include devulcanisation and pyrolysis for material recovery.

10. Recover

When the materials have lost value for recycling, energy recovery can be considered through incineration. I

t is the last option in using the material and diverting it from landfilling, which must be reduced or eliminated completely. Instead of fossil fuels, ELTs are incinerated in controlled facilities to produce energy for industrial processes like cement production. 

ELT recycling has improved considerably in the last twenty years. In 1994, only 8 per cent ELTs were recycled, and 14 per cent were used for energy recovery; treatment of the remaining 78 per cent ELTs was unknown.

By 2019, ELT recycling had increased dramatically and 52 per cent were used for material recovery, 40 per cent for energy recovery, and 3 per cent for civil engineering uses. Unknown uses were down to 5 per cent, according to a 2023 Tire Industry Project report. 

However, ELT management is not standardised among the major tire consumers. The EU collects 91 per cent of ELTs for materials recovery (60 per cent) and energy recovery (>30 per cent). In the USA, only 81 per cent of ELTs are recycled or reused, and in China only 60 per cent of ELTs are treated.

Reinvesting in innovation to drive circularity for the tire industry

None of the above circularity methods will work without reinvesting funds to support R&D efforts to innovate and develop sustainable technologies for the circular economy.

Moreover, cooperation among stakeholders within the tire supply chain will be necessary to develop industry specifications like the American Society for Testing and Materials (ASTM International) to provide useful components and secondary raw materials, and creation of adequate markets for recycled products.

By integrating the circular economy principles through the 10 Rs strategies, it should be possible to make manufacturing sustainable and economically efficient. This will have ripple effects, such as creating thousands of local jobs, saving money for the country and society, and saving the environment through efficient resource use. Joining the circular economy also increases brand value and helps in ESG compliance.

At Contec, we enable tire manufacturers interested in transitioning to a circular economy by providing recovered Carbon Black (ConBlack®), recovered Tire Pyrolysis Oil (ConPyro®), and recovered Steel (ConWire®) from ELTs as sustainable alternatives to current industrial production.

Get in touch to learn more about our solutions.

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In 2021, 16.13 million tonnes of plastics were used in the European Union, and only 40 per cent was recycled.

The average global situation is more critical, as only 9 per cent of plastic waste is recycled worldwide. Can this plastic waste be upcycled into circular products to be returned to the economic cycle?

Mechanical recycling methods of plastics are neither versatile enough to deal with the various types of polymers nor adequate for the volumes of waste produced. Also, the market is glutted with mechanically recycled secondary plastics. 

Chemical recycling can be a viable and sustainable alternative to convert end-of-life plastics to their base chemicals and divert waste from incineration and landfills. In this article, you will learn:

• What is chemical plastic waste recycling?
• How chemical recycling differs from pyrolysis, and
• The advantages and disadvantages of these two plastic recycling methods.

Subscribe to the Contec Monthly on our LinkedIn Page and gain relevant insights into circularity and sustainable business models.

Understanding the Processes: Chemical Recycling vs Pyrolysis

Chemical recycling or advanced recycling is a set of technologies for mixed (laminated and multilayered) or contaminated plastic waste that is difficult to recycle mechanically. The process can also treat waste plastic without economic potential after mechanical recycling. 

The British Plastics Federation states chemical recycling breaks end-of-life plastics into simple hydrocarbons. These hydrocarbons can be monomers or polymers used as molecular building blocks for new virgin-quality plastic production or as chemical feedstocks. 

Depolymerisation and purification are two technologies used to chemically recycle plastics. Theoretically, these processes can recycle plastics multiple times without degradation of quality.

Depolymerisation

Chemolysis, or depolymerisation, reverses the polymerisation used to produce plastics and yields single individual molecules (monomers) or short chains of oligomers.

The end products’ quality is comparable to virgin monomers produced from fossil fuels, meaning the products of depolymerisation can be used to produce virgin-quality plastics that could be food-grade. Various solvents, such as water/steam, glycols, amines, and menthols are necessary for different types of plastic. The plastic waste streams that can be recycled by these various depolymerisation processes are:

• Methanolysis and glycolysis can recycle polyethylene terephthalate (PET) plastics, such as beverage bottles and food packaging. 
• Hydrolysis, still in the laboratory testing stage, could recycle polyamides (PA) or nylon found in clothes, toothbrush bristles, and carpets. 
• Glycolysis and hydrolysis can recycle polyurethanes (PU) or foams. Flexible foams are found in upholstery, car seats, etc.; rigid foam is used in construction and insulation; other applications are paints, adhesives, etc. 

