As interest in sustainable products continues to increase, so does the demand for materials made from renewable energy polyurethane.
Natural oil polyols (NOP) and sugars have long been raw materials for alkyd coatings and are now used to make polyurethane (PU) foam for automotive applications, while thermoplastic polyurethane (TPU) made from bio-based polyester polyols are available For sporting goods, especially shoes and medical equipment.
The commercialization of a wider range of high-performance, cost-competitive bio-based polyols from established polyol manufacturers and new companies focused on the production of renewable materials will drive further growth in the sustainable polyurethane segment.
Lightweight cars provide a key role for PU
Bio-based polyols can directly replace existing polyols because they have similar structures and properties, but are derived from renewable raw materials instead of petrochemical products, and alternatives to existing polyols with slightly different structures and properties, or Completely different new compounds with new functions and performance characteristics.
In addition to polyols based on natural oils (soy, castor and palm) and sugars (sorbitol and sucrose), there are now bio-based glycols 1,3-propanediol (PDO) and 1,4-butanediol ( BDO) and diacids, including succinic acid and larger acids, such as Elevance’s inherent C18 octadecanedioic acid (ODDA), and those produced using carbon dioxide (CO2), including polypropylene , Polyethylene, polyether polycarbonate and polycyclohexene carbonate (PPC, PEC, PPP and PCHC) polyols, said Doris de Guzman, senior consultant for biomaterials and intermediates of Tecnon OrbiChem.
Reverdia President Marcel Lubben pointed out that other methods include manufacturing polyols based on chemically recycled polymers such as polyethylene terephthalate (PET), and optimizing production to reduce energy consumption, material usage and emissions from traditional processes.
Since the properties of PUs are closely related to the properties of the polyols from which they are produced, it is vital that bio-based polyols provide the performance required for a given PU application.
"In addition to having measurable advantages in terms of sustainability, in order to promote market acceptance, green polyols must also provide the same or better performance, with no or only small changes in handling and processing," Novomer Chief Commercial Officer Peter Shepard said.
de Guzman said the production process must also have similar or improved characteristics in terms of energy and water consumption and waste and emissions generation, and the product quality must be the same as or better than traditional polyols. In addition, many green polyol customers now prefer renewable materials that do not use food as raw materials.
In addition, Shepard stated that the price of bio-based polyols should be similar to equivalent traditional products, especially for direct substitutes, because trying to obtain a "green premium" severely limits market adoption. On the other hand, Lubben believes that improved performance combined with the advantages of renewable ingredients and reduced carbon footprint may result in a premium.
"Although many manufacturers claim that the cost of biopolyols must be competitive compared with petroleum polyols, at present, bio-based polyols, and even natural oil polyols, still have a premium that can be passed along the value-added chain," Degu Ziman said.
“The amount of renewable ingredients in finished polyurethane products is usually small enough to justify the premium in exchange for marketing the product as green or renewable ingredients that have the same characteristics as the PU made from petroleum-based polyols,” she explained. .
Trainers can benefit from bio-based PU
Celene DiFrancia, Senior Vice President of Engineering Polymers and Coatings, Elevance Renewable Sciences, said: "The focus of the broader market today is to find solutions that combine transformative performance with improved product sustainability. This expectation applies to all major categories of polyols. .
"To be successful, the technology must provide value for the application, and the application can have multiple definitions. Alternative solutions may be a green option for NOPs, while performance solutions are value-added and on an equal basis Competing with all options. In addition, improving product quality and consistency through a better overall manufacturing process is also valuable," she observes.
NOP continues to account for the largest proportion of sustainable polyols on the market. "There are a large number of vegetable oil raw materials available, and the possibilities for producing polyols from vegetable oil are almost limitless, and the characteristics of NOP may vary greatly depending on the source of the oil used," said De Guzman.
DuPont produces PDO through corn fermentation and cooperates with manufacturers of biosuccinic acid and other bio-based chemicals to produce 100% bio-based polyester polyols. Genomatica is the first major commercial supplier to produce bio-BDO through the fermentation of crop-derived sugars, but other companies are also producing or approaching commercial processes, including BASF through joint ventures with Purac, Myriant, BioAmber and Metabolix.
BASF plans to produce biosuccinic acid, and DSM and Roquette’s joint ventures BioAmber and Reverdia have commercial biosuccinic acid products on the market. BioAmber claims that 100% renewable polyester polyols made from biosuccinic acid, such as polypropylene succinate (PPS) and polybutylene succinate (PBS), provide performance, sustainability and economy Unique combination.
Lubben said that Reverdia's Biosuccinium is a potential substitute for traditional petroleum-based diacids (such as adipic acid in polyester polyols) for the production of PU with enhanced mechanical and chemical properties, such as TPU and microcellular polyurethane.
"We have seen strong interest in biosuccinic acid in the fields of sporting goods, automobiles, coatings and adhesives, and Reverdia has participated in multiple application development projects with partners," he said. Lubben added that Biosuccinium has been proven to improve the chemical resistance of TPU and the abrasion resistance of microporous PU, but it is a nearly disposable product, so these PUs can be produced using a process similar to the corresponding conventional products. Since the end of 2013, Reverdia has been producing commercial supplies of Biosuccinium at its Cassano Spinola plant in Italy.
Renewable Sciences launched its Inherent C18 Diacid in September 2013. According to DiFrancia, polyester polyols made of ODDA solve the industry challenges of traditional TPU, including moisture absorption, chemical resistance, product transparency, electrical properties and adhesion of different materials.
"The inherent C18 diacid enables the PU market to expand the range of products, such as ski boots, automotive fuel pipes, roller bearings, medical pipes and sports equipment," she said. The diacid is produced by a 180,000 ton/year joint venture biorefinery plant between Elevance and Wilmar International in Greswick, Indonesia, using a proprietary metathesis chemical reaction. "Compared with typical petrochemical technologies, low-pressure, low-temperature processes consume significantly less energy and reduce greenhouse gas (GHG) emissions by 50%," DiFrancia said.
It takes longer for these types of polyols to be approved for commercial use in many applications. Since they are not direct substitutes, their performance must be proven. de Guzman said that regulatory requirements in these markets are also very strict, and obtaining the necessary approvals may delay product launches.
On the other hand, regulation may actually promote the use of polyols made from CO2 in construction applications, which is also a much cheaper raw material compared to the raw materials used to produce petroleum and other bio-based polyols. Manufacturers of CO2-based polyols also report that in certain applications, the final PU product has better performance/quality.
Novomer launched Converge polypropylene carbonate polyol for PU in May 2014. These products are produced through the polymerization of waste carbon dioxide and epoxides in a commercial-scale toll facility of tens of thousands of tons in Houston, Texas.
"The unique polycarbonate skeleton improves the strength and durability of polyurethane, produces foam with higher tensile and tear strength, and increases load-bearing capacity; bonding with improved adhesion, cohesive strength and weather resistance Agents and coatings; and elastomers with higher tensile and flexural strength," Shepard said.
In addition, the heat content (heat of combustion) of PU produced using Converge polyols is 40-50% lower than that of traditional polyether, polyester, and polycarbonate polyols, which is especially important in PU applications that must meet strict flammability requirements important.
At the same time, according to Karsten Malsch, vice president of PU, Bayer MaterialScience’s Dream Production project resulted in a manufacturing process for producing polyether carbonate polyols from carbon dioxide and propylene oxide. "We have seen a great improvement in the sustainability of fossil fuel resource depletion and greenhouse gas emissions because they are 15-20% lower than traditional polyols."
These polyols are specifically designed for the production of flexible PU foam, and the mattress is the first consumer product. The research phase of the Dream Production project was completed in 2013, and BMS plans to launch the first batch of CO2-based polyols to the market in 2016. The company is in trial production and will continue to support this effort to establish processes and products as industry standards.
"The development of bio-based isocyanates has also received a lot of attention, because if it is achieved, then 100% bio-based polyurethane can be obtained," observed De Guzman. The development of isocyanate-free PU materials is also under study as a way to avoid the toxicity problems usually associated with isocyanates.
Keep abreast of market fluctuations and provide information for your business strategