Glycolysis: an efficient route for recycling of end of life polyurethane foams

Self-evolutionary recycling of flame-retardant polyurethane foam enabled by controllable catalytic cleavage

Polyurethane (PU) foams, pivotal in modern life, face challenges suh as fire hazards and environmental waste burdens. The current reliance of PU on potentially ecotoxic halogen-/phosphorus-based flame retardants impedes large-scale material recycling. Here, our demonstrated controllable catalytic cracking strategy, using cesium salts, enables self-evolving recycling of flame-retardant PU. The incorporation of cesium citrates facilitates efficient urethane bond cleavage at low temperatures (160 °C), promoting effective recycling, while encouraging pyrolytic rearrangement of isocyanates into char at high temperatures (300 °C) for enhanced PU fire safety. Even in the absence of halogen/phosphorus components, this foam exhibits a substantial increase in ignition time (+258.8%) and a significant reduction in total smoke release (-79%). This flame-retardant foam can be easily recycled into high-quality polyol under mild conditions, 60 °C lower than that for the pure foam. Notably, the trace amounts of cesium gathered in recycled polyols stimulate the regenerated PU to undergo self-evolution, improving both flame-retardancy and mechanical properties. Our controllable catalytic cracking strategy paves the way for the self-evolutionary recycling of high-performance firefighting materials.

Scleroglucan-Based Foam Incorporating Recycled Rigid Polyurethane Waste for Novel Insulation Material Production

This study details the synthesis and performance evaluation of a novel lightweight thermal and acoustic insulation material, resulting from the combination of a scleroglucan-based hydrogel and recycled rigid polyurethane waste powder. Through a sublimation-driven water-removal process, a porous three-dimensional network structure is formed, showcasing notable thermal and acoustic insulation properties. Experimental data are presented to highlight the material's performance, including comparisons with commercially available mineral wool and polymeric foams. This material versatility is demonstrated through tunable mechanical, thermal and acoustic characteristics, achieved by strategically adjusting the concentration of the biopolymer and additives. This adaptability positions the material as a promising candidate for different insulation applications. Addressing environmental concerns related to rigid polyurethane waste disposal, the study contributes to the circular economy.

Identification and characterization of a fungal cutinase-like enzyme CpCut1 from Cladosporium sp. P7 for polyurethane degradation

Plastic degradation by biological systems emerges as a prospective avenue for addressing the pressing global concern of plastic waste accumulation. The intricate chemical compositions and diverse structural facets inherent to polyurethanes (PU) substantially increase the complexity associated with PU waste management. Despite the extensive research endeavors spanning over decades, most known enzymes exhibit a propensity for hydrolyzing waterborne PU dispersion (i.e., the commercial Impranil DLN-SD), with only a limited capacity for the degradation of bulky PU materials. Here, we report a novel cutinase (CpCut1) derived from Cladosporium sp. P7, which demonstrates remarkable efficiency in the degrading of various polyester-PU materials. After 12-h incubation at 55°C, CpCut1 was capable of degrading 40.5% and 20.6% of thermoplastic PU film and post-consumer foam, respectively, while achieving complete depolymerization of Impranil DLN-SD. Further analysis of the degradation intermediates suggested that the activity of CpCut1 primarily targeted the ester bonds within the PU soft segments. The versatile performance of CpCut1 against a spectrum of polyester-PU materials positions it as a promising candidate for the bio-recycling of waste plastics.IMPORTANCEPolyurethane (PU) has a complex chemical composition that frequently incorporates a variety of additives, which poses significant obstacles to biodegradability and recyclability. Recent advances have unveiled microbial degradation and enzymatic depolymerization as promising waste PU disposal strategies. In this study, we identified a gene encoding a cutinase from the PU-degrading fungus Cladosporium sp. P7, which allowed the expression, purification, and characterization of the recombinant enzyme CpCut1. Furthermore, this study identified the products derived from the CpCut1 catalyzed PU degradation and proposed its underlying mechanism. These findings highlight the potential of this newly discovered fungal cutinase as a remarkably efficient tool in the degradation of PU materials.