Purification

This process dissolves plastics in suitable solvents, followed by purification to remove additives and contaminants.

The dissolved plastic polymers are later recrystallised with their properties unchanged and can be used for new plastic production. This chemical recycling process is helpful for several types of plastics, such as:

• Polyvinyl chloride (PVC), used to produce medical devices, pipes, and cables.
• Polypropylene (PP), found in packaging, housewares, domestic appliances, medical, automotives, and industrial items.
• Polystrene (PS), which is used to make disposable food packaging and cups.
• There are two types of polyethylene (PE). High-density polyethylene (HDPE) is used in fresh produce bags, caps, bottles, and carrier bags. Low-density polyethylene (LDPE) is used to produce films, bags, sacks, protective sheeting, etc.

Pyrolysis

Pyrolysis and gasification are advanced recycling processes that produce chemical feedstocks. Pyrolysis, also called cracking, is a thermal process, so it is considered different from purification and depolymerisation which are purely chemical processes.

Pyrolysis recycling applies high temperatures to plastic waste in an oxygen-free environment. This decomposes complex polymers into a mixture of basic hydrocarbon gases and char. The gases are distilled to produce heavy oils, light oils, naphtha, and waxes. Any non-distillable fraction remains a gas. The product composition can be altered to shift production to the more desirable lighter oils and gas by changing the temperature and treatment time. Heavier hydrocarbons can be re-treated to get lighter products. 

This process produces lower-value products and oils that can’t be directly recycled for plastic production. The pyrolysis oils are comparable in quality to some fossil oils (diesel) used as fuels. 

Pyrolysis is useful for treating difficult-to-recycle plastic streams like mixed or contaminated plastics and PP to produce circular products. Pyrolysis plants treat other waste streams, notably end-of-life tires, to make oils and char. Though applying pyrolysis to recycle plastics is a recent development, pilot projects worldwide have proved it is possible. 

What is the difference between chemical recycling and pyrolysis?

Though pyrolysis is a type of chemical recycling, it differs significantly from purely chemical processes, and these differences are worth highlighting.

End products and circularity

Chemical recycling’s end products are high-value monomers that can be used instead of mined fossil petrochemicals to produce virgin-quality plastics.

This secondary plastic retains its value and can be recycled several times, making it a good fit for the circular economy. In comparison, pyrolysis recycling’s end products are lower-value fuels, feedstock, and char.

Burning pyrolysis oil and gas for energy is just as polluting as burning fossil fuels. The pyrolysis oils must be refined before use as feedstocks to produce plastic.

The process is less circular, as the end products can’t be directly used in the next cycle of plastic production. However, the secondary plastic produced is comparable to virgin plastics in quality and is food grade, which makes it useful for medical items and packaging for cosmetics and food.

Energy use efficiency and carbon footprint

Depending on the technology, chemical recycling processes can consume substantial energy. However, optimised chemical recycling processes are more energy efficient and have a smaller carbon footprint than manufacturing plastic from virgin fossil fuels.

Pyrolysis recycling always needs considerable energy to attain the high temperatures necessary. Additional energy use is also necessary for refining the end products. Therefore, the carbon footprint can be large.

However, carbon emissions from pyrolysis are significantly reduced by using renewable pyrolysis gas instead of fossil fuels for heating. Overall, pyrolysis recycling has a smaller carbon footprint than chemical recycling.    

Feedstock flexibility 

Chemical recycling processes accept specific plastic streams, which increases their efficiency. However, the proper sorting of post-consumer products may require additional effort.

Pyrolysis recycling has feedstock flexibility and can treat mixed and contaminated plastic. Some types of co-pyrolysis treat plastic mixed with biomass. However, this versatility is offset by lower-value products from pyrolysis. Moreover, PET plastics, which contain oxygen, can comprise efficiency as pyrolysis needs oxygen-free environments to be effective. 

Pyrolysis has the advantage of handling waste that mechanical recycling can’t. It offers an opportunity to go beyond mechanical recycling and increase the amount of waste diverted from landfills and incineration to meet European Union (EU) targets of 2025 and 2030.

