Waste Polyurethane Research Articles

Optimization of mechanical properties of recycled polyurethane waste microfiller epoxy composites using grey relational analysis and taguchi method

Mechanical properties and thermal conductivity of epoxy composites reinforced with recycled clamshell container waste as a micro filler (RCCF) were studied. The studies have been carried out to identify the influence of the two variables, the heating time periods (HT) within the range of 2, 4, 6 min., and wt % within the range of 1 %, 2 %, 4 % of recycled clamshell container waste that has been used as a reinforcing filler of epoxy composites. Recycling polyurethane waste aims to control and maintain a pollution-free environment, which is currently considered a difficult issue in addition to achieving low-cost aspects in preparing the composites. According to the method of no-combustion heating, the clamshell waste was converted from the natural plastic state into solids that were later made into 75 μm micro filler by grinding. Composites were ranked using grey relational analysis (GRA). The effect of each control parameter on response variables was analyzed by the Taguchi method. Using MINITAB 19 software, regression equations were obtained for each variable of mechanical properties and thermal conductivity to predict the properties of epoxy composites. The results of the addition of recycled clamshell container waste to epoxy resin show an improvement in the mechanical properties and thermal conductivity of the composites. The optimal value of the two factors was at HT2wt2, i.e. HT and wt % of 4 min and 2 %, respectively. The optimization values for the bending strength, impact strength, tensile strength, stiffness and thermal conductivity are 68.2 MPa, 10.348 kJ/m2, 21.08 MPa, 80 Shore D and 0.504 W/m·C°, respectively. The proposed Taguchi methodology based on grey relational analysis has been shown to be effective in solving multi-feature decision-making problems.

Bismuth Oxychloride Microcrystals Decorated Carbon Foams Based on Waste Polyurethane Elastomer for Enhanced Removal of Methylene Blue

Bismuth Oxychloride Microcrystals Decorated Carbon Foams Based on Waste Polyurethane Elastomer for Enhanced Removal of Methylene Blue

Exploring the Potential to Repurpose Flexible Moulded Polyurethane Foams as Acoustic Insulators.

Polyurethane flexible foams are widely used for a variety of applications to improve comfort and durability. Their long-term frequent use inevitably leads to the generation of waste that needs to be treated. The recycling and reuse of polyurethane waste are essential to achieve an environmentally friendly economy. The present study investigates the potential to reuse and repurpose flexible polyurethane foam from automotive seat cushion waste materials. Flexible foams were prepared with different hardnesses using isocyanate–polyol ratios between 0.8 and 1.2 NCO-index. Dry heat aging tests were performed to mimic the long-term usage of the materials. The decrease in compressive strength was compared with the change in acoustic damping properties before and after the aging tests using an acoustic tube, and the change in foam cell structures was also analyzed by micro-CT. On the basis of the results obtained, although the foam systems are no longer suitable to be used as seat cushions due to aging, they can still be used as sound insulation materials within a given frequency range, as their sound absorption capacity is suitable for such purpose.

Resistance to severe environmental conditions of prototypical recycling-based under ballast mats (UBMs) used as vibration isolators in the ballasted track systems

The present paper focuses on laboratory tests of resistance to severe environmental conditions performed on prototypical under ballast mats (UBMs) according to the procedure described in the European standard EN 17282, which was introduced at the end of 2020. Most of the analyzed samples of UBMs were based on elastomeric materials from recycling, such as styrene butadiene rubber (SBR) granulate and fibers from recycled waste tires and rebond polyurethane from polyurethane waste, and additionally, for comparative reasons, one of the tested UBM samples was based on mineral wool. It was proved that in the case of mineral wool- and polyurethane-based samples, there are significant differences in static and dynamic characteristics determined before and after the resistance tests and permanent deformations are observed. Elastomeric mats based on recycled rubber exhibited good properties in the performed tests and thus, they should be regarded as effective and durable vibration isolators which can be used to protect people and the surrounding environment against structure-borne noise and vibration generated by railway traffic. The results of experimental tests were additionally used by the authors to create a viscoelastic model of the vibration isolator (UBM) with fractional derivatives. Using the original model of the ballasted track structure with four degrees of freedom, a significant influence of severe environmental conditions together with the dynamic cyclic loading on the level of vibration suppression (insertion loss factor) was demonstrated. Additionally, the authors proposed the assessment criteria for the resistance to severe environmental conditions of UBMs, tested according to the new standard EN 17282.

Recovery of Waste Polyurethane from E-Waste. Part II. Investigation of the Adsorption Potential for Wastewater Treatment.

This study explored the performances of waste polyurethane foam (PUF) derived from the shredding of end-of-life refrigerators as an adsorbent for wastewater treatment. The waste PUF underwent a basic pre-treatment (e.g., sieving and washing) prior the adsorption tests. Three target pollutants were considered: methylene blue, phenol, and mercury. Adsorption batch tests were performed putting in contact waste PUF with aqueous solutions of the three pollutants at a solid/liquid ratio equal to 25 g/L. A commercial activated carbon (AC) was considered for comparison. The contact time necessary to reach the adsorption equilibrium was in the range of 60–140 min for waste PUF, while AC needed about 30 min. The results of the adsorption tests showed a better fit of the Freundlich isotherm model (R2 = 0.93 for all pollutants) compared to the Langmuir model. The adsorption capacity of waste PUF was limited for methylene blue and mercury (Kf = 0.02), and much lower for phenol (Kf = 0.001). The removal efficiency achieved by waste PUF was lower (phenol 12% and methylene blue and mercury 37–38%) compared to AC (64–99%). The preliminary results obtained in this study can support the application of additional pre-treatments aimed to overcome the adsorption limits of the waste PUF, and it could be applied for “rough-cut” wastewater treatment.

Experimental and Analytical Investigation for Reduction in Cost of Polyurethane Waste Disposal at Adani Hazira Port Pvt. Ltd.

Abstract: Adani hazira Port handles all types of cargo including bulk, break-bulk, bulk liquid chemicals, petroleum products & edible oil, containers, automotive and crude. project includes to investigation and estimation of reduction in cost of pig foam by experimental data collection and analysis of the pig foam for manufacturing of foam squeezing machine. and study the property of same.Adani is facing issue of more use of polyurethane foam, high disposal cost of polyurethane, higher time of reutilization. pipeline clearance is done with pigging operation. work plan is to Reduction in cost of foam pig utilization per annum, reduction in cost of polyurethane foam disposal. Keyword: 1. Project Management , 2. Waste Management, 3. Pipeline management , 4. Mechanical Engineering.

Fast pyrolysis of polyurethanes and polyisocyanurate with and without flame retardant: Compounds of interest for chemical recycling

To date, the recycling of polyurethane (PU) and polyisocyanurate (PIR) waste still poses a significant problem. Within this contribution, the thermal degradation of high-resilient ether PU, semirigid PU, rigid PU, and (PIR) with and without TCPP flame retardant was studied at different temperatures to identify and quantify the main products. For this, a tandem micropyrolyzer coupled to GC × GC with FID and ToF-MS detectors was used, and the yield volatiles, light gases, and residue was quantified. The volatile pyrolysis vapours obtained from pyrolyzing high-resilient ether PU and semirigid PU at 600 °C were very similar, and the main products obtained were ethylene and propylene (combined yield of ~13 wt%), ~16 wt% of various oxygenates, and 4–6 wt% organic nitrogen compounds. The oxygenates included mostly poly-ether type compounds with varying molecular weight, and these are attributed to the decomposition of the polyol chains forming the soft segments of the polymer. The main semi-volatile nitrogen compound was 4,4′-methylenedianiline, attributed to the decomposition of the hard segments in the PU structure synthesized from MDI. The pyrolysis vapours from rigid PU contained several ether-type compounds and high yields of heteroatom-free monoaromatics—in particular styrene. The PIRs were more difficult to decompose and volatilize than the PUs, resulting in ~20 wt% higher residue yields. The charring propensity was even higher in the absence of a flame retardant in the formulation. Pyrolysis of TCPP-containing PIR produced Cl-containing pyrolysis vapours such as allyl chlorides. While the yield of H2O was comparable for the different PUs and PIR, pyrolysis of PIR produced higher yields of CO2 and less CO compared to the different PUs. The use of catalysts can help to convert PU waste pyrolysis vapours more efficiently to desirable chemicals.