Reduction of polystyrene/polyurethane plastic wastes from the environment into binders for water-resistant emulsion paints

Waste management is fundamental to resource and environmental sustainability. Expanded polystyrene (EPS) and polyurethane (PU) waste plastics were recycled and applied as binder in emulsion paint formulation. The recycled polystyrene (rPS) and polyurethane (rPU) were blended into composite resins, where toluene was used as the solvent. The blends of rPS and rPU were optimized, while some physicochemical properties of the composite blends (rPS/PU) were evaluated. The results showed that the incorporation of rPU into rPS increased the viscosity (1818 mPa-3924 mPa), rate of gelation (dry-to-touch time: 15 min-0.25 min), moisture content (2.7%-8.1%), moisture uptake (3.2%-5.0%), solid content (48%-53.4%) and density (0.82 g/cm3 to 1.050.82 g/cm3) of the rPS/PU composite resins. Characterization was carried out using Fourier transform infrared (FT-IR) spectroscopy, X-ray diffraction (XRD), thermogravimetric analysis (TGA), scanning electron microscope (SEM), and atomic force microscopy (AFM). The results summarily showed that there are interactions among the rPS and rPU molecules in the composite, where complimentary structural and morphological characteristics were also achieved. The composite resin also exhibited superior bond strength (0.5-4.24 Mpa) on wood, cast mortar, ceramic, and steel surfaces due to its stronger intra- and inter-surface interactions compared to the neat rPS resin. The composite resin was used as a binder in the formulation of emulsion paint. The paint exhibited stronger resistance to water, among other superior properties, when compared to the paints formulated using neat rPS and conventional polyvinyl acetate (PVA) resins. The reduction of plastic waste in this study holds potential for the production of highly water-resistant emulsion paint for outdoor and indoor applications.

Catalytic polymer self-cleavage for CO2 generation before combustion empowers materials with fire safety

Polymeric materials, rich in carbon, hydrogen, and oxygen elements, present substantial fire hazards to both human life and property due to their intrinsic flammability. Overcoming this challenge in the absence of any flame-retardant elements is a daunting task. Herein, we introduce an innovative strategy employing catalytic polymer auto-pyrolysis before combustion to proactively release CO2, akin to possessing responsive CO2 fire extinguishing mechanisms. We demonstrate that potassium salts with strong nucleophilicity (such as potassium formate/malate) can transform conventional polyurethane foam into materials with fire safety through rearrangement. This transformation results in the rapid generation of a substantial volume of CO2, occurring before the onset of intense decomposition, effectively extinguishing fires. The inclusion of just 1.05 wt% potassium formate can significantly raise the limiting oxygen index of polyurethane foam to 26.5%, increase the time to ignition by 927%, and tremendously reduce smoke toxicity by 95%. The successful application of various potassium salts, combined with a comprehensive examination of the underlying mechanisms, underscores the viability of this strategy. This pioneering catalytic approach paves the way for the efficient and eco-friendly development of polymeric materials with fire safety.

Polyurethane Foam Chemical Recycling: Fast Acidolysis with Maleic Acid and Full Recovery of Polyol

Chemical recycling of polyurethane (PU) waste is essential to displace the need for virgin polyol production and enable sustainable PU production. Currently, less than 20% of PU waste is downcycled through rebinding to lower value products than the original PU. Chemical recycling of PU waste often requires significant input of materials like solvents and slow reaction rates. Here, we report the fast (<10 min) and solvent-free acidolysis of a model toluene diisocyanate (TDI)-based flexible polyurethane foam (PUF) at <200 °C using maleic acid (MA) with a recovery of recycled polyol (repolyol) in 95% isolated yield. After workup (hydrolysis of repolyl ester and separations), the repolyol exhibits favorable physical properties that are comparable to the virgin polyol; these include 54.1 mg KOH/g OH number and 624 cSt viscosity. Overall, 80% by weight of the input PUF is isolated into two clean-cut fractions containing the repolyol and toluene diamine (TDA). Finally, end-of-life (EOL) mattress PUF waste is recycled successfully with high recovery of repolyol using MA acidolysis. The solvent-free and fast acidolysis with MA demonstrated in this work with both model and EOL PUF provides a potential pathway for sustainable and closed-loop PU production.

