Session: 2021-2025

Submitted to:

Submitted by:

Institute of Metallurgy and Materials Engineering

Faculty of Chemical and Materials Engineering
University of the Punjab Lahore
Life cycle of Polyurethane
Raw materials
Polyurethane foams are produced by reacting
• polyols and
• diisocyanates, both products often derived from crude oil. So the raw material for
polyurethane are as follow
• Petroleum: Petroleum is a fossil fuel that is used to produce a variety of products,
including polyurethane. Petroleum is used to make diisocyanates, which are one of the
two main components of polyurethane.
• Natural gas: Natural gas is another fossil fuel that is used to produce polyurethane.
Natural gas is used to make polyols, which are the other main component of
polyurethane.
Following are the green house gases evolved during the extraction of raw materials
• Methane (CH4): Methane is a potent greenhouse gas that is about 25 times more
effective at trapping heat than carbon dioxide. Methane is emitted during the extraction
of both petroleum and natural gas, is 0.5 to 1.5 metric tons of CO2 equivalent per ton of
polyurethane produced.
• Carbon dioxide (CO2): Carbon dioxide is a greenhouse gas that is released when fossil
fuels are burned. CO2 is emitted during the extraction of both petroleum and natural
gas, as well as during the processing and transportation of these fuels.
• Nitrous oxide (N2O): Nitrous oxide is a greenhouse gas that is about 300 times more
effective at trapping heat than carbon dioxide. N2O is emitted 0.05 to 0.1 metric tons of
CO2 equivalent per ton of polyurethane produceding the extraction of petroleum and
natural gas, primarily from the use of nitrogen fertilizers.
Polyurethane synthesis:
Polyurethane may be produced through different routes.38 The most important and more useful
method is through the reaction between a polyol (an alcohol that has two or more hydroxyl groups
within a molecule) and a diisocyanate. The main diisocynate used in the production of flexible
polyurethane foam is TDI (Toluene diisocyanate). Some foams, notably so-called visco-elastic
or memory foams, can also be made with MDI (Methylene diphenyl diisocyanate). Moulded
foams are more often made with MDI. Other suitable additives and catalysts may also be
incorporated for the Polyurethane synthesis.
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Following are the green house gases evolved during the synthesis and processing of
polyurethane :

• The production of chemicals like isocyanates and polyols can release CO2 (1 to 2 metric tons of CO2
equivalent per ton of polyurethane produced) , methane(0.1 to 0.2 metric tons of CO2 equivalent per ton
of polyurethane produced), and nitrous oxide (0.05 to 0.1 metric tons of CO2 equivalent per ton of
polyurethane produced) emissions due to energy-intensive processes and chemical reactions.During the
chemical reaction to produce polyurethane, emissions of volatile organic compounds (VOCs) can occur.
These VOCs can contribute to ground-level ozone formation, which is a potent greenhouse gas.And there
is a lot of heat required which evolved carbon dioxide gas 2 to 3 metric tons of CO2 equivalent per ton of
polyurethane produced.
Engineering Materials :
After the synthesis and processing of polyurethane we get different types of polyurethane
Which are as follow
 Rigid polyurethane foams
Rigid polyurethane foams represent one of the most commonly known versatile and energy saving
insulation materials. These foams can significantly reduce energy costs on the one hand and can make
commercial and residential appliances more comfortable and efficient on the other.
 Flexible polyurethane foams
Flexible polyurethane (FPU) foams comprise some block copolymers whose flexibility is based on the
phase separations between the soft and hard segments. Thus, PU foams may be modified through
deliberate control of the individual compositional ratios of these segments.
 Thermoplastic polyurethanes
Thermoplastic polyurethanes (TPUs) reveal vast combinations of both physical properties and processing
applications. Usually, they are flexible and elastic with good resistance to impact, abrasion and weather.
With TPUs, there is the possibility for colouring as well fabrication using a wide range of techniques.
 Polyurethane ionomers
The presence of ionic groups in the polyurethane backbone chain has many advantages, such as better
dispersion in polar solvents due to their enhanced hydrophobicity and improved thermal and mechanical
properties.
Product manufacturing and Design
We can get polyurethane products by the following manufacturing techniques
 Compression molding is a process in which liquid polyurethane is poured into a mold
and then placed under pressure in a heated press. The heat and pressure cause the
polyurethane to cure and solidify into the shape of the mold. Compression molding is a
common process for manufacturing polyurethane foam products, such as mattresses
and cushions.
 Injection molding is a process in which liquid polyurethane is injected into a mold
under high pressure. The mold is then cooled, causing the polyurethane to cure and
solidify into the shape of the mold. Injection molding is a common process for
manufacturing polyurethane parts with complex shapes, such as automotive
components and medical devices.
 Spin casting is a process in which liquid polyurethane is poured into a rotating mold.
The centrifugal force of the rotation causes the polyurethane to spread evenly across the
mold and cure into a thin, uniform layer. Spin casting is a common process for
manufacturing polyurethane films and coatings.
 Open cast molding is a process in which liquid polyurethane is poured into an open
mold. The mold is then placed in an oven and heated until the polyurethane cures and
 solidifies. Open cast molding is a common process for manufacturing polyurethane
foam products with large, open shapes, such as insulation panels and furniture
cushions.is a process in which liquid polyurethane is poured into an open mold. The
mold is then placed in an oven and heated until the polyurethane cures and solidifies.
Open cast molding is a common process for manufacturing polyurethane foam products
with large, open shapes, such as insulation panels and furniture cushions.
The amount of emissions released depends on the manufacturing process used.
Carbon dioxide: 0.5 to 1 metric tons of CO2 equivalent per ton of polyurethane product
produced
Nitrous oxide: 0.05 to 0.1 metric tons of CO2 equivalent per ton of polyurethane product
produced
Applications of Polyurethane products :
Following are the applications of polyurethane products
 Building and construction applications
 Automotive applications
 Marine applications
 Coating applications
 Medical applications
 Appliances, flooring and packaging applications
 Apparels applications
 Wood composite applications
The use phase of polyurethane products does not typically emit greenhouse gases. However,
some polyurethane products, such as foam insulation, can help to reduce energy consumption
and greenhouse gas emissions.
Waste of Polyurethane:
The disposal technology for polyurethane foam wastes is major consisted of three types,
landfill,
Incineration.
Landfill :
At first, people directly dealing with polyurethane wastes is landfill or burning. Because of
small
Polyurethane foam plastic pile-up density, landfill will be serious waste of land resources. At
the same time polyurethane wastes are very difficult to decomposition in the natural
conditions, and in some.European countries, such as the Netherlands, Sweden, Denmark,
Switzerland, they have promulgated Rules prohibiting the use of land disposal. Australia and
Germany, respectively in 2004 and 2005, issued The same provisions. New on the introduction
of the EU regulations also banned in high carbon content Material is land landfill.Therefore,
landfill treatment is not wise.