The Circular Economy Package wants to reduce landfilling to 10% of municipal waste by 2035. The EU has set ambitious targets to reduce landfilling and incineration of plastic waste. 

Contec uses a proprietary pyrolysis process to turn end-of-life tires into new commodities. Learn more about our process.

Which process is more sustainable?

Context matters. 

If circular plastics are the goal, chemical recycling is better as it reduces virgin raw material use.

However, plastic waste of all kinds is mixed or contaminated by the products it contains, even in the EU. In these cases, chemical recycling technology cannot be used.

Pyrolysis recycling is the ideal solution for mixed PE, PP, and PS plastics to prevent incineration for energy recovery or landfilling, which carries the risk of plastic ending up in oceans, for example.

Pyrolysis is the dominant and most profitable technology among chemical recycling processes. Since 2021, pyrolysis recycling capacity has increased by 60 per cent globally. The pyrolysis oil yield can be as high as 70 per cent, but the yield of new plastic is low. Pyrolysis recycling has a small carbon footprint if renewable gas, one of its products, is used for heating.

All chemical recycling processes have these advantages over mechanical recycling, beyond circularity: 

• Resources are abundant, especially for pyrolysis recycling (mixed and contaminated plastic waste), and there is a high demand for circular plastics. 
• The process encourages plastic waste collection and treatment, makes waste treatment economical, and establishes a sustainable supply chain. 
• R&D efforts by industry leaders, research institutions, and national governments are promoting innovation and attracting investments to increase capacity.  

According to Plastics Europe, the planned investment in chemical recycling is expected to be 2.6 billion Euros by 2025 and 8 billion Euros by 2030. Feedstock technologies such as pyrolysis and gasification are expected to account for 60 per cent of the planned capacity of 44 projects in 13 EU nations.

This will reduce plastic waste disposal and provide recycled feedstocks that could account for two-thirds of plastics and petrochemicals by 2030, cutting the use of virgin fossil fuels and boosting the circular economy.

While chemical recycling is efficient, pyrolysis recycling provides a ready solution for the problem of some mixed plastic streams to meet EU goals of reducing landfilling, increasing plastic recycling, and producing circular products.

Pilot pyrolysis recycling projects have been tested, and investments are being earmarked for expansion. Increased capacity is possible by building many small units or a few large-scale centralised plants.

Tire Pyrolysis at Contec

Contec uses a novel molten salts pyrolysis process to recycle waste tires, a complex plastic polymer.

It is one of the few pyrolysis companies in Europe that has received investments to expand its capacity threefold. Contec aims to produce circularly recovered Carbon Black, pyrolysis oil, steel, and gas. Carbon Black is a critical raw material that can be supplied to the tire industry to support the circular economy.

At Contec, we enable tire manufacturers interested in transitioning to a circular economy by providing recovered Carbon Black (ConBlack®), recovered Tire Pyrolysis Oil (ConPyro®), and recovered Steel (ConWire®) from ELTs as sustainable alternatives to current industrial production.

Get in touch to learn more about our solutions.

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Companies are beginning to embrace sustainable transformation.

Contec’s CFO and Member of the Board, Dominika Żelazek, interviewed with My Company Polska to discuss business transformation and offer strategic insights for growing companies.

With the CleanTech market expected to skyrocket by 2025, this sector is set to triple in the coming years, positioning it as one of the most promising investment opportunities of this decade.

In this short article, read a digest of what was discussed during the interview with Dominika.

• Transformation is at the heart of what Contec does, embedded into our DNA, and how we provide to the industry. We view end-of-life tires (ELTs) as an opportunity, to be reentered into the economic cycle.
• Transformation and innovation enable us to develop dynamically in our operations and throughout the entire value chain. We stay true to our commitments to development, with a large plant opening in Szczecin and further planned across Europe.
• It’s paramount to have a strategic plan in place to successfully transform. Businesses must start this process earlier before being faced with obstacles that hinder their development.

After the interview with Dominik, one thing is clear: There is no better time than the present to be involved and invest in CleanTech.

At Contec, we enable tire manufacturers interested in transitioning to a circular economy by providing recovered Carbon Black (ConBlack®), recovered Tire Pyrolysis Oil (ConPyro®), and recovered Steel (ConWire®) from ELTs as sustainable alternatives to current industrial production.

