Deamination of Polyols from the Glycolysis of Polyurethane

Methylenedianiline (MDA) is a secondary, undesired, product of the glycolysis process of polyurethane (PU) scraps due to hydrolysis and pyrolysis side reactions. As an aromatic and carcinogen amine, MDA poses different problems in handling, transporting, and labelling recycled polyols derived from glycolysis, hindering the closure of PU recycling loop. Aiming to provide a solution to this issue, in this work different deaminating agents (DAs) were investigated with the purpose of analyzing their reactivity with MDA. A first part of the study was devoted to the analysis of MDA formation as a function of reaction time and catalyst concentration (potassium acetate) during glycolysis. It was observed that the amount of MDA increases almost linearly with the extent of PU depolymerization and catalyst content. Among the DAs analyzed 2-ethylhexyl glycidyl ether (2-EHGE), and acetic anhydride (Ac2 O) showed interesting performance, which allowed MDA content to be diminished below the limit for labelling prescription in 30 minutes. PU rigid foams were, therefore, synthesized from the corresponding recycled products and characterized in terms of thermal and mechanical performance. Ac2 O-deaminated polyols led to structurally unstable foams with poor compressive strength, while 2-EHGE-deaminated products allowed the production of foams with improved mechanical performance and unaltered thermal conductivity.

Chemical Recycling of Flexible Polyurethane Foams by Aminolysis to Recover High-Quality Polyols

Polyurethane foams (PUFs) are widely used commodity materials, but most of them end up in landfills at the end of their life, which is not in line with the circular economy approach. Here, we introduce microwave-assisted aminolysis with amine reagents that contain primary and tertiary amino groups in the structure. These reagents enable complete degradation of the urethane groups in the structure of the flexible PUFs with a much lower amount of degradation reagent than is typically required for solvolysis reactions. The purified, recovered polyols are close equivalents to the corresponding virgin polyols in terms of their structural and molar mass characteristics. Therefore, they can be used for the production of high-quality PUFs without having to adapt the synthesis process. The flexible PUFs made from recovered polyols have comparable mechanical properties to those made from virgin polyols.

Chemical Recycling of Polyurethane Waste via a Microwave-Assisted Glycolysis Process

In this work, we explored a microwave-assisted glycolysis process to chemically recycle rigid polyurethane (PU) foam waste to obtain a single-phase product with suitable physio-chemical properties as a secondary raw material for the preparation of new rigid PU products. Such an approach was compared to a conventionally heated (ConvH) process, analyzing the performances of different catalysts. The use of microwaves allowed a 94% decrease in the reaction time scale of rigid PU depolymerization, with a concurrent 45% reduction in energy expense. By using a PU/diethylene glycol mass ratio of 1.5, best performances were obtained with a 30 mmol/100g_PU potassium acetate concentration, both in terms of the product viscosity and aromatic amine byproduct content. The glycolysis products recovered were employed in substitution to virgin polyol for rigid PU foam preparation, showing improved compressive strength and comparable thermal insulation properties up to a 30% content with respect to the traditional non-recycled counterpart.

Assessment of the economic recycling potential of a glycolysis treatment of rigid polyurethane foam waste: A case study from Thailand

This research assessed the economic feasibility of recovering polyol from rigid polyurethane foam (RPUF) waste, collected from dismantled, discarded refrigerators, by a single-phase glycolysis recycling process using domestic crude glycerol (a byproduct of biodiesel production) as a transesterification agent. The study, conducted in Thailand, took into account benefits from the added value of the recovered product, the investment and related operating costs of the process, demand (the need for the recovered product) and supply (the amount of RPUF waste). The results showed that the production of recovered polyol from RPUF waste is economically feasible, with a net present value of 1,113,018 USD, an internal rate of return (IRR) of 22.9%, and a payback period of 4.4 years. Due to the high IRR, project investment should be attractive to both the government and private sector investors. In addition, a sensitivity analysis was conducted to assess the economic resilience of the process to uncertainties in key factors, including the prices of the machinery, recovered polyol, crude glycerol and stannous octoate, and the amount of RPUF waste available. The sensitivity analysis showed that the economic feasibility was most sensitive to the price of the recovered polyol, followed by the amount of RPUF waste and the prices of the machinery, crude glycerol and stannous octoate. Based on these results, technological, operational, financial, and regulatory policy recommendations were also presented.

