As the European Union prepares to tighten regulations on end-of-life vehicles (ELVs), new research from ETH Zurich and BASF SE points to a promising recycling route for mixed automotive plastic waste.
The study demonstrates that co-gasifying one kilogram of automotive shredder residue (ASR) with three kilograms of biomass can cut greenhouse gas emissions by more than 3 kilograms of CO₂-equivalent compared to conventional incineration for energy recovery, a finding with direct implications for circular economy policy and industrial decarbonization.
The study builds on a 2025 pilot project conducted by BASF and BEST GmbH in Austria, where biomass and ASR were gasified together for the first time in a single process. Unlike incineration, which merely recovers energy, co-gasification produces both steam and synthesis gas (syngas) — a feedstock for chemicals and new materials. This approach allows carbon to remain within the production cycle, enabling the chemical industry to replace fossil-based inputs with circular carbon sources.
From Waste to Feedstock: Integrating Plastic and Biomass Streams
Europe’s automotive sector generates an estimated one million tonnes of plastic waste from ELVs annually. While part of it can be mechanically recycled, a substantial mixed residue stream remains that is either landfilled or incinerated. ETH Zurich’s analysis confirms that this residual fraction can be transformed into high-quality raw materials through co-gasification, yielding performance plastics with mechanical properties equivalent to virgin materials, suitable even for safety-critical automotive components.
The environmental benefits are tied to the dual nature of the process. Biomass acts as a renewable carbon source, while ASR provides energy and additional carbon content for synthesis gas production. The result is a more efficient carbon utilization cycle, significantly reducing dependency on natural gas and crude oil derivatives used in chemical manufacturing.
Policy Gaps and Industrial Integration
Despite the demonstrated advantages, researchers caution that policy frameworks lag behind technology readiness. Current EU and national laws support the gasification of biomass, particularly for producing maritime and aviation fuels, but exclude plastic waste from comparable recognition or incentives.
The findings position co-gasification as a strategically scalable solution for integrating waste management with the chemical and energy sectors. By producing circular synthesis gas rather than relying on fossil-based feedstocks, the approach supports both resource conservation and emissions abatement. It could also enhance Europe’s industrial resilience by creating domestic supply chains for non-fossil carbon materials.
