Life Cycle Assessment of Polyurethane Foams from Polyols Obtained through Chemical Recycling

An overview on polyurethane-degrading enzymes

Polyurethanes (PUR) are durable synthetic polymers widely used in various industries, contributing significantly to global plastic consumption. PUR pose unique challenges in terms of degradability and recyclability, as they are characterised by intricate compositions and diverse formulations. Additives and proprietary structures used in commercial PUR formulations further complicate recycling efforts, making the effective management of PUR waste a daunting task. In this review, we delve into the complex challenge of enzymatic degradation of PUR, focusing on the structural and functional attributes of both enzymes and PUR. We also present documented native enzymes with reported efficacy in hydrolysing specific bonds within PUR, analysis of these enzyme structures, reaction mechanisms, substrate specificity, and binding site architecture. Furthermore, we propose essential features for the future redesign of enzymes to optimise PUR biodegradation efficiency. By outlining prospective research directions aimed at advancing the field of enzymatic biodegradation of PUR, we aim to contribute to the development of sustainable solutions for managing PUR waste and reducing environmental pollution.

Revealing Dynamic Behavior in High Dielectric Poly(thiourethane)-Based Vitrimer-like Materials

Here, we have explored covalent adaptable networks (CANs) comprising poly(thiourethane)-based systems (PTUs). The PTUs were synthesized through the combination of thiol and isocyanate monomers in stoichiometric proportions, in the presence of dibutyltin dilaurate (DBTDL) as catalyst. Dynamic mechanical analysis (DMA) provided detailed insight into the vitrimeric behavior. Through these investigations, we evaluated the viscoelastic, thermomechanical, and vitrimeric properties. Additionally, broadband dielectric spectroscopy (BDS) revealed the various relaxation processes inherent in such vitrimer-like materials. We methodically examined the evolution of each relaxation in every prepared sample to comprehend the operational mechanisms in these vitrimer-like systems. Our findings underscore that depending on the PTU formulation, the glass transition temperature (Tg) and the topology freezing transition temperature (Tv) can be effectively distinguished and studied. Considering the high dipole moment of the dynamic bonds present in these systems, there is potential for utilizing them as dielectric materials working under the concept of dipolar glass polymers. Furthermore, the reversibility exhibited by their inner chemical structures positions them as promising candidates for active layers in capacitor devices, particularly for energy-related applications, with the ability to be recyclable while maintaining almost invariant both their mechanical and dielectric properties, thus promoting the extension of the lifespan of electronic devices.

Depolymerization within a Circular Plastics System

The societal importance of plastics contrasts with the carelessness with which they are disposed. Their superlative properties lead to economic and environmental efficiency, but the linearity of plastics puts the climate, human health, and global ecosystems at risk. Recycling is fundamental to transitioning this linear model into a more sustainable, circular economy. Among recycling technologies, chemical depolymerization offers a route to virgin quality recycled plastics, especially when valorizing complex waste streams poorly served by mechanical methods. However, chemical depolymerization exists in a complex and interlinked system of end-of-life fates, with the complementarity of each approach key to environmental, economic, and societal sustainability. This review explores the recent progress made into the depolymerization of five commercial polymers: poly(ethylene terephthalate), polycarbonates, polyamides, aliphatic polyesters, and polyurethanes. Attention is paid not only to the catalytic technologies used to enhance depolymerization efficiencies but also to the interrelationship with other recycling technologies and to the systemic constraints imposed by a global economy. Novel polymers, designed for chemical depolymerization, are also concisely reviewed in terms of their underlying chemistry and potential for integration with current plastic systems.