Toward chemical recycling of PU foams: study of the main purification options

The recovery of the polyol component, after glycolysis of polyurethane (PU) foams coming from automotive waste, was investigated. Several separation methods such as simple sedimentation, centrifugation and liquid-liquid extraction, eventually preceded by an acid washing step, were tested. The obtained fractions were characterized by infrared spectroscopy and CHN elemental analysis. Furthermore, multivariate data analysis was carried out on the infrared spectra by principal component analysis to classify the fractions based on purity. IR spectroscopy coupled with principal component analysis was able to estimate the success of the separation and eventual culprits such as contaminations, which were then quantified by CHN elemental analysis. This approach addresses some critical limitations associated with classical analytical techniques such as NMR, TGA, GPC, MALDI-TOF that often require an extremely accurate separation of the depolymerized product fractions. Moreover, IR spectroscopy and CHN elemental analysis techniques are cheap and widespread in standard materials science laboratories. At last, based on the results of the analysis of the regenerated polyol fractions, and on the foaming tests, considerations were made to guide the choice of the purification method according to the application specifications and greenness.

Selective Electrocatalytic Degradation of Ether-Containing Polymers

Leveraging electrochemistry to degrade robust polymeric materials has the potential to impact society's growing issue of plastic waste. Herein, we develop an electrocatalytic oxidative degradation of polyethers and poly(vinyl ethers) via electrochemically mediated hydrogen atom transfer (HAT) followed by oxidative polymer degradation promoted by molecular oxygen. We investigated the selectivity and efficiency of this method, finding our conditions to be highly selective for polymers with hydridic, electron-rich C-H bonds. We leveraged this reactivity to degrade polyethers and poly(vinyl ethers) in the presence of polymethacrylates and polyacrylates with complete selectivity. Furthermore, this method made polyacrylates degradable by incorporation of ether units into the polymer backbone. We quantified degradation products, identifying up to 36 mol % of defined oxidation products, including acetic acid, formic acid, and acetaldehyde, and we extended this method to degrade a polyether-based polyurethane in a green solvent. This work demonstrates a facile, electrochemically-driven route to degrade polymers containing ether functionalities.

Circular Reprocessing of Thermoset Polyurethane Foams

Thermoset polyurethane (PU) foams are widely used in industrial applications, but they cannot be recycled by conventional melt reprocessing because of their cross-linked structures. The introduction of carbamate exchange catalysts converts thermoset PU into covalent adaptable networks (CANs), which are amenable to reprocessing at elevated temperatures. However, this approach has produced solid PU films, which have fewer uses and lower commercial demand. In this work, simultaneous reprocessing and refoaming of thermoset PU foams is demonstrated by leveraging the melt-processability of PU CANs and allowing cell growth by gas generation in a twin-screw extruder. The optimal operating temperature of the refoaming process is determined through chemical, thermal, and structural analysis of PU foam extrudates. The foam-to-foam extrusion process produces controllable, continuous, and uniform foam structures, as characterized by cell diameter and cell number density. Low-density PU foams are obtained through a process simulating injection molding. The compression properties of reprocessed PU foam are compared with as-synthesized PU foam to demonstrate efficacy of the refoaming processes. These results demonstrate that PU foams can be prepared through recycling while maintaining microstructural and chemical integrity. In the future, this strategy may be applied to thermoset PU foams of various chemical compositions and shows promise for scalability.

Improving Sustainability through Covalent Adaptable Networks in the Recycling of Polyurethane Plastics

The global plastic waste problem has created an urgent need for the development of more sustainable materials and recycling processes. Polyurethane (PU) plastics, which represent 5.5% of globally produced plastics, are particularly challenging to recycle owing to their crosslinked structure. Covalent adaptable networks (CANs) based on dynamic covalent bonds have emerged as a promising solution for recycling PU waste. CANs enable the production of thermoset polymers that can be recycled using methods that are traditionally reserved for thermoplastic polymers. Reprocessing using hot-pressing techniques, in particular, proved to be more suited for the class of polyurethanes, allowing for the efficient recycling of PU materials. This Review paper explores the potential of CANs for improving the sustainability of PU recycling processes by examining different types of PU-CANs, bond types, and fillers that can be used to optimise the recycling efficiency. The paper concludes that further research is needed to develop more cost-effective and industrial-friendly techniques for recycling PU-CANs, as they can significantly contribute to sustainable development by creating recyclable thermoset polymers.

