Synthesis and characterization of polyurethane foams derived of fully renewable polyester polyols from sorbitol

Tapping into fungal potential: Biodegradation of plastic and rubber by potent Fungi

Plastic polymers are present in most aspects of routine daily life. Their increasing leakage into the environment poses a threat to environmental, animal, and human health. These polymers are often resistant to microbial degradation and are predicted to remain in the environment for tens to hundreds of years. Fungi have been shown to degrade complex polymers and are considered good candidates for bioremediation (biological pollutant reduction) of plastics. Therefore, we screened 18 selected fungal strains for their ability to degrade polyurethane (PU), polyethylene (PE), and tire rubber. As a proxy for plastic polymer mineralization, we quantified O2 consumption and CO2 production in an enclosed biodegradation system providing plastic as the sole carbon source. In contrast to most studies we demonstrated that the tested fungi attach to, and colonize the different plastic polymers without any pretreatment of the plastics and in the absence of sugars, which were suggested essential for priming the degradation process. Functional polymer groups identified by Fourier-transform infrared spectroscopy (FTIR), and changes in fungal morphology as seen in light and scanning electron microscopy (SEM) were used as indicators of fungal adaptation to growth on PU as a substrate. Thereby, SEM analysis revealed new morphological structures and deformation of the cell wall of several fungal strains when colonizing PU and utilizing this plastic polymer for cell growth. Strains of Fusarium, Penicillium, Botryotinia cinerea EN41, and Trichoderma demonstrated a high potential to degrade PU, rubber, and PE. Growing on PU, over 90 % of the O2 was consumed in <14 days with 300-500 ppm of CO2 generated in parallel. Our study highlights a high bioremediation potential of some fungal strains to efficiently degrade plastic polymers, largely dependent on plastic type.

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.

Flexible Polyurethane Foams Modified with Novel Coconut Monoglycerides-Based Polyester Polyols

Coconut oil, a low-molecular-weight vegetable oil, is virtually unutilized as a polyol material for flexible polyurethane foam (FPUF) production due to the high-molecular-weight polyol requirement of FPUFs. The saturated chemistry of coconut oil also limits its compatibility with widely used polyol-forming processes, which mostly rely on the unsaturation of vegetable oil for functionalization. Existing studies have only exploited this resource in producing low-molecular-weight polyols for rigid foam synthesis. In this present work, high-molecular-weight polyester polyols were synthesized from coconut monoglycerides (CMG), a coproduct of fatty acid production from coconut oil, via polycondensation at different mass ratios of CMG with 1:5 glycerol:phthalic anhydride. Characterization of the CMG-based polyol (CMGPOL) products showed number-average molecular weights between 1997 and 4275 g/mol, OH numbers between 77 and 142 mg KOH/g, average functionality between 4.8 and 5.8, acid numbers between 4.49 and 23.56 mg KOH/g, and viscosities between 1.27 and 89.57 Pa·s. The polyols were used to synthesize the CMGPOL-modified PU foams (CPFs) at 20 wt % loading. The modification of the foam formulation increased the monodentate and bidentate urea groups, shown using Fourier transform infrared (FTIR) spectroscopy, that promoted microphase separation in the foam matrix, confirmed using atomic force microscopy (AFM) and differential scanning calorimetry (DSC). The implications of the structural change to foam morphology and open cell content were investigated using a scanning electron microscope (SEM) and gas pycnometer. The density of the CPFs decreased, while a significant improvement in their tensile and compressive properties was observed. Also, the CPFs exhibited different resiliency with a correlation to microphase separation. These findings offer a new sustainable polyol raw material that can be used to modify petroleum-based foam and produce flexible foams with varying properties that can be tailored to meet specific requirements.

Sustainable cycloaliphatic polyurethanes: from synthesis to applications

Polyurethanes (PUs) are a versatile and major polymer family, mainly produced via polyaddition between polyols and polyisocyanates. A large variety of fossil-based building blocks is commonly used to develop a wide range of macromolecular architectures with specific properties. Due to environmental concerns, legislation, rarefaction of some petrol fractions and price fluctuation, sustainable feedstocks are attracting significant attention, e.g., plastic waste and biobased resources from biomass. Consequently, various sustainable building blocks are available to develop new renewable macromolecular architectures such as aromatics, linear aliphatics and cycloaliphatics. Meanwhile, the relationship between the chemical structures of these building blocks and properties of the final PUs can be determined. For instance, aromatic building blocks are remarkable to endow materials with rigidity, hydrophobicity, fire resistance, chemical and thermal stability, whereas acyclic aliphatics endow them with oxidation and UV light resistance, flexibility and transparency. Cycloaliphatics are very interesting as they combine most of the advantages of linear aliphatic and aromatic compounds. This original and unique review presents a comprehensive overview of the synthesis of sustainable cycloaliphatic PUs using various renewable products such as biobased terpenes, carbohydrates, fatty acids and cholesterol and/or plastic waste. Herein, we summarize the chemical modification of the main sustainable cycloaliphatic feedstocks, synthesis of PUs using these building blocks and their corresponding properties and subsequently present their major applications in hot-topic fields, including building, transportation, packaging and biomedicine.

