Continental ContiTech pioneers purified pyrolysis oil technology to recycle complex rubber and replace fossil resources

Thermal Pyrolysis and Chemical Oxidation

(IN BRIEF) Continental’s ContiTech division has launched a new era in rubber recycling by acquiring exclusive patent rights for an advanced pyrolysis-based purification process and commissioning a pilot plant to produce high-quality pyrolysis oil. The breakthrough allows waste rubber, including complex and hard-to-recycle products, to be transformed into valuable raw materials that can substitute fossil resources in the production of new rubber and plastic goods. Developed from technology by LowSulphurFuels, the process overcomes the long-standing challenge of vulcanized rubber recycling, producing oil, carbon black, and energy sources at industrial quality standards. By making this step, Continental strengthens its role as an innovation leader in sustainable materials, expanding its commitment to closing resource cycles and reducing dependence on crude oil.

(PRESS RELEASE) HANOVER, 3-Sep-2025 — /EuropaWire/ — Continental’s ContiTech division has taken a decisive step toward sustainable materials management by securing exclusive rights to a patent family for an innovative thermal purification process and putting a new pilot facility into operation. This marks the first time the company is fully utilizing the industrial potential of pyrolysis technology to recycle complex rubber compounds on a broader scale. The approach makes it possible to extract valuable raw materials from waste rubber and significantly reduce the dependence on fossil-based resources.

The patented technology, originally developed by British start-up LowSulphurFuels, relies on a controlled thermal process that breaks down vulcanized rubber into its chemical building blocks. One of the main products is a purified pyrolysis oil, refined to a level comparable with crude oil, which can then be used as a base material for the production of new rubber and plastics. ContiTech’s pilot plant is the first to employ this special purification method, paving the way for its large-scale application in industry.

Dr. Michael Hofmann, Chief Technology Officer at ContiTech, emphasized the importance of the development: “By closing this loop in the circular materials economy, we are turning waste into a resource. The purified pyrolysis oil can replace crude oil while enabling new products to be created from old materials. This breakthrough shows how innovation drives sustainable industry and makes resource cycles commercially viable.”

Rubber recycling has long posed significant obstacles due to the irreversible chemical changes caused by vulcanization. Conventional approaches have often failed to separate essential components such as rubber, carbon black, and additives effectively. Pyrolysis, however, overcomes these barriers by using high-temperature treatment in a low-oxygen environment to generate gaseous fuels, recovered carbon black, and a premium-grade oil similar to fossil crude. While the method had limited commercial application in the past due to process complexity and strict quality standards, ContiTech’s new purification system now allows consistent production of industrial-grade materials.

This progress is especially relevant for difficult-to-recycle items like food-grade hoses or rubber-metal composites containing multiple additives and intricate structures. Purified pyrolysis oil provides a viable pathway to reintroduce such products into the circular economy.

The acquisition of the patent and the commissioning of the pilot facility reinforce Continental’s long-term commitment to innovation and sustainability. ContiTech’s leadership in this field is reflected not only in this breakthrough but also in its broader portfolio of projects, including hydrocarbon recovery from used rubber and the development of recyclable automotive interior materials. Last year alone, Continental filed over 150 patent applications and was granted about 250 patents, further underscoring its role as a driver of forward-looking industrial technologies.

Media contact:

Angelika Anna Kohns
Media & PR Manager
ContiTech
+49 511 938-14022
+49 151 17240441
angelika.anna.kohns@continental.com

SOURCE: Continental AG