LyondellBasell, Audi use automotive plastic scrap to make seatbelt buckle covers

LyondellBasell, based in Rotterdam, Netherlands, is collaborating with Germany-based Audi on a project the companies call Project PlasticLoop to create automotive plastic parts from mixed automotive plastic scrap. Audi is installing plastic seatbelt buckle covers in its Q3 e-tron made using LyondellBasell plastic that comes from feedstocks of mixed automotive plastic scrap.

According to LyondellBasell, plastic components from customer vehicles that can no longer be repaired are dismantled, shredded and processed using chemical recycling technology into pyrolysis oil. LyondellBasell says the pyrolysis oil is then used as a raw material in its manufacturing process to produce new plastics. LyondellBasell says this recycled content is attributed to the Audi product via a mass balance approach.

“As part of the PlasticLoop project, we are working with Audi to establish an innovative closed-loop process, recycling plastic automotive parts for use in new vehicles,” says Erik Licht, advanced polymer solutions new business development director at LyondellBasell. “For the first time, we are using chemical recycling to recycle mixed automotive plastic waste into plastic granulate for automotive interior applications. The plastic granulate is then used in the production of the seatbelt buckle covers for the Audi Q8 e-tron.”

With this process, LyondellBasell, Audi and chemical recycler SynCycle (Next Generation Group and BDI-BioEnergy International), which is based in Austria, recycle a stream of material that is typically only used in energy recovery markets. According to LyondellBasell, materials produced from pyrolysis oil contain the same properties and qualities as virgin materials.

"Audi’s vision is to use secondary materials wherever it is technically possible, economically viable and ecologically beneficial,” says Philipp Eder, project manager for circular economy in the supply chain at Audi. “The PlasticLoop project is part of Audi’s circular economy strategy and a good example of cross-sector cooperation within the Audi supply chain. Findings from the project are also incorporated into the product development of future vehicle projects via the ‘Design for Recycling’ approach.”