Glycerin as a new glycolysing agent for chemical recycling of cold cure polyurethane foam wastes in “split-phase” condition

Polyurethane Recycling: Conversion of Carbamates-Catalysis, Side-Reactions and Mole Balance

Diisocyanates, a key monomer in polyurethane, are generally lost during recycling. Polyurethane alcoholysis to carbamate and subsequent cracking to isocyanate represents a promising, phosgene-free recycling route. This work reports the thermal and catalytic cracking of a model carbamate (Methyl N-phenyl carbamate, MPC) to isocyanate (Phenyl isocyanate). Multiple catalysts (ZnO, Bi₂O₃, Al₂O₃, and Montmorillonite K-10) were evaluated in a closed system (batch autoclaves) to decompose MPC at temperatures of 160-200 °C, with a thorough analysis of the products and high (≥90%) mole balance. The thermal reaction was very limited at these temperatures, whereas the catalytic reaction led mainly to aniline and urea and seemed to be dominated by water adsorbed on the catalyst surface.

Insight into Chemical Recycling of Flexible Polyurethane Foams by Acidolysis

Acidolysis is emerging as a promising method for recycling polyurethane foam (PUF) waste. Here, we present highly efficient acidolysis of PUFs with adipic acid (AA) by heating the reaction mixtures with microwaves. The influence of experimental conditions, such as reaction temperature, time, and amount of the degradation reagent, on the polyol functionality, molecular weight characteristics, the presence of side products, and the degree of degradation of the remaining PUF hard segments was studied by matrix-assisted laser desorption/ionization time-of-flight mass spectroscopy (MALDI-TOF MS), nuclear magnetic resonance (NMR), size-exclusion chromatography (SEC) coupled to a multidetection system, and Fourier transform infrared (FT-IR) spectroscopy. The purified recycled polyols were used for the synthesis of flexible PUFs. The morphology and mechanical properties of the PUFs show that the degree of functionalization of the polyol by the carboxylic end groups, which is higher for larger amounts of AA used to degrade the PUFs, significantly affects the quality and performance of the flexible PUFs from the recycled polyols.

Recycling of Flexible Polyurethane Foam by Split-Phase Alcoholysis: Identification of Additives and Alcoholyzing Agents to Reach Higher Efficiencies

Split-phase alcoholysis of flexible polyurethane (PU) foam yields an apolar phase containing the recycled polyether polyol, and a lower, polar phase of the alcoholyzing agent and aromatic compounds. However, multiple purification steps are required to render the polyether polyol suitable for synthesis of new flexible PU foams; the unfavorable mass balance limits industrial applications. In this work, 2-pyrrolidone was identified as a performant additive for accelerating the dissolution and depolymerization process. By applying a lactam to PU foam in a weight ratio of 0.1:1, the glycol to PU foam weight ratio can be decreased from 1.5:1 to only 0.5:1, without loss of purity or yield of the recycled polyether polyol. Diglycerol was discovered as a novel, promising alcoholyzing agent; it allows the recycling of the polyether polyol in high purity (97 %) and excellent yields (98 %), and after a single washing with diglycerol, a sufficiently low hydroxyl value (61 mgKOH  g-1 ) is reached. The recycled polyether polyol can replace the virgin polyether polyol (48 mgKOH  g-1 ) for up to 50 % in the synthesis of new flexible PU foams with effects on the foam quality that stay within the limits of generally accepted specifications. A first step towards the valorization of the lower phase was also taken by applying hydrolysis of the newly formed carbamates to toluenediamines, which are readily reintegrated in new PU foams.

Recent Developments in Polyurethane Foams Containing Low-Cost and Pro-Ecological Modifiers

Diversity of the polyurethane (PU) foams applications cause that investigation of the relationships between their structure and properties is currently very popular topic among the many research institutions and companies. At the turn of the last years many scientific papers about PU foams and their composites were published. The one of the main trends in research in this field is related to the reduction of production costs of PU foams. This aim can be successfully achieved through the incorporation of raw materials of natural origin or the utilization of waste materials. This work reviews the progress and recent developments in area of PU foams containing low-cost and pro-ecological modifiers, such as crude glycerol, liquefied biomass, ground tire rubber, etc.