Isolation and characterization of a polyurethane-degrading bacterium

Biodegradation of polyurethane (PUR) pollutants by microorganisms has received widespread attention currently. Identification of microorganisms capable of efficiently degrading PUR plastics is a key point. In this study, a strain P10 capable of degrading PUR was isolated from the plastic wastes, and identified as a bacterium belonging to the genus of Brevibacillus based on colony morphology and 16S rDNA phylogenetic analysis. Brevibacillus sp. P10 was capable of degrading 71.4% of waterborne polyurethane (Impranil DLN) after 6 days growth in MSM medium with DLN as a sole carbon source. In addition, strain P10 can use commercial PUR foam as the sole carbon source for growth. Brevibacillus sp. P10 can degrade 50 mg PUR foam after 6 days growth in MSM medium supplemented with 5% (V/V) LB after optimization of degradation conditions. This indicates that Brevibacillus sp. P10 has potential to be used in biodegradation of PUR waste.

Recovery of Waste Polyurethane from E-Waste-Part I: Investigation of the Oil Sorption Potential.

The shredding of end-of-life refrigerators produces every year in Italy 15,000 tons of waste polyurethane foam (PUF), usually destined for energy recovery. This work presents the results of the investigation of the oil sorption potential of waste PUF according to ASTM F726–17 standard. Three oils (diesel fuel and two commercial motor oils) having different densities (respectively, 0.83, 0.87, and 0.88 kg/dm3) and viscosities (respectively, 3, 95, and 140 mm2/s at 40 °C) were considered. The waste PUF was sampled in an Italian e-waste treatment plant, and its characterization showed 16.5 wt% particles below 0.71 mm and 13 wt% impurities (paper, plastic, aluminum foil), mostly having dimensions (d) above 5 mm. Sieving at 0.071 mm was applied to the waste PUF to obtain a “coarse” (d > 0.71 mm) and a “fine” fraction (d < 0.71 mm). Second sieving at 5 mm allowed an “intermediate” fraction to be obtained, with dimensions between 0.71 and 5 mm. The oil sorption tests involved the three fractions of waste PUF, and their performances were compared with two commercial oil sorbents (sepiolite and OKO-PUR). The results of the tests showed that the “fine” PUF was able to retain 7.1–10.3 g oil/g, the “intermediate” PUF, 4.2–7.4 g oil/g, and the “coarse” PUF, 4.5–7.0 g oil/g, while sepiolite and OKO-PUR performed worse (respectively, 1.3–1.6 and 3.3–5.3 g oil/g). In conclusion, compared with the actual management of waste PUF (100 wt% sent to energy recovery), the amount destined directly to energy recovery could be limited to 13 wt% (i.e., the impurities). The remaining 87 wt% could be diverted to reuse for oil sorption, and afterward directed to energy recovery, considered as a secondary option.

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.

Breakthrough in polyurethane bio-recycling: An efficient laccase-mediated system for the degradation of different types of polyurethanes.

Development of green, efficient and profitable recycling processes for plastic material will contribute to reduce the expanding plastic pollution and microplastics accumulation in the environment. Polyurethanes (PU) are versatile polymers with a large range of chemical compositions and structures. This variability increases the complexity of PU waste management. Biological recycling researchers have recently demonstrated great interest in polyethylene terephthalate. The adaptation of this route towards producing polyurethanes requires the discovery of enzymes that are able to depolymerize a large variety of PU. A laccase mediated system (LMS) was tested on four representative PU models, with different structures (foams and thermoplastics), and chemical compositions (polyester- and polyether-based PU). Size exclusion chromatography was performed on the thermoplastics and this revealed a significant reduction in the molar masses after 18days of incubation at 37°C. Degradation of foams under the same conditions was demonstrated by microscopy and compression assay for both polyester- and polyether-based PU. This study represents a major breakthrough in PU degradation, as it is the first time that enzymatic degradation has been clearly demonstrated on a polyether-based PU foam. This work is a step forward in the development of a sustainable recycling pathway, adapted to a large variety of PU materials.