Biodegradation of aliphatic polyurethane foams in soil: Influence of amide linkages and supramolecular structure

Polyurethane (PU) foams are classified as physically nonrecyclable thermosets. The current effort of sustainable and eco-friendly production makes it essential to explore methods of better waste management, for instance by modifying the structure of these frequently used polymers to enhance their microbial degradability. The presence of ester links is known to be a crucial prerequisite for the biodegradability of PU foams. However, the impact of other hydrolysable groups (urethane, urea and amide) occurred in PU materials, as well as the supramolecular structure of the PU network and the cellular morphology of PU foams, is still relatively unexplored. In this work, fully aliphatic PU foams with and without hydrolyzable amide linkages were prepared and their aerobic biodegradation was investigated using a six-month soil burial test. Besides the variable chemical composition of the PU foams, the influence of their different supramolecular arrangement and cellular morphologies on the extent of biodegradation was also evaluated. Throughout the soil burial test, the release of carbon dioxide, and enzyme activities of proteases, esterases, and ureases were measured. At the same time, phospho-lipid fatty acids (PLFA) analysis was conducted together with an assessment of microbial community composition achieved by analysing the genetic information from the 16S rRNA gene and ITS2 region sequencing. The results revealed a mineralization rate of 30-50 % for the PU foams, indicating a significant level of degradation as well as indicating that PU foams can be utilized by soil microorganisms as a source of both energy and nutrients. Importantly, microbial biomass remained unaffected, suggesting that there was no toxicity associated with the degradation products of the PU foams. It was further confirmed that ester linkages in PU foam structure were easily enzymatically cleavable, while amide linkages were not prone to degradation by soil microorganisms. In addition, it was shown that the presence of amide linkages in PU foam leads to a change in the supramolecular network arrangement due to increased content of hard segments, which in turn reduces the biodegradability of PU foam. These findings show that it is important to consider both chemical composition and supramolecular/macroscopic structure when designing new PU materials in an effort to develop environmentally friendly alternatives.

Application of Modified Seed Oils of Selected Fruits in the Synthesis of Polyurethane Thermal Insulating Materials

The use of alternative raw material sources in polyurethane chemistry is necessary given the limited supply of fossil fuels, their rising prices and the concern for sustainability. The production of biopolyols from edible vegetable oils such as rapeseed oil, soybean oil or sunflower oil is often proposed. In order to avoid conflict with the global food economy, non-edible or waste oils are hoped to find application in chemical synthesis. The possibility of using oils from selected fruit seeds to obtain biopolyols is analyzed in this manuscript. Five biopolyols were obtained from watermelon, cherry, black currant, grape and pomegranate fruit seeds using the transesterification reaction of the oils with triethanolamine. Thermal insulating polyurethane foams were then obtained by replacing 75% of petrochemical polyol with the biopolyols in polyurethane systems. Based on an analysis of the foaming process, it was found that the incorporation of triethanolamine molecules into the biopolyols causes a catalytic effect. The use of such biopolyols allows eliminating the catalyst from a polyurethane foam formulation. The polyurethane biofoams obtained with the pomegranate-seed-based biopolyol were characterized by the highest content of closed cells (45 vol.%). The lowest content was found for the foams containing the currant-seed-based biopolyol (9%). The foams were characterized by thermal conductivity coefficients between 32 and 35 kW/m·K and densities of approximately 40 kg/m3. Good dimensional stability and compressive strength between 100 and 250 kPa make them suitable for use in construction.

Chemical upcycling of commodity thermoset polyurethane foams towards high-performance 3D photo-printing resins

Polyurethane thermosets are indispensable to modern life, but their widespread use has become an increasingly pressing environmental burden. Current recycling approaches are economically unattractive and/or lead to recycled products of inferior properties, making their large-scale implementation unviable. Here we report a highly efficient chemical strategy for upcycling thermoset polyurethane foams that yields products of much higher economic values than the original material. Starting from a commodity foam, we show that the polyurethane network is chemically fragmented into a dissolvable mixture under mild conditions. We demonstrate that three-dimensional photo-printable resins with tunable material mechanical properties-which are superior to commercial high-performance counterparts-can be formulated with the addition of various network reforming additives. Our direct upcycling of commodity foams is economically attractive and can be implemented with ease, and the principle can be expanded to other commodity thermosets.

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.

