Polyurethane Foam Chemical Recycling: Fast Acidolysis with Maleic Acid and Full Recovery of Polyol,ACS Sustainable Chemistry & Engineering

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Polyurethane Foam Chemical Recycling: Fast Acidolysis with Maleic Acid and Full Recovery of Polyol
ACS Sustainable Chemistry & Engineering ( IF 7.1 ) Pub Date : 2024-03-07 , DOI: 10.1021/acssuschemeng.3c07040
Baoyuan Liu ₁ , Zach Westman ₂ , Kelsey Richardson ₂ , Dingyuan Lim ₁ , Alan L Stottlemyer ₃ , Thomas Farmer ₃ , Paul Gillis ₃ , Nasim Hooshyar ₄ , Vojtech Vlcek ₁ , Phillip Christopher ₂ , Mahdi M Abu-Omar _{1,

2}

Affiliation

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.

中文翻译：

聚氨酯泡沫化学品回收：马来酸快速酸解并完全回收多元醇

聚氨酯 (PU) 废物的化学回收对于取代原始多元醇生产的需求和实现可持续聚氨酯生产至关重要。目前，只有不到 20% 的 PU 废料通过重新粘合转化为比原始 PU 价值更低的产品，从而实现降级循环。聚氨酯废料的化学回收通常需要大量的溶剂输入和缓慢的反应速率。在此，我们报告了使用马来酸 (MA) 在 <200 °C 下快速（<10 分钟）且无溶剂地酸解基于甲苯二异氰酸酯 (TDI) 的软质聚氨酯泡沫 (PUF)，并回收了回收的多元醇 ( repolyol) 的分离产率为 95%。经过后处理（再多元醇酯的水解和分离）后，再多元醇表现出与原始多元醇相当的良好物理性能；其中包括 54.1 mg KOH/g OH 值和 624 cSt 粘度。总体而言，按重量计 80% 的输入 PUF 被分离成两个含有再多元醇和甲苯二胺 (TDA) 的干净馏分。最后，使用 MA 酸解可成功回收报废 (EOL) 床垫 PUF 废料，并高回收再多元醇。这项工作中通过模型和 EOL PUF 证明了 MA 的无溶剂快速酸解为可持续闭环 PU 生产提供了潜在途径。

更新日期：2024-03-07

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