Evaluation of Properties and Micro-Characteristics of Waste Polyurethane/Styrene-Butadiene-Styrene Composite Modified Asphalt.

In order to solve the problems caused by asphalt diseases and prolong the life cycle of asphalt pavement, many studies on the properties of modified asphalt have been conducted, especially polyurethane (PU) modified asphalt. This study is to replace part of the styrene-butadiene-styrene (SBS) modifier with waste polyurethane (WP), for preparing WP/SBS composite modified asphalt, as well as exploring its properties and microstructure. On this basis, this paper studied the basic performance of WP/SBS composite modified asphalt with a conventional performance test, to analyze the high- and low-temperature rheological properties, permanent deformation resistance and storage stability of WP/SBS composite modified asphalt by dynamic shear rheometer (DSR) and bending beam rheometer (BBR) tests. The microstructure of WP/SBS composite modified asphalt was also observed by fluorescence microscope (FM) and Fourier transform infrared spectroscopy (FTIR), as well as the reaction between WP and asphalt. According to the results of this study, WP can replace SBS as a modifier to prepare WP/SBS composite modified asphalt with good low-temperature resistance, whose high-temperature performance will be lower than that of SBS modified asphalt. After comprehensive consideration, 4% SBS content and 15% WPU content (4 S/15 W) are determined as the suitable types of WPU/SBS composite modified asphalt.

Preparation of hydrogen-rich gas from waste polyurethane foam by steam gasification and catalytic reforming in a two-stage fixed bed reactor

Preparation of hydrogen-rich gas from waste polyurethane foam by steam gasification and catalytic reforming in a two-stage fixed bed reactor

Investigation of gypsum composites with different lightweight fillers

Structure and behaviour of gypsum composites, prepared from flue gas desulfurization binder and three types of fine fillers (silica sand, perlite, expanded clay aggregate and waste polyurethane foam) were studied. Their structure and composition were investigated by SEM, XRD and porosimetry, mechanical, thermal and moisture properties were tested. It was found that the type and surface quality of the aggregates affect the shape and size of gypsum crystals significantly. Largest gypsum crystals are formed in the mortars with non-porous particles. With increasing surface roughness of particles the strength of the mortars increases. Mortar with expanded clay filler has the highest strength, its compressive strength was comparable with the compressive strength of the reference material with silica sand, but its bulk density was more than 40% lower and its thermal conductivity decreased to 20% of the thermal conductivity of reference material. The mortar with waste polyurethane foam has the lowest strength (2.9 MPa at 7 days) but best thermal conductivity (0.211 W/m.K) of all materials. Technical properties of composite with waste polyurethane are still sufficient for building purposes and its environmental impact is lowest of all materials.

Advances in Low-Density Flexible Polyurethane Foams by Optimized Incorporation of High Amount of Recycled Polyol.

An industrially manufactured recycled polyol, obtained by acidolysis process, was for the first time proved to be a possible replacement of the reference fossil-based polyol in a low-density formulation suitable for industrial production of flexible polyurethane foams. The influence of increasing recycled polyol amounts on the properties of the polyurethane foam has been studied, also performing foam emission tests to evaluate the environmental impact. Using 10 pbw recycled polyol in the standard formulation, significant differences of the physical properties were not observed, but increase of the recycled polyol amount to 30 pbw led to a dramatic decrease of the foam air flow and a very tight foam. To overcome this drawback, N,N′-bis[3-(dimethylamino)propyl]urea was selected as tertiary amine catalyst, enabling the preservation of foam properties even at high recycled polyol level (30 pbw). Foam emission data demonstrated that this optimized foam formulation also led to an important reduction of volatile organic compounds. The results open the way for further optimization studies in low-density flexible polyurethane foam formulations, to increase the reutilization of the polyurethane waste and reduce the amount of petroleum-based raw materials.