Biodegradation of polyester polyurethane by the marine fungus Cladosporium halotolerans 6UPA1

Lack of degradability and the accumulation of polymeric wastes increase the risk for the health of the environment. Recently, recycling of polymeric waste materials becomes increasingly important as raw materials for polymer synthesis are in short supply due to the rise in price and supply chain disruptions. As an important polymer, polyurethane (PU) is widely used in modern life, therefore, PU biodegradation is desirable to avoid its accumulation in the environment. In this study, we isolated a fungal strain Cladosporium halotolerans from the deep sea which can grow in mineral medium with a polyester PU (Impranil DLN) as a sole carbon source. Further, we demonstrate that it can degrade up to 80% of Impranil PU after 3 days of incubation at 28 ℃ by breaking the carbonyl groups (1732 cm^-1) and C-N-H bonds (1532 cm^-1 and 1247 cm^-1) as confirmed by Fourier-transform infrared (FTIR) spectroscopy analysis. Gas chromatography-mass spectrometry (GC-MS) analysis revealed polyols and alkanes as PU degradation intermediates, indicating the hydrolysis of ester and urethane bonds. Esterase and urease activities were detected in 7 days-old cultures with PU as a carbon source. Transcriptome analysis showed a number of extracellular protein genes coding for enzymes such as cutinase, lipase, peroxidase and hydrophobic surface binding proteins A (HsbA) were expressed when cultivated on Impranil PU. The yeast two-hybrid assay revealed that the hydrophobic surface binding protein ChHsbA1 directly interacts with inducible esterases, ChLip1 (lipase) and ChCut1 (cutinase). Further, the KEGG pathway for "fatty acid degradation" was significantly enriched in Impranil PU inducible genes, indicating that the fungus may use the degradation intermediates to generate energy via this pathway. Taken together, our data indicates secretion of both esterase and hydrophobic surface binding proteins by C. halotolerans plays an important role in Impranil PU absorption and subsequent degradation. Our study provides a mechanistic insight into Impranil PU biodegradation by deep sea fungi and provides the basis for future development of biotechnological PU recycling.

Design and Synthesis of Conducting Polymer Bio-Based Polyurethane Produced from Palm Kernel Oil

Polyurethane (PU) is a unique polymer that has versatile processing methods and mechanical properties upon the inclusion of selected additives. In this study, a freestanding bio-based polyurethane film the screen-printed electrode (SPE) was prepared by the solution casting technique, using acetone as solvent. It was a one-pot synthesis between major reactants, namely, palm kernel oil-based polyol and 4,4-methylene diisocyanate. The PU has strong adhesion on the SPE surface. The synthesized bio-based polyurethane was characterized using thermogravimetry analysis, differential scanning calorimetry, Fourier-transform infrared spectroscopy (FTIR), surface area analysis by field emission scanning electron microscope, and cyclic voltammetry. Cyclic voltammetry was employed to study electrocatalytic properties of SPE-polyurethane towards oxidation of PU. Remarkably, SPE-PU exhibited improved anodic peak current as compared to SPE itself using the differential pulse voltammetry method. Furthermore, the formation of urethane linkages (-NHC(O) backbone) after polymerization was analyzed using FTIR and confirmed by the absence of peak at 2241 cm-1 attributed to the sp-hydridized carbons atoms of C≡C bonds. The glass transition temperature of the polyurethane was detected at 78.1°C.

Characterization of the enzymatic degradation of polyurethanes

For decades, polyurethanes (PUR) have mainly been synthesized for long-term applications and are therefore highly persistent in the environment. Proper waste disposal approaches, including recycling techniques, must be developed to limit the accumulation of PUR in the environment. Evaluation of enzymatic polyurethane degradation is needed for the development of enzymatic recycling. A series of techniques has been carefully implemented to monitor the biotic and abiotic degradation of PUR. Both the degraded polymer and the degradation products are analyzed to obtain a complete overview of the degradation.

Reviewing the thermo-chemical recycling of waste polyurethane foam

The worldwide production of polymeric foam materials is growing due to their advantageous properties of light weight, high thermal insulation, good strength, resistance and rigidity. Society creates ever increasing amounts of poly-urethane (PU) waste. A major part of this waste can be recycled or recovered in order to be put into further use. The PU industry is committed to assist and play its part in the process. The recycling and recovery of PU foam cover a range of mechanical, physical, chemical and thermo-chemical processes. In addition to the well-documented mechanical and chemical processing options, thermo-chemical treatments are important either as ultimate disposal (incineration) or towards feedstock recovery, leading to different products according to the thermal conditions of the treatment. The review focuses on these thermo-chemical and thermal processes. As far as pyrolysis is concerned, TDI and mostly polyol can be recovered. The highest recovery yields of TDI and polyols occur at low temperatures (150-200 °C). It is however clear from literature that pure feedstock will not be produced, and that a further upgrading of the condensate will be needed, together with a thermal or alternative treatment of the non-condensables. Gasification towards syngas has been studied on a larger and industrial scale. Its application would need the location of the PU treatment plant close to a chemical plant, if the syngas is to be valorized or considered in conjunction with a gas-fired CHP plant. Incineration has been studied mostly in a co-firing scheme. Potentially toxic emissions from PU combustion can be catered for by the common flue gas cleaning behind the incineration itself, making this solution less evident as a stand-alone option: the combination with other wastes (such as municipal solid waste) in MSWI's seems the indicated route to go.

