A joint study by ETH Zurich and BASF SE has demonstrated the feasibility of recycling mixed plastic waste from end-of-life vehicles alongside biomass through co-gasification, marking a potential breakthrough in circular chemical feedstocks. According to the research, recycling one kilogram of automotive shredder residue (ASR) with three kilograms of biomass reduces greenhouse gas emissions by more than 3 kg CO₂-equivalent compared to conventional incineration for energy recovery.
The findings arrive as the European Union prepares to update its end-of-life vehicle (ELV) legislation, underscoring the importance of integrating chemical recycling into broader circular economy and emissions-reduction frameworks.
Pilot Project Validates Co-Gasification Feasibility
The ETH Zurich study builds on a mid-2025 pilot project conducted at the Austrian pilot plant of BEST GmbH, where BASF and BEST jointly tested the gasification of biomass and plastic waste streams for the first time. The process transforms mixed waste materials into synthesis gas—a valuable input for producing chemicals—rather than burning them for energy.
“Closing the carbon loop by plastics recycling is not only beneficial for the climate but also crucial for conserving resources,” said Prof. André Bardow from ETH Zurich. “It’s an essential step toward a plastics industry that operates within planetary boundaries.”
From Waste to Feedstock: Lower Emissions, Higher Value
The co-gasification process produces both steam and synthesis gas, allowing the chemical industry to reduce its reliance on fossil feedstocks. This circular approach not only lowers emissions but also keeps carbon circulating within the material system instead of releasing it into the atmosphere.
However, researchers emphasized that legislative frameworks must evolve to recognize mixed plastic waste as recyclable. “Ambition in target-setting rather than opt-out and review clauses should be the baseline for policies that allow industries to reach ecological goals,” noted Prof. Catharina Bening from ETH Zurich. “Sector-coupling and collaboration across industries is essential to speed up emission reductions.”
Policy Gaps and Industry Implications
While EU policy already supports gasification of biomass—leading to early investments in sustainable aviation and maritime fuels—plastic waste streams lack equivalent regulatory recognition. BASF’s Martin Jung, President of the company’s Performance Materials division, called for a unified approach:
“It is simply not efficient to operate separate gasification plants for bio-waste and plastics waste streams. We need policy frameworks that enable multi-purpose plants through an audited, flexible mass balance approach.”
Untapped Potential: One Million Tons of Plastic Waste
In Europe, more than one million tons of automotive plastic waste are either incinerated or landfilled annually. Although part of this waste can be sorted for mechanical recycling, a significant residual stream remains mixed and unsuitable for conventional methods. The ETH–BASF research indicates that co-gasifying this residual waste with biomass can convert it into high-quality raw materials suitable for producing new, performance-grade plastics—including those used in safety-critical automotive components.
BASF creates chemistry for a sustainable future, combining economic success with environmental protection and social responsibility. With around 112,000 employees worldwide, BASF operates across multiple sectors including Chemicals, Materials, Industrial Solutions, and Nutrition & Care, with standalone businesses in Surface Technologies and Agricultural Solutions. In 2024, BASF reported global sales of €65.3 billion. BASF shares are traded in Frankfurt (BAS) and as American Depositary Receipts (BASFY) in the U.S.