Selective deconstruction of mixed plastics by a tailored organocatalyst

Plastic represents an essential material in our society; however, a major imbalance between their high production and end-of-life management is leading to unrecovered energy, economic hardship, and a high carbon footprint. The adoption of plastic recycling has been limited, mainly due to the difficulty of recycling mixed plastics. Here, we report a versatile organocatalyst for selective glycolysis of diverse consumer plastics and their mixed waste streams into valuable chemicals. The developed organocatalyst selectively deconstructs condensation polymers at a specific temperature, and additives or other polymers such as polyolefin or cellulose can be readily separated from the mixed plastics, providing a chemical recycling path for many existing mixed plastics today. The Life Cycle Assessment indicates that the production of various condensation polymers from the deconstructed monomers will result in a significant reduction in greenhouse gas emissions and energy input, opening a new paradigm of plastic circularity toward a net-zero carbon society.

A facile alternative strategy of upcycling mixed plastic waste into vitrimers

Chemical depolymerization has been identified as a promising approach towards recycling of plastic waste. However, complete depolymerization may be energy intensive with complications in purification. In this work, we have demonstrated upcycling of mixed plastic waste comprising a mixture of polyester, polyamide, and polyurethane through a reprocessable vitrimer of the depolymerized oligomers. Using poly(ethylene terephthalate) (PET) as a model polymer, we first demonstrated partial controlled depolymerization, using glycerol as a cleaving agent, to obtain branched PET oligomers. Recovered PET (RPET) oligomer was then used as a feedstock to produce a crosslinked yet reprocessable vitrimer (vRPET) despite having a wide molecular weight distribution using a solventless melt processing approach. Crosslinking and dynamic interactions were observed through rheology and dynamic mechanical analysis (DMA). Tensile mechanical studies showed no noticeable decrease in mechanical strength over multiple repeated melt processing cycles. Consequently, we have clearly demonstrated the applicability of the above method to upcycle mixed plastic wastes into vitrimers and reprocessable composites. This work also afforded insights into a potentially viable alternative route for utilization of depolymerized plastic/mixed plastic waste into crosslinked vitrimer resins manifesting excellent mechanical strength, while remaining reprocessable/ recyclable for cyclical lifetime use.

Experimental research on the thermal properties of innovative insulation boards made of polyurethane-polyisocyanurate (PUR/PIR)

In this work, the results of investigations of polyurethane materials were presented. Innovative materials based on polyurethane-polyisocyanurate (PUR/PIR) foam were obtained. Different types of additives (flame retardants, aerogels – additives that decrease thermal conductivity) are used in the composition of PUR/PIR foam. Foams are a type of composite composed of two phases: continuous (polyurethane polymers) and dispersed (composed of gases). All samples have been tested for thermal parameters: thermal conductivity, specific heat, and thermal diffusivity. Then they have been compared with each other and with a reference sample (RS) without additives. Based on the research, it was shown that innovative insulation materials were characterized by thermal conductivity λ in the range of 0.0254–0.0294 W/(m · K). The thermal properties of foams depending on the type and chemical composition of the material. Depending on the used substrates, their molar ratio, type, synthesis conditions, modifying agents and catalysts, a different polyurethane material is obtained.

Upgrading Polyurethanes into Functional Ureas through the Asymmetric Chemical Deconstruction of Carbamates

The importance of systematic and efficient recycling of all forms of plastic is no longer a matter for debate. Constituting the sixth most produced polymer family worldwide, polyurethanes, which are used in a broad variety of applications (buildings, electronics, adhesives, sealants, etc.), are particularly important to recycle. In this study, polyurethanes are selectively recycled to obtain high value-added molecules. It is demonstrated that depolymerization reactions performed with secondary amines selectively cleave the C-O bond of the urethane group, while primary amines unselectively break C-O and C-N bonds. The selective cleavage of C-O bonds, catalyzed by an acid:base mixture, led to the initial polyol and a functional diurea in several hours to a few minutes for both model polyurethanes and commercial polyurethane foams. Different secondary amines were employed as nucleophiles to synthesize a small library of diureas obtained in good to excellent yields. This study not only targets the recovery of the initial polyol but also aims to form new diureas which are useful building blocks for the polymerization of innovative materials.