Get in touch to learn more about our solutions.

Molten salts technology is attracting intensive R&D efforts and emerging in the circular economy. It is leading advancements in renewable electricity generation and heat storage as a safe, green alternative to conventional technologies. 

The demand for molten salts for thermal energy storage alone was worth 8.6 billion USD in 2024 and is expected to have a CAGR of 9.4% in the same year. Molten salts technology is also being developed for recycling critical resources and hazardous tire waste, and its advantages are driving more usage across different industries, which we will cover in this article, along with: 

• The many properties of molten salts technology,
• What the uses of molten salts in various industries are, 
• And how molten salts are used to recycle important resources.

Subscribe to the Contec Monthly on our LinkedIn Page and gain relevant insights into circularity and sustainable business models.

What is a molten salts mixture? 

Molten salts are simple inorganic compounds, such as fluorides, chlorides, and nitrates. A common example is sodium chloride or table salt. The standard molten salts mixture in industrial settings is 60 per cent sodium nitrate (NaNO3) and 40 per cent potassium nitrate (KNO3). 

Molten salts are phase change materials that are solid at room temperature and atmospheric pressure. High temperatures, specific to the salt, melt them to produce stable liquids made of positively- and negatively-charged ions. For example, sodium nitrate, potassium nitrate, and sodium chloride all melt at different temperatures of 306.5°C, 334°C, and 801°C, respectively. The 60 per cent sodium nitrate + 40 per cent potassium nitrate mix remains a liquid only at high temperatures of 220-600°C. 

How and what molten salts are used for depend on their following properties:

• Fluid stability: Molten salts have a viscosity similar to water at high temperatures and the ability to flow, which is useful in heat transfer applications. When the molten salts cool, they solidify and contract unlike water that expands when frozen and can burst pipes.
• High heat capacity: Molten salts have a higher latent heat capacity than conventional materials and store the heat applied to melt them. They can store heat over 700°C making them suitable as a heat transfer or storage medium. 
• Electricity conductivity: In the liquid state where the chemicals are ionic in form, molten salts conduct electricity.
• Solvent: Molten salts act as solvents and can be used as alternatives to toxic volatile organic compounds (VOC). They can dissolve or dilute several organic and inorganic materials, such as metal oxides, or crystallise basic oxides at their freezing points. 
• Catalysts: Some molten salts are catalysts and used in the synthesis of chemicals.

Molten salts are used in various applications, including direct heating, baths, and circulation. They are nonflammable and nonvolatile, making them ideal for industrial applications as a safe and environmentally friendly technology.

What are molten salts used for? 

Several standard industrial processes use molten salts technology, such as nuclear reactors, heat transfer, electrochemistry, etc. The first use of molten salts was in 1950 to develop and test a nuclear-powered aircraft in the USA! 

Molten salts as a heat transfer medium      

Currently, one of the main uses of molten salts is as a heat transfer medium. Molten salts’ high heat capacity and viscosity are useful in transferring high temperatures in many energy systems for storing or producing energy, according to a 2022 review (Roper et al.).

A few examples are:  

• Thermal energy storage: Renewable energy storage has been a challenge that molten salts address. Molten salts as thermal energy storage and heat transfer fluids are integral to new concentrating solar power (CSP) plants. Molten salts absorb heat from solar radiation that is focused by mirrors and lenses on a small receiver. Molten salts store the heat up to 600ºC for extended periods for later use. When required, the heat stored in molten salts is transferred using a heat exchanger to generate steam to turn a steam turbine for electricity production. Nitrate-nitrite molten salts are common in solar applications. Molten salts technology increases efficiency and storing capacity of solar power plants.
• Nuclear reactors:  Molten salts cool solid fuels in nuclear reactors due to their heat transfer capabilities. Molten salts can also be used as fuel salts in nuclear reactors. Since the molten salts remain liquid even under low atmospheric pressures, it is an advantage that allows for use of systems that have relatively thin walls.
• Pyrolysis: The use of molten salts as heat transfer mediums has been further extended by integration into end-of-life tire (ELT) pyrolysis. Pyrolysis is a thermo-chemical process that uses high temperatures between 400-700ºC to break down the complex mix of substances in tires into simpler components that provide a range of secondary recycled products that can narrow the material loop to produce new tires, rubber, and paints. 

Molten Salts Pyroprocessing of Non-Ferrous Metals 

Pyroprocessing extracts non-ferrous metals by dissolving them in a molten salt bath. For example, metal ores like titanium oxide are combined with chlorine and carbon, and the resultant compound titanium tetrachloride (TiCl4) is smelted in molten salts. Once melted, the metal is boiled and then distilled to separate it from impurities to give pure TiCl4. 

Using molten salt electrolysis for metal production is a more common method.

Molten Salts in Electrolytics and Fuel Cells 

Molten salts are popular for electrolysis because their electrical conductivity is several times higher than aqueous and organic electrolysis. Molten salts’ high temperatures support rapid electrode reactions, therefore a higher voltage, though this property can be a disadvantage at times.  

Examples of molten salts in electrolytics include:

• Metal extraction: Molten salts with high melting points, electrical conductivity, and electrochemical stability are useful in extracting aluminium and titanium from raw ores. 
• Critical resources recovery: Molten salts electrolysis can help in the recovery of critical resources and metals from waste/secondary resources such as abandoned rare earth metals, spent lithium batteries, waste cemented in carbide scrap, and spent fuel. With the rise of renewable energy, demand for critical metals is increasing. The metals are considered critical as they are essential to the security and economy of a country and their supply chains are fragile, since they are sourced from regions with less government control. Molten salts address challenges in conventional aqueous solution electrolysis. They provide anhydrous and oxygen-free conditions and inhibit hydrogen production that interferes with the electrodeposition of metals. Therefore, molten salt electrolysis is preferred for extracting, purifying, and resource recycling of rare earth metals, alkali, aluminium, and magnesium. 
• Fuel Cells: Molten salts are used as electrolytes with other compounds in batteries called fuel cells that use electrochemical conversion to convert chemical energy to electrical energy. This process is used with carbon-containing fuels, including biofuels, to generate electricity. These Molten Carbonate Fuel Cells (MCFCs), can operate at high temperatures of 580-700oC. However, electrolyte vaporisation and corrosion can be disadvantages.

Molten Salts Cleaning for Remanufacturing 

Cleaning secondary and reusable materials is essential during remanufacturing. Cleaning helps detect repair needs during processing and assembly. Molten salts combinations of sodium nitrite/nitrate baths are used to strip metals of impurities like carbon compounds, oil, and metal depositions. Cleaning with high quality molten salts uses their catalytic and oxidative properties and does not deform surfaces. However, corrosion must be tackled. For example, appliance manufacturers use molten salts baths to clean paint from items that fail quality tests in order to reuse materials again.

Molten Salts Oxidation (MSO)

The many uses of molten salts shows their versatility. Among thermal methods, molten salts oxidation (MSO) is a non-flame process that can destroy several kinds of wastes while retaining items of interest like inorganic or radioactive materials. MSO can oxidise several categories of waste, such as hazardous, mixed plastics, and medicinal wastes. It is also used to destroy biological and chemical weapons, munitions, explosives, and rocket fuel. 

In this process, waste and air are sent to a molten sodium carbonate bath and the only emissions are steam, oxygen, carbon dioxide, and nitrogen. Conventional technologies use acidic gases that react with waste material, while MSO is stable and non-reactive. 

MSO technology was pioneered for nuclear processing and applied for coal gasification initially. In the future, it could become a viable recycling method for challenging waste streams like plastics.

How are molten salts used in tire pyrolysis?  

Contec is the only company in the world that uses molten salts as a heat transfer medium in ELT pyrolysis to produce circular secondary raw materials. Contec developed the patented technology after five years of R&D efforts in close collaboration with the Warsaw University of Technology and engineers.

Molten®, Contec’s proprietary technology, uses a commercial mix of sodium nitrate and potassium nitrate. The molten salts are heated, melted, and pumped into a jacket that keeps circulating them in a loop around the reactor containing ELT rubber granules. This thermal treatment of rubber is even and without hotspot formation due to heat transfer from the molten salts and an auger that rotates the rubber granules. As a result, the tire waste is broken down to yield high quality Recovered Carbon Black.

Contec has found various other advantages in using molten salts. The medium requires less energy to melt and retains its high temperature, considerably reducing the energy requirement and carbon footprint of pyrolysis. Moreover, using molten salts as a heat transfer medium prevents the buildup of pressure and avoids accidents and explosions, for which pyrolysis plants are notorious.

Molten® has helped to make Contec’s tire pyrolysis process safe, efficient, and environmentally friendly. Its pilot plant situated in Szczecin, Poland has two pyrolysis plants and the company aims to triple its capacity soon following successful fundraising in 2023.

Improving circularity with molten salts

Several new technologies are emerging to usher in the circular economy. Molten salt technology is one of them. Molten salts are used to produce and store renewable energy and help recover critical resources. The long list of molten salts’ properties is also increasing how, where, and what molten salts are used for in industrial waste reduction. 

At Contec, we’re dedicated to advancing molten salt technology for the circular economy. We provide sustainable and circular products such as recovered Carbon Black (ConBlack®), recovered Tire Pyrolysis Oil (ConPyro®), and recovered Steel (ConWire®), applying molten salts.

If you liked reading this article, we recommend the following content:

• Explore Contec’s registered Molten® technology
• Pyrolysis: 5 heat transfer systems
• Making plastics circular: what is chemcycling?

Molten salts are a heat storage solution with a great potential to help enable the manufacturing industry to transition to carbon neutrality.

The demand for molten salt storage is expected to grow at a compound annual growth rate (CAGR) of 9.4% in 2024, reaching 8.6 billion USD in the same year. 

Thermal energy companies are especially interested in molten salts for their applications in the renewable energy industry. However, molten salt applications can extend beyond this industry!

Heat storage materials have limited capacities, which makes thermal heat storage one of the biggest challenges in the renewable energy industry. Efficiency depends on a properly designed system to ensure energy extraction at a constant temperature.

Molten salts are one of the upcoming technologies that will help thermal energy companies succeed.

In this article, you will learn:

• What molten salt storage is,
• How molten salt storage works, and
• The pros and cons of this technology.

Subscribe to the Contec Monthly on our LinkedIn Page and gain relevant insights into circularity and sustainable business models.

What is molten salt storage?

Molten salt storage uses molten salts as a heat storage medium. This promising technology addresses the challenge of an energy storage that is safe, consistent, and sustainable for several manufacturing processes.

Currently, this technology is primarily used with concentrated solar power (CSP) plants, but it has potential applications in other forms of renewable energy and industrial processes. Molten salt storage can:

• Enhance the efficiency and reliability of CSP plants by allowing them to generate electricity even when it’s not sunny.
• Increase grid stability with a consistent power output.
• Integrate hybrid systems with other renewable energy technologies (solar PV, wind) and energy storage systems (batteries) to maximise energy availability.
• Serve as a backup power source for critical infrastructure, providing energy during periods of high demand.
• Provide a consistent and safe heat transfer for tire pyrolysis.

With plenty of business opportunities available for this technology, it’s essential to understand how molten salt storage works, which will prompt even more research and development.

How does molten salt storage work?

Molten salts, typically a mixture of sodium nitrate and potassium nitrate, have a high heat capacity and thermal stability. They remain liquid even at high temperatures (between 220°C and 560°C), making them excellent for storing and transferring heat.

In CSP plants, molten salt storage works in the following steps:

• Mirrors concentrate solar radiation onto a receiver.
• Molten salts absorb heat from the receiver.
• The heated molten salt is stored in insulated tanks.
• When electricity is needed, the hot molten salt is pumped to a conventional steam generator.
• The steam drives turbines to generate electricity.

Molten salts can store up to 600ºC of heat for extended periods of time, addressing one of the main concerns regarding CSP plants: heat storage. However, despite its many impressive benefits, molten salt storage has some disadvantages.

What are the pros and cons of molten salt storage?

Molten salt storage is a promising technology with significant benefits, particularly in large-scale and high-temperature applications.

• Molten salts have a high heat capacity, allowing for efficient heat storage and thermal energy transfer of around 90%.
• Molten salt storage systems can be scaled up for large operations and are suitable for utility-scale applications like CSP plants.
• Molten salts can store energy for several hours to days, increasing the reliability of CSP plants even when it’s not sunny.
• The materials used to make molten salts (sodium nitrate and potassium nitrate) are inexpensive and commercially available.
• Molten salts are stable at high temperatures, typically from 220°C to 550°C.
• Molten salt storage systems can have a long operational life with proper maintenance, often exceeding 20-30 years.