Solubility-governed architectural design of polyhydroxyurethane-graft-poly(ε-caprolactone) copolymers

Polyhydroxyurethane-graft-poly(ε-caprolactone) copolymers were prepared in bulk by designing a polyhydroxyurethane system with polymer-in-monomer solubility.

Isolation and characterization of different promising fungi for biological waste management of polyurethanes

As a highly resistant polymer family, polyurethanes (PU) are responsible for increasing environmental issues. Then, PU biodegradation is a challenging way to develop sustainable waste management processes based on biological recycling. Since the metabolic diversity of fungi is a major asset for polymer degradation, nearly thirty strains were isolated from sampling on six different PU wastes-containing environments. A screening of the fungi on four thermoplastic PU (TPU) with different macromolecular architectures led to the selection of three strains able to use two polyester PU as sole carbon source: Alternaria sp., Penicillium section Lanata-Divaricata and Aspergillus section flavi. Weight loss, FT-IR, Scanning Electron Microscopy and Size Exclusion Chromatography analyses revealed that these three fungi degrade slightly and similarly a fatty acid dimer-based TPU while variability of degradation was noticed on a polycaprolactone-based TPU. On this last TPU, robust analysis of the degraded polymers showed that the Penicillium strain was the best degrading microorganism. Membrane enzymes seemed to be involved in this degradation. It is the first time that a strain of Penicillium of the section Lanata-Divaricata displaying PU biodegradation ability is isolated. These newly discovered fungi are promising for the development of polyester PU waste management process.

Enzymatic recycling of thermoplastic polyurethanes: Synergistic effect of an esterase and an amidase and recovery of building blocks

Biological recycling of polyurethanes (PU) is a huge challenge to take up in order to reduce a large part of the environmental pollution from these materials. However, enzymatic depolymerization of PU still needs to be improved to propose valuable and green solutions. The present study aims to identify efficient PU degrading enzymes among a collection of 50 hydrolases. Screenings based on model molecules were performed leading to the selection of an efficient amidase (E4143) able to hydrolyze the urethane bond of a low molar mass molecule and an esterase (E3576) able to hydrolyze a waterborne polyester polyurethane dispersion. Degradation activities of the amidase, the esterase and a mix of these enzymes were then evaluated on four thermoplastic polyurethanes (TPU) specifically designed for this assay. The highest degradation was obtained on a polycaprolactone polyol-based polyurethane with weight loss of 33% after 51 days measured for the esterase. Deep cracks on the polymer surface observed by scanning electron microscopy and the presence of oligomers on the remaining TPU detected by size exclusion chromatography evidenced the polymer degradation. Mixing both enzymes led to an increased amount of urethane bonds hydrolysis of the polymer. 6-hydroxycaproic acid and 4,4'-methylene dianiline were recovered after depolymerization as hydrolysis products. Such building blocks could get a second life with the synthesis of new macromolecular architectures.

From D-sorbitol to five-membered bis(cyclo-carbonate) as a platform molecule for the synthesis of different original biobased chemicals and polymers

Bis(cyclo-carbonate) was successfully synthesized from D-sorbitol (Sorb-BisCC) through an environmentally friendly process with dimethyl carbonate (DMC) as a reactant. In agreement with green chemistry principles, solvent free reactions were catalyzed and took place at low temperature. The reaction yield was increased until 50%, with the use of 1.3.5-triazabicyclo[4.4.0]dec-5-ene as catalyst and a continuous DMC feed to limit the side-reactions or the loss of reactant by azeotropic flux with a reactional subsidiary product. The obtained Sorb-BisCC is a remarkable platform molecule which could compete with others polycyclic platform molecules (isosorbide). Sorb-BisCC can be e.g., used to synthesize different chemicals such as short and long polyols, or novel biobased non-isocyanate polyurethanes (NIPU). Two Sorb-BisCC molecules have been coupled to obtain novel cyclic diols with pendant side chains. Polyether polyols were also obtained by anionic ring opening polymerization. According to the synthesis conditions, these synthetized polyether polyols range from partially to highly cross-linked materials. Finally, NIPU were synthesized with short and biobased fatty diamines. These different modifications and synthesis highlight the versatility of the Sorb-BisCC and demonstrated its high potential as building block. Sorb-BisCC can be considered as a platform molecule to open the way to different original and biobased chemical architectures.

Renewable polyols for advanced polyurethane foams from diverse biomass resources

This review highlights recent advances in the synthesis of renewable polyols, used for making polyurethane foams, from biomass.