Incineration:
Incineration is one way through the burning waste polyurethane materials for heat recovery. 1
kg Polyurethane burning can produce calorific value of about 7000 kcal/kg, which can provide
heat Equivalent to the same weight of coal provides energy. Through burning, it can make the
wastes Volume reduced by 99 %. Polyurethane foam wastes can shattered into grain, as fuel
alternative coal, oil And natural gas recovery energy, and applied to cement or power. The
American polyurethane industry Federation conducted a series of experiments, and pointed
out that in municipal solid wastes adding waste Polyurethane elastomer and other components
of solid plastic wastes (the most proportion 20%), can Obviously improve its fuel calorific
value.

Landfilling: 0.5 to 1 metric tons Of CO2 equivalent per ton of polyurethane product
landfilled Incineration: 1 to 2 metric tons of CO2 equivalent per ton of polyurethane product
incinerated
Recycling:
There are two ways, physical recycling and chemical recycling, for recycling polyurethane
foam
wastes .Physical recycling is directly reusing polyurethane wastes without chemical treatment.
Chemical recycling is following the degradation principle. Polyurethane wastes will gradually
Depolymerize for original reactant or other oligomer and even small molecule organic
compound.

Physical recycling
Physical recycling method is crushing polyurethane foam wastes, only changing physical form.
The Smashing solid particles have no reactive activity, but directly make new polyurethane
products as Recovery processing of raw materials. Through mixed with adhesives, they can
make all kinds of mold Products by the compression molding method. This is currently the
most widely used method. The usage Of waste polyurethane powder can be as high as 90%.
Physical recycling method is simple and convenient, with low cost, but there are still certain
technical Limitations at various physical recycling method processing. Performance of recovery
products is poor, Which only apply to some of the cheap products, and limit the market.

Chemical recycling
The polyurethane polymerization is reversible. Function groups such as carbamic acid ester
base, ester Bond and ether bond will gradually depolymerize for original reactant or other
oligomer and even small Molecule organic compound under the condition of chemical
reagents, catalysts and heating .Through the distillation equipment, pure raw material
monomer polyol and isocyanate, amine can be Obtained. Chemical recycling is following the
degradation principle. High molecular weight Polyurethane depolymerized for a reaction
activity of low molecular weight oligomers at different Degradation reagents. Oligomers and
other compound reacted to prepare new polyurethane products.According to the different
degradation reagents, the physicochemical properties and function of
Degradation products are different. This paper mainly introduces alcoholysis, hydrolysis, and
amine Solution and phosphate ester method.

When polyurethane recycle this process don’t produce any kind of green house
gases.However, it is important to note that the transportation of polyurethane to and from
recycling facilities does produce some carbon dioxide emissions. Additionally, the energy used
to power the recycling process also produces some carbon dioxide emissions. However, these
emissions are significantly lower than the emissions that would be produced if polyurethane
was not recycled and instead ended up in a landfill.