Celanese Ahead of the Curve on Recycled Plastics for Auto Sector

European Union (EU) legislation mandating certain levels of plastic recyclate content in automobiles is leading to accelerated initiatives by automakers to develop materials and infrastructure to ensure supply availability come the early 2030s, when 25% recycled content will be signed into law. In a recent webinar, materials supplier Celanese outlined its approach to delivering on solutions to assist in the realization of recycled content targets.

“More than six million cars reach end of life [annually in Europe], and there's a lot of plastic content in those cars,” noted Oliver Kuisle, sustainability leader EU at Celanese. Further, the materials supplier estimates that 20 to 40% of automotive shredder residue (ASR) is plastic and is ultimately landfilled or incinerated. Kuisle also noted that impending EU legislation will be applied to all cars sold in Europe, not just those manufactured there.

Grade segregation

Celanese’s portfolio of recycled content engineering plastics currently includes:

Most grades on offer from Celanese are supplied using the segregated approach, meaning a Celanex PBT/PET blend with minimum 25% recycled content, for example, actually contains that ratio of PCR PET. Rynite PET grades with up to 100% PCR PET content are offered, with a product carbon footprint (PCF) reduction of up to 59%.

In terms of performance, while each grade will have its own map, a PA 6 grade with 35% glass-fiber reinforcement, cited as an example by Celanese, exhibits no drop-off in tensile modulus, while the notched Sharpy impact strength, stress, and strain performance are in the ranges that can be expected for the respective performance tolerances.

Mass-balance polyamide

Celanese has opted for the mass-balance approach for commercially available grade Zytel 70G30HSLR ECO-0R 312 BK099, which is a 30% glass-fiber-reinforced material. The ISCC+ third-party certified material offers a seamless transition to recycled materials with a 30% allocation of recycled content. 

Celanese can extend this mass-balance approach to a range of different offerings, from glass-filled to unfilled toughened grades, through medium toughened and super-toughened grades, to a smaller number of glass-filled and toughened combination grades. “This is a great way to maintain your performance and get that recycled content to help meet your targets,” said Micheal Chisholm, sustainability leader AM at Celanese.

“We have a large portfolio, but we are continually working to bring more solutions to market,” added Chisholm. These include flame-retardant grades in the PA 66 sphere, as well as a Zytel HTN51 high-temperature polyphthalamide semi-aromatic PA grade based on PIR PA. 

Recycled input quality assurance

Key to successful delivery of recycled content solutions is ensuring the quality of the recycled inputs. “[Here], we don't really make a difference between post-consumer, post-industrial, or virgin feedstock,” says Kuisle. “We demand the same quality standards — we don't make any concessions — and it's by engaging with our recycled feedstock suppliers by way of agreements and long-term contracts [that we ensure quality].”

Mechanical properties of recycled content grades are within performance tolerances of fossil fuel–based materials. Image Courtesy of Celanese.

“We're working with our suppliers as a key driver of success in this arena, and then internally, from Celanese, we have controlled blending approaches and quality controls that we use to help ensure consistent performance and quality in all the products we sell,” added Chisholm.

Audience survey highlights hidden interior applications

An attendee survey during the webinar indicated that while 33% of respondents were exploring all options when it came to the use of recycled content grades, an equal 33% identified “interior – hidden” for priority implementation of recycled solutions. At the other extreme of implementation, only 6% of attendees cited “interior – visible” as highest on the agenda, perhaps due to concerns about aesthetics. LyondellBasell and OEM Dacia, however, have demonstrated how recycled content might be leveraged as an inherent design aspect. The EVA battery and powertrain also scored 6% among respondents, perhaps due to concerns regarding mechanical strength and flame retardance.