Chemical recycling has become increasingly important in recent years as a response to the growing problem of plastic and textile waste, sectors that generate tons of waste each year. Faced with the limitations of traditional mechanical recycling, research and industry are investing in chemical methods that transform waste into high-value raw materials, promoting the circular economy and sustainability in various areas.
Companies, technology centers, and textile manufacturers are driving innovative solutions aimed at improving the efficiency, profitability, and environmental viability of these processes. Although technical and cost challenges remain, recent projects and developments point to a promising future for waste valorization using chemical technologies.
Innovation in chemical textile and plastic recycling: projects and new technologies
In Spain and Europe, cutting-edge initiatives are being developed to address the growing generation of textile waste, driven largely by regulations prohibiting its disposal in landfills and mandating the establishment of effective recycling and reuse channels. AIMPLAS (Technological Institute of Plastics) is participating in international projects such as tExtended , which aims to demonstrate, on a real-world scale, the viability of processes that allow for the recovery, reuse, and recycling of textiles in a collaborative environment among urban industries.
The technology developed includes advanced systems for identifying and separating textile materials , such as optical sensors and electrostatic separation, which facilitate the efficient management of difficult-to-treat waste. Furthermore, methods for the selective dissolution of materials like PVC and chemical recycling processes for polyurethane foams are being investigated, thus obtaining reusable products.
Thanks to this comprehensive approach, the aim is to reduce the volume of textile waste ending up in landfills by up to 80% and to promote public awareness of circularity by involving the community in tasks such as sorting and returning used textiles. Extended producer responsibility platforms are also being created to coordinate the efficient and mandatory management of textile and footwear waste, such as SCRAP RE-VISTE.
Chemical recycling as a driver of the circular economy: examples in industry
One of the most illustrative applications of chemical recycling can be found in the tire and plastics sector. Schwalbe, a German manufacturer of bicycle inner tubes, has implemented a comprehensive circular model in collaboration with BASF and Pyrum Innovations AG . The process begins with the recycling of used tires, from which pyrolysis oil is obtained. This oil is used as an alternative raw material in the production of TPU (thermoplastic polyurethane), allowing the manufacture of new inner tubes with up to 91% certified recycled material.
The same pyrolysis technology applied to the recovery of plastic waste, as demonstrated by BASF's ChemCycling project, allows for the replacement of fossil resources and the utilization of byproducts in new production chains. Furthermore, tire recycling also recovers gas to generate electricity and produces recycled carbon black, which is already an essential component in the manufacture of new tires and other plastic products.
Chemical recycling offers key advantages over other methods: it allows for the separation and treatment of complex or mixed waste, produces secondary raw materials of similar quality to virgin materials, and facilitates the transition to a truly circular economy. However, it is still essential to improve the energy efficiency of the processes and reduce costs to enable more widespread and sustainable industrial integration.
Challenges and future prospects: efficiency, sustainability and scalability
Despite technical advances, chemical recycling still faces a number of challenges. The energy consumption of the processes, especially pyrolysis, remains high , and sustainability depends heavily on the energy used coming from renewable sources. Furthermore, recycled materials often have higher costs than conventional ones, limiting access to circular products for the general public.
Collaboration between research institutes, businesses, manufacturers, and citizens is emerging as essential to overcoming these challenges. Pilot projects at European and national levels, real-world testing, and the active involvement of local communities are driving the development and acceptance of new chemical recycling solutions.
The regulatory environment is also pushing the sector to accelerate the adoption of sustainable technologies. The creation of extended producer responsibility systems, the application of digital solutions in sorting, and investment in R&D will continue to be key to boosting the circular economy in textile and plastic waste through chemical recycling.
Chemical recycling is opening up new opportunities for the management of complex waste, enabling the recovery of valuable materials and moving toward more sustainable production. Ongoing projects and collaboration across the entire industrial value chain predict an increasingly important role for this technology in the future of the circular economy.