Research on the Dynamic Response Properties of Nonlethal Projectiles for Injury Risk Assessment

Based on the models already on the market, we have manufactured six types of nonlethal projectiles. We have made convex heads out of polyurethane foam (PUR) filled with mineral fillers like alumina (Al₂O₃) and montmorillonite (MMT). We chose a suitable holder for nonlethal projectiles. Also, we made a custom industrial model and used CAD modeling in SolidWorks to simulate the deformation of the nonlethal projectiles. The polymeric nonlethal projectile holders were then 3D-printed. We performed a dynamic mechanical analysis (DMA) and discussed the results. Likewise, we conducted ballistic impact experiments on nonlethal projectiles (XM1006) and nonlethal projectiles manufactured that were evaluated using a rigid wall and a pneumatic launcher. Furthermore, we looked at cell structure, the spread of the mean pore diameter, and the particle size distributions of the mineral fillers using scanning electron microscopy (SEM). We evaluated and discussed injury risks from nonlethal impacts. Data on nonlethal projectile lethality and safe impact speed are collected. This study explains how lab studies and real-world practice coexist through nonlethal projectile properties.

Analysis of Factors Influencing the Efficiency of Catalysts Used in Waste PU Degradation

Polyurethane (PU) is an indispensable part of people's lives. With the development of polyurethane, the disposal of polyurethane waste has become a significant issue around the world. Conventional degradation catalysts have poor dispersion and low degradation efficiency when used in the process of solid degradation into liquid. Therefore, this paper innovatively adopts self-made core-shell nanoscale titanium catalysis, traditional alkali metal catalyst (KOH), and polyol to carry out the glycolysis of waste polyurethane (PU) pipeline foam. The homogenized nanoscale titanium catalyst coated with alcohol gel has an obvious core-shell structure. The alcohol gel not only protects the catalyst but also dissolves with the alcoholysis agent in the process of glycolysis and disperses more evenly into the alcoholysis agent to avoid the phenomenon of nanocatalyst agglomeration, so as to facilitate catalytic cracking without reducing catalyst activity. In this study, investigated and compared the production of renewable polyurethane foam via a one-step method based on use of a homogeneous core-shell nanostructured titanium catalyst vs. a traditional alkaline catalyst in terms of the properties of regenerated polyether polyols as well as of the foams produced from these polyols. The physicochemical properties of regenerated polyether polyols that were analyzed included viscosity, hydroxyl value, and average molecular weight. The regenerated polyurethane foams were characterized based on water absorption, TG, SEM, and thermal conductivity analyses. The results show that, when the addition of homogeneous titanium catalyst was T2 0.050 wt.%, the viscosity of regenerated polyether polyols was the lowest, at 5356.7 mPa·s, which was reduced by 9.97% compared with those obtained using the alkali metal catalyst (KOH). When the amount of titanium catalyst was T3 0.075 wt.%, the hard foam made of regenerated polyurethane prepared by the catalyst showed the best properties, with a compressive strength of 0.168 MPa, which is 4.76% higher than that of the foam prepared using KOH catalyst.

Current Prospects for Plastic Waste Treatment

The excessive amount of global plastic produced over the past century, together with poor waste management, has raised concerns about environmental sustainability. Plastic recycling has become a practical approach for diminishing plastic waste and maintaining sustainability among plastic waste management methods. Chemical and mechanical recycling are the typical approaches to recycling plastic waste, with a simple process, low cost, environmentally friendly process, and potential profitability. Several plastic materials, such as polypropylene, polystyrene, polyvinyl chloride, high-density polyethylene, low-density polyethylene, and polyurethanes, can be recycled with chemical and mechanical recycling approaches. Nevertheless, due to plastic waste’s varying physical and chemical properties, plastic waste separation becomes a challenge. Hence, a reliable and effective plastic waste separation technology is critical for increasing plastic waste’s value and recycling rate. Integrating recycling and plastic waste separation technologies would be an efficient method for reducing the accumulation of environmental contaminants produced by plastic waste, especially in industrial uses. This review addresses recent advances in plastic waste recycling technology, mainly with chemical recycling. The article also discusses the current recycling technology for various plastic materials.