Synthesis of activated carbon foams with high specific surface area using polyurethane elastomer templates for effective removal of methylene blue

Abstract Carbon foams have gained significant attention due to their tuneable properties that enable a wide range of applications including catalysis, energy storage and wastewater treatment. Novel synthesis pathways enable novel applications via yielding complex, hierarchical material structure. In this work, activated carbon foams (ACFs) were produced from waste polyurethane elastomer templates using different synthesis pathways, including a novel one-step method. Uniquely, the produced foams exhibited complex structure and contained carbon microspheres. The ACFs were synthesized by impregnating the elastomers in an acidified sucrose solution followed by direct activation using CO2 at 1000 ℃. Different pyrolysis and activation conditions were investigated. The ACFs were characterized by a high specific surface area (SBET) of 2172 m2/g and an enhanced pore volume of 1.08 cm3/g. Computer tomography and morphological studies revealed an inhomogeneous porous structure and the presence of numerous carbon spheres of varying sizes embedded in the porous network of the three-dimensional carbon foam. X-ray diffraction (XRD) and Raman spectroscopy indicated that the obtained carbon foam was amorphous and of turbostratic structure. Moreover, the activation process enhanced the surface of the carbon foam, making it more hydrophilic via altering pore size distribution and introducing oxygen functional groups. In equilibrium, the adsorption of methylene blue on ACF followed the Langmuir isotherm model with a maximum adsorption capacity of 592 mg/g. Based on these results, the produced ACFs have potential applications as adsorbents, catalyst support and electrode material in energy storage systems.

Development of Highly Efficient, Glassy Carbon Foam Supported, Palladium Catalysts for Hydrogenation of Nitrobenzene.

Glassy carbon foam (GCF) catalyst supports were synthesized from waste polyurethane elastomers by impregnating them in sucrose solution followed by pyrolysis and activation (AC) using N2 and CO2 gas. The palladium nanoparticles were formed from Pd(NO3)2. The formed palladium nanoparticles are highly dispersive because the mean diameters are 8.0 ± 4.3 (Pd/GCF), 7.6 ± 4.2 (Pd/GCF-AC1) and 4.4 ± 1.6 nm (Pd/GCF-AC2). Oxidative post-treatment by CO2 of the supports resulted in the formation of hydroxyl groups on the GCF surfaces, leading to a decrease in zeta potential. The decreased zeta potential increased the wettability of the GCF supports. This, and the interactions between –OH groups and Pd ions, decreased the particle size of palladium. The catalysts were tested in the hydrogenation of nitrobenzene. The non-treated, glassy-carbon-supported catalyst (Pd/GCF) resulted in a 99.2% aniline yield at 293 K and 50 bar hydrogen pressure, but the reaction was slightly slower than other catalysts. The catalysts on the post-treated (activated) supports showed higher catalytic activity and the rate of hydrogenation was higher. The maximum attained aniline selectivities were 99.0% (Pd/GCF-AC1) at 293 K and 98.0% (Pd/GCF-AC2) at 323 K.

Catalytic Hydrogenation of Polyurethanes to Base Chemicals: From Model Systems to Commercial and End-of-Life Polyurethane Materials.