Recycling of polyurethanes from laboratory to industry, a journey towards the sustainability

The recycling of any kind of plastic to convert it in valuable products is one of the main challenges of today's society. Besides, if the recycling process is itself green, then it would be a great achievement. This paper reviews the way covered from the first attempts of reusing the polyurethane (PU) scraps as a filler for cushions to the last chemical routes employing green recycling agents. Polyurethane is the 6th most used polymer all over the world with a production of 18 millions tons per year, which means a daily production of PU specialties greater than 1 million of cubic meters, equivalent to the volume of the Empire State Building. The thermostable nature of the majority of the polyurethanes specialties has made that the preferred solution for their recycling are the chemical recycling processes. Among them, glycolysis is the one that receives a greater attention from an industrial point of view, so this review puts the spotlight on it. However, the existing reviews in literature do not paid a special attention on glycolysis and only give a superficial description of the process. Nevertheless, in the present review, the scientific literature relative to glycolysis is completely reviewed, updated and ordered according the type of PU specialty recycled. Additionally, the other main chemical recycling processes are also revisited in a more extended and deeper way than in the previous approaches to this topic. Moreover, it is crucial to take into account that some of these technologies, which were described in the literature as promising technologies at laboratory scale are now commercial processes running at industrial scale. For that reason, it is essential to remark that the present review comprises not only a detailed state of art of the scientific literature on the subject, also includes a detailed revision of the past and running on pilot plants and industrial facilities, including several patents, which has never been covered in the current literature. Moreover, this review also describes the most recent studies employing crude glycerol (biodiesel subproduct) as an economic, sustainable and environmental friendly cleavage agent, which should lead the way to the industrial implantation of split-phase glycolysis in a near future, providing high quality recovered products, susceptible of replacing raw ones in the synthesis of new PU specialties. What is more, this review intends that any reader could know and understand the reactions involved in the polyurethane chemistry and recycling, the main polyurethanes types and the fundamentals of the recycling strategies in order to comprehend what are the advantages and drawbacks of each recycling process as starting point for looking for new advantageous alternatives from an environmental, technical and economic point of view. Broader context. This paper reviews the main advances in the polyurethane (PU) recycling field, from laboratory and academia processes to pilot plant and industrial scale ones, including the most relevant patents in the subject. Opposite to other common used plastics, PUs are not polymerization but condensation polymers, synthesized from polyols and isocyanates. The wide diversity of polyols and isocyanates allows the synthesis of numerous different compounds covering a huge range of applications. As a direct consequence of their commercial success, an increasing quantity of PU waste is being disposed by landfilling in the last decades. Such waste comprises not only post-consumer products but also scrap from slabstock manufacturing, which can reach the 10% of the total foam production. However, the massive enforcement of the environmental laws is pointing out a new route in the polymer waste removal sector based in the polymer recycling, and this fact has placed the research in waste treatment as one of the most prolific topics nowadays. In fact, polymer recycling processes have experienced a growing attention from the research and industrial worlds as a direct result of the enforcement of the environmental legislations. Hence, it is essential to develop new environmental sustainable recycling processes with the aim of conserving the natural resources, reducing the amount of waste disposed in landfills and enhancing the sustainability for forthcoming generation.

Synthesis and Characterization of Polyurethane Nanocomposites Formulated by Incorporation of Polyols from PET Waste

Polyethylene terephthalate (PET) was depolymerized using trimethylolpropane (TMP) and glycerin as a binary solvent mixture to provide oligomeric polyol for rigid polyurethanes foam formulation. Recyclate containing rigid polyurethane foam nanocomposites were prepared by introducing of different portions (1-5%) of nanoclays namely, NaMMT, 30B, 20A, 15A Cloisites. The parallel effects of recycled polyol and nano clays on mechanical and thermal characteristics of the nanocomposites were investigated. Dispersion of clay nano particles in polymer matrix was characterized by SEM what confirm the exfoliation of nanoparticles. The thermal properties were also studied by TMA and DMA.

Isolation and characterization of an ether-type polyurethane-degrading micro-organism and analysis of degradation mechanism by Alternaria sp

AIMS

To degrade ether-type polyurethane (ether-PUR), ether-PUR-degrading micro-organism was isolated. Moreover, ether-PUR-degrading mechanisms were analysed using model compounds of ether-PUR.

METHODS AND RESULTS

A fungus designated as strain PURDK2, capable of changing the configuration of ether-PUR, has been isolated. This isolated fungus was identified as Alternaria sp. Using a scanning electron microscope, the grid structure of ether-PUR was shown to be melted and disrupted by the fungus. The degradation of ether-PUR by the fungus was analysed, and the ether-PUR was degraded by the fungus by about 27.5%. To analyse the urethane-bond degradation by the fungus, a degraded product of ethylphenylcarbamate was analysed using GC/MS. Aniline and ethanol were detected by degradation with the supernatant, indicating that the fungus secreted urethane-bond-degrading enzyme(s). PURDK2 also degraded urea bonds when diphenylmethane-4,4'-dibutylurea was used as a substrate.

CONCLUSIONS

The enzyme(s) from PURDK2 degraded urethane and urea bonds to convert the high molecular weight structure of ether-PUR to small molecules; and then the fungus seems to use the small molecules as an energy source.

SIGNIFICANCE AND IMPACT OF THE STUDY

Ether-PUR-degrading fungus, strain PURDK2, was isolated, and the urethane- and urea-bonds-degrading enzymes from strain PURDK2 could contribute to the material recycling of ether-PUR.