Recent Advances in Development of Waste-Based Polymer Materials: A Review

Limited petroleum sources, suitable law regulations, and higher awareness within society has caused sustainable development of manufacturing and recycling of polymer blends and composites to be gaining increasing attention. This work aims to report recent advances in the manufacturing of environmentally friendly and low-cost polymer materials based on post-production and post-consumer wastes. Sustainable development of three groups of materials: wood polymer composites, polyurethane foams, and rubber recycling products were comprehensively described. Special attention was focused on examples of industrially applicable technologies developed in Poland over the last five years. Moreover, current trends and limitations in the future “green” development of waste-based polymer materials were also discussed.

Evaluation of Manganese Catalysts for the Hydrogenative Deconstruction of Commercial and End-of-Life Polyurethane Samples

Polyurethane (PU) is a thermoset plastic that is found in everyday objects, such as mattresses and shoes, but also in more sophisticated materials, including windmills and airplanes, and as insulation materials in refrigerators and buildings. Because of extensive inter-cross linkages in PU, current recycling methods are somewhat lacking. In this work, the effective catalytic hydrogenation of PU materials is carried out by applying a catalyst based on the earth-abundant metal manganese, to give amine and polyol fractions, which represent the original monomeric composition. In particular, Mn-^Ph MACHO is found to catalytically deconstruct flexible foam, molded foams, insulation, and end-of-life materials at 1 wt.% catalyst loading by applying a reaction temperature of 180 °C, 50 bar of H₂ , and 0.9 wt.% of KOH in isopropyl alcohol. The protocol is showcased in the catalytic deconstruction of 2 g of mattress foam using only 0.13 wt.% catalyst, resulting in 90 % weight recovery and a turnover number of 905.

Mechanical Properties and Thermal Conductivity of Thermal Insulation Board Containing Recycled Thermosetting Polyurethane and Thermoplastic

This study used a mechanochemical method to analyze the recycling mechanism of polyurethane foam and optimize the recycling process. The use of mechanochemical methods to regenerate the polyurethane foam powder breaks the C–O bond of the polyurethane foam and greatly enhances the activity of the powder. Based on orthogonal test design, the mesh, proportion, temperature, and time were selected to produce nine recycled boards by heat pressing. Then, the influence of four factors on the thermal conductivity and tensile strength of the recycled board was analyzed. The results show that 120 mesh polyurethane foam powder has strong activity, and the tensile strength can reach 9.913 Mpa when it is formed at 205 °C and 40 min with 50% PP powder. With the help of the low thermal conductivity of the polyurethane foam, the thermal conductivity of the recycled board can reach 0.037 W/m·K at the parameter of 40 mesh, 80%, 185 °C, 30 min. This research provides an effective method for the recycling of polyurethane foam.

Possibility Routes for Textile Recycling Technology

The fashion industry contributes to a significant environmental issue due to the increasing production and needs of the industry. The proactive efforts toward developing a more sustainable process via textile recycling has become the preferable solution. This urgent and important need to develop cheap and efficient recycling methods for textile waste has led to the research community's development of various recycling methods. The textile waste recycling process can be categorized into chemical and mechanical recycling methods. This paper provides an overview of the state of the art regarding different types of textile recycling technologies along with their current challenges and limitations. The critical parameters determining recycling performance are summarized and discussed and focus on the current challenges in mechanical and chemical recycling (pyrolysis, enzymatic hydrolysis, hydrothermal, ammonolysis, and glycolysis). Textile waste has been demonstrated to be re-spun into yarn (re-woven or knitted) by spinning carded yarn and mixed shoddy through mechanical recycling. On the other hand, it is difficult to recycle some textiles by means of enzymatic hydrolysis; high product yield has been shown under mild temperatures. Furthermore, the emergence of existing technology such as the internet of things (IoT) being implemented to enable efficient textile waste sorting and identification is also discussed. Moreover, we provide an outlook as to upcoming technological developments that will contribute to facilitating the circular economy, allowing for a more sustainable textile recycling process.