Despite the benefits of molten salt storage, there are some drawbacks to this technology.

• The upfront costs for setting up molten salt storage systems, including infrastructure and installation, can be high. This can be a barrier in smaller applications or regions with limited financial resources.
• Molten salts can be corrosive to certain materials, necessitating specialised, often more expensive, materials for containment and heat exchange. Molten salt systems require regular maintenance and monitoring to prevent and manage corrosion-related issues.
• Handling and storing large quantities of molten salts pose safety risks, including the potential for leaks and burns.
• The optimal use of molten salt storage is typically in regions with high levels of solar radiation, limiting its applicability in less sunny areas.
• Despite molten salt storage’s high efficiency, some energy is still lost during conversion from thermal to electrical energy, which can affect overall system efficiency.

The advantages and disadvantages of molten salt storage influence its adoption and effectiveness in different applications. As technology advances and more teams invest in R&D surrounding molten salts, these drawbacks could be mitigated, making molten salt storage more attractive for several industries.

Molten salts at Contec

Molten®, Contec’s proprietary technology, uses a commercial mix of sodium and potassium nitrate—a patented technology developed after five years of R&D efforts in close collaboration with the Warsaw University of Technology.

Contec is currently the only company that uses molten salts as a heat transfer medium in end-of-life tire pyrolysis to produce circular secondary raw materials. Molten® has helped to make Contec’s tire pyrolysis process safe, efficient, and environmentally friendly. 

At Contec, we’re dedicated to advancing molten salt technology for the circular economy. We provide sustainable and circular products such as recovered Carbon Black (ConBlack®), recovered Tire Pyrolysis Oil (ConPyro®), and recovered Steel (ConWire®), applying molten salts.

If you liked reading this article, we recommend the following content:

• Molten salts: Why they’re an excellent heat transfer medium
• Explore Contec’s registered Molten® technology
• What are the SDGs: A sustainable transformation in manufacturing

We welcome Dominika Żelazek to the Contec team.

Dominika Żelazek joins Contec S.A. as Chief Financial Officer (CFO) and a member of the Management Board. This strategic move underscores Contec’s commitment to innovation and sustainable growth as it prepares for international expansion and fundraising efforts.

Dominika Żelazek’s expertise and strategic role

Dominika brings over 20 years of financial management experience in demanding and regulated sectors. Her previous roles include key positions at Arriva Poland, where she oversaw finance, IT, communication, and external relations as Vice President of the Management Board and CFO.

As Contec focuses on strengthening competencies and developing products using its unique Molten® technology, Dominika will play a crucial role in supporting the company’s growth, enhancing management capabilities, and driving fundraising initiatives for new plant construction and product development.  

For the last 15 years, she’s held key positions at Arriva Polska, supervising finance, IT, communication, and external relations as the Vice President of the Management Board and Financial Director. 

Joining Contec as CFO and Member of the Management Board represents an exciting challenge for me and an opportunity to leverage my financial and executive expertise to advance the company’s strategic expansion. Contec’s clearly defined goals and our commitment to sustainable development position us as a formidable player in the rapidly evolving Clean Tech industry.

– Dominia Żelazek, CFO and Member of the Management Board

Contec’s Recent Milestones and Future Plans  

Contec recently completed the expansion of its plant in Szczecin, Poland,  marking a significant step in its growth trajectory. Dominika’s role as CFO and board member is integral to Contec’s broader strategy. The company seeks to strengthen its position in both Polish and international markets, attract new investors, and build on its successful €15 million funding round in 2023.

Krzysztof Wróblewski, CEO of Contec, emphasises the company’s unique value proposition and the importance of the new appointment.

Sustainable raw materials produced by Contec have significantly lower carbon footprint in comparison with their conventional, virgin counterparts. This makes us an ideal partner for companies seeking sustainable solutions and aiming to decarbonize their supply chains. With Dominika joining our executive team as CFO and Management Board Member, we’re well-positioned to capitalize on these opportunities and drive our financial and strategic objectives forward, addressing the growing demand for our products and building our part in the circular ecosystem of tire manufacturing.

– Krzysztof Wróblewski, CEO

We’re looking forward to working with Dominika. Welcome to the team!

Download the press release in English or Polish. For media inquiries, please contact Anna Goławska at a.golawska@contec.tech.