Polyurethane (PU) is a highly valued polymer prepared from diisocyanates and polyols, and it is used in everyday products, such as shoe soles, mattresses, and insulation materials, but also for the construction of sophisticated parts of medical devices, wind turbine blades, aircrafts, and spacecrafts, to name a few. As PU is most commonly used as a thermoset polymer composed of cross-linked structures, its recycling is complicated and inefficient, leading to increasing PU waste accumulating every year. Catalytic hydrogenation represents an atom-efficient means for the deconstruction of polyurethanes, but so far the identification of an efficient catalyst for the disassembly of real-life and end-of-life PU samples has not been demonstrated. In this work, we reveal that a commercially available catalyst, Ir-iPrMACHO, under 30 bar H2 and 150–180 °C, is a general catalyst for the effective hydrogenation of the four cornerstones of PU: flexible solid, flexible foamed, rigid solid, and rigid foamed, leading to the isolation of aromatic amines and a polyol fraction. For the first time, a variety of commercial PU materials, including examples of foams, inline skating wheels, shoe soles, and insulation materials, has been deconstructed into the two fractions. Most desirable, our reaction conditions include the use of isopropyl alcohol as a representative of a green solvent. It is speculated that a partial glycolysis at the surface of the PU particles is taking place in this solvent and reaction temperatures in the presence of catalytic amounts of base. As such a more efficient hydrogenation of the solubilized PU fragments in isopropyl alcohol becomes possible. As the isolated anilines are precursors to the original isocyanate building blocks, and methods for their conversion are well-known, the work reported in this paper provides a realistic indication of a potential circular plastic economy solution for PU. Preliminary experiments were also undertaken applying Mn-iPrMACHO for the deconstruction of a commercial flexible PU foam. Although successful, more forcing conditions were required than those when applying Ir-iPrMACHO.

Effect of different catalysts on recovery and reuse of waste polyurethane rigid foam

The sharp increase of waste polyurethane rigid foam has caused great harm to the natural environment. Ethylene glycol (EG) and propylene glycol (PG) was the alcoholysis agents, and KOH and Zn3[Co(CN)6]2(DMC) were used as catalysts for alcoholysis of waste polyurethane rigid foam. Regenerated polyols were prepared. The effects of different catalysts on the infrared, viscosity and hydroxyl content of alcoholysis products were discussed. Regenerated polyurethane rigid foam was prepared from alcoholysis products and analyzed by compression strength, thermal conductivity, water absorption, scanning and thermogravimetry. The effects of different catalysts on the recycling of waste polyurethane rigid foam were studied. The experimental results show that DMC catalyst is more effective than KOH catalyst under the same conditions.The alcoholysis product of DMC system has lower viscosity and higher hydroxyl content, which is more suitable for the preparation of regenerated polyurethane rigid foam., The compressive strength of the prepared regenerated polyurethane rigid foam is 254 Kpa, and the thermal conductivity is 0.0213 W m−1·K−1 when the amount of DMC added is 0.04%. Meanwhile, the regenerated polyurethane rigid foam has good hydrophobicity, excellent heat preservation performance, complete cell morphology and good thermal stability. It can replace the traditional polyols to prepare the regenerated polyurethane material which meets the national standard ‘rigid polyurethane foam for building insulation’ (GB/ T21558-2005).

Recycling of polyurethane wastes using different carboxylic acids via acidolysis to produce wood adhesives

AbstractThis study aims to provide further understanding on the depolymerization of polyurethanes (PU) via acidolysis. Therefore, polyurethane foams scraps are chemical recycled using different dicarboxylic acids, namely succinic and phthalic dicarboxylic acids, being the reaction products identified using Fourier‐transform infrared spectroscopy, nuclear magnetic resonance and gel permeation chromatography. The results obtained show that succinic acid has higher efficiency as cleavage agent, as a result, the succinic acid ensuing recovered polyol (RP) presents higher hydroxyl value and lower viscosity. Additionally, from the oxidative‐induction time measurements, it is observed that the RP is considerably more thermally stable, than the petroleum‐based polyol, due to the higher content of aromatic moieties. Afterwards, the RP is used as substitute of petroleum‐based polyol in the production of polyurethane adhesives (PUA) and compared with conventional polyol based PUA. Due to the higher content of aromatic moieties, higher bonding strength is achieved using the RP. Overall, further understanding on the acidolysis is obtained, proving the suitability of this method for the recycling of PU.