Material Flows of Polyurethane in the United States

Today, polyurethanes are effectively not recycled and are made principally from nonrenewable, fossil-fuel-derived resources. This study provides the first high-resolution material flow analysis of polyurethane flows through the U.S. economy, tracking back to fossil fuels and covering polyurethane-relevant raw materials, trade, production, manufacturing, uses, historical stocks, and waste management. According to our analysis, in 2016, 2900 thousand tonnes (kt) of polyurethane were produced in the United States and 920 kt were imported for consumption, 2000 kt entered the postconsumer waste streams, and 390 kt were recycled and returned to the market in the form of carpet underlayment. The domestic production of polyurethane consumed 1100 kt of crude oil and 1100 kt of natural gas. With the developed polyurethane flow map, we point out the limitation of the existing mechanical recycling methods and identify that glycolysis, a chemical recycling method, can be used to recycle the main components of postconsumer polyurethane waste. We also explore how targeting biobased pathways could influence the supply chain and downstream markets of polyurethane and reduce the consumption of fossil fuels and the exposure to toxic precursors in polyurethane production.

Synthesis of Mono Ethylene Glycol (MEG)-Based Polyurethane and Effect of Chain Extender on Its Associated Properties

This study depicts the investigations of the effect of composition of aromatic polyester polyol produced from terephthalic acid (TPA) and different concentrations of mono ethylene glycol (mEG) as a chain extender on the mechanical properties of polyurethane (PU) elastomer. Aromatic polyester polyols are prepared via the poly-esterification of adipic acid, terephthalic acid, catalyst, and mono ethylene glycol; while a polyurethane elastomer is formulated via the pre-polymerization of polyol with pure monomeric Methylene diphenyl diisocyanate (MDI.) Mechanical properties of polyurethane elastomers are examined, such as hardness via shore A hardness, apparent density via ASTM (American Society for Testing and Materials) D1622–08, and abrasion wear resistance via a Deutches Institut fur Normung (DIN) abrasion wear resistance tester. Structural properties are investigated through Fourier-transform infrared spectroscopy (FTIR) analysis. Results reveal that the shore A hardness of the PU elastomer increases with an increasing concentration of mEG from 4g to 12g. Nevertheless, the elastomer’s density depicts a reduction with an increasing extender content. The abrasion wear resistance of polyurethane, however, increases with an increasing concentration of glycol. A structural analysis through FTIR confirms the formation of polyurethane elastomer through the characteristic peaks demonstrated.

Glycolysis of Polyurethanes Composites Containing Nanosilica

Rigid polyurethane (RPU) foams have been successfully glycolyzed by using diethylene glycol (DEG) and crude glycerol (CG) as transesterification agents. However, DEG did not allow to achieve a split-phase process, obtaining a product with low polyol purity (61.7 wt %). On contrary, CG allowed to achieve a split-phase glycolysis improving the recovered polyol purity (76.5%). This is an important novelty since, up to now, RPUs were glycolyzed in single-phase processes giving products of low polyol concentration, which reduced the further applications. Moreover, the nanosilica used as filler of the glycolyzed foams was recovered completely pure. The recovered polyol successfully replaced up to 60% of the raw polyol in the synthesis of RPU foams and including the recovered nanosilica in the same concentration than in glycolyzed foam. Thus, the feasibility of the chemical recycling of this type of polyurethane composites has been demonstrated. Additionally, PU foams were synthesized employing fresh nanosilica to evaluate whether the recovered nanosilica has any influence on the RPU foam properties. These foams were characterized structurally, mechanically and thermally with the aim of proving that they met the specifications of commercial foams. Finally, the feasibility of recovering the of CG by vacuum distillation has been demonstrated.