Recycling of Thermoset Materials and Thermoset-Based Composites: Challenge and Opportunity

Thermoset materials and their composites are characterized by a long life cycle with their main applications in aircrafts, wind turbines and constructions as insulating materials. Considering the importance of recovery and valorization of these materials at their end-of-life, avoiding landfilling, the interest concerning their recycling grows continuously. The thermoset materials and their composites, to be successfully recovered and valorized, must degrade their three-dimensional structures and recover the mono-oligomers and/or fillers. The thermoset materials could successfully degrade through thermal treatment at different temperatures (for example, above 1000 °C for incineration, ca. 500 °C for oxidation/combustion of organic constituents, etc.), chemical degradation by catalyst, irradiation with or without the presence of water, alcohol, etc., and mechanical recycling, obtaining fine particles that are useful as filler and/or reinforcement additives. Among these recycling methods, this mini-review focuses on the formulation and recovery method of innovative thermoset with in-build recyclability, i.e., materials having chemical links that could be degraded on-demand or containing dynamic covalent bonds to have re-processable and/or recyclable thermoset. This issue could be considered the future perspective in developing novel thermoset materials. The aim of this review is to get an overview of the state of the art in thermoset recycling and of the most commonly used thermoset composites, recovering valuable reinforcing fibers. Additionally, in this work, we also report not only known recycling routes for thermoset and thermoset-based composites, but also new and novel formulating strategies for producing thermosets with built-in recyclability, i.e., containing chemical-triggered on-demand links. This mini-review is also a valuable guide for educational purposes for students and specialized technicians in polymer production and recycling.

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.

Polyurethane Composites Reinforced with Walnut Shell Filler Treated with Perlite, Montmorillonite and Halloysite

In the following study, polyurethane (PUR) composites were modified with 2 wt.% of walnut shell filler modified with selected mineral compounds–perlite, montmorillonite, and halloysite. The impact of modified walnut shell fillers on selected properties of PUR composites, such as rheological properties (dynamic viscosity, foaming behavior), mechanical properties (compressive strength, flexural strength, impact strength), dynamic-mechanical behavior (glass transition temperature, storage modulus), insulation properties (thermal conductivity), thermal characteristic (temperature of thermal decomposition stages), and flame retardant properties (e.g., ignition time, limiting oxygen index, heat peak release) was investigated. Among all modified types of PUR composites, the greatest improvement was observed for PUR composites filled with walnut shell filler functionalized with halloysite. For example, on the addition of such modified walnut shell filler, the compressive strength was enhanced by ~13%, flexural strength by ~12%, and impact strength by ~14%. Due to the functionalization of walnut shell filler with thermally stable flame retardant compounds, such modified PUR composites were characterized by higher temperatures of thermal decomposition. Most importantly, PUR composites filled with flame retardant compounds exhibited improved flame resistance characteristics-in all cases, the value of peak heat release was reduced by ~12%, while the value of total smoke release was reduced by ~23%.

Mechanically Strong Polyurethane Composites Reinforced with Montmorillonite-Modified Sage Filler (Salvia officinalis L.)

Rigid polyurethane (PUR) foams reinforced with 1, 2, and 5 wt.% of salvia filler (SO filler) and montmorillonite-modified salvia filler (MMT-modified SO filler) were produced in the following study. The impact of 1, 2, and 5 wt.% of SO filler and MMT-modified SO filler on the morphological, chemical, and mechanical properties of PUR composites were examined. In both cases, the addition of 1 and 2 wt.% of SO fillers resulted in the synthesis of PUR composites with improved physicomechanical properties, while the addition of 5 wt.% of SO fillers resulted in the formation of PUR composites with a less uniform structure and, therefore, some deterioration in their physicomechanical performances. Moreover, the results showed that the modification of SO filler with MMT improved the interphase compatibility between filler surface and PUR matrix. Therefore, such reinforced PUR composites were characterized by a well-developed closed-cell structure and improved mechanical, thermal, and flame-retardant performances. For example, when compared with reference foam, the addition of 2 wt.% of MMT-modified SO filler resulted in the formation of PUR composites with greater mechanical properties (compressive strength, flexural strength) and improved dynamic-mechanical properties (storage modulus). The PUR composites were characterized by better thermal stability as well as improved flame retardancy-e.g., decreased peak rate of heat release (pHRR), reduced total smoke release (TSR), and increased limiting oxygen index (LOI).