Evonik, Toyotsu Chemiplas and Sanyo Chemical will evaluate a recycling model for recovering polyols and amines from post-consumer polyurethane foam and production scrap.
Evonik has partnered with Toyotsu Chemiplas and Sanyo Chemical Industries to develop a chemical recycling model for polyurethane foam in Japan.
The companies intend to collect post-consumer flexible foam and post-industrial production scrap and convert it into high-purity recycled polyols and amines. These materials would then be used as raw materials in new polyurethane products.
Toyotsu Chemiplas will coordinate the initiative and contribute its collection network and logistics expertise. Sanyo Chemical will provide its knowledge of polyol development and process technology, while Evonik will supply its proprietary hydrolysis-based recycling process and technical expertise.
“This collaboration with our Japanese partners represents an important step toward developing a practical recycling model for polyurethane foam in Japan,” said Martin Trocha, head of Comfort & Adhesives in Evonik’s Interface & Polyurethane Additives business line.
Flexible polyurethane foam is widely used in automotive seating, mattresses and furniture. According to Evonik, discarded foam is frequently incinerated or sent to landfill, while conventional mechanical recycling generally limits the recovered material to lower-value applications.
Evonik’s chemical recycling process breaks polyurethane foam down into polyols and amines. The company said the process produces recycled polyols with sufficient purity and consistency to serve as a drop-in raw material for foam manufacturers.
New flexible foam has already been produced using 100% recycled polyol obtained through the process.
The three partners will evaluate the complete proposed value chain, including collection, sorting, chemical recycling, recycled-polyol production and the manufacture of new polyurethane products. The work will also include product-quality assessments.
Evonik will update its existing life-cycle assessment to reflect the proposed Japanese collection and manufacturing system. The company said its hydrolysis process could significantly reduce the carbon footprint of polyol production compared with virgin raw materials.
The partners’ objective is to commercialize the technology and establish a scalable polyurethane foam recycling model in Japan.
Source: pu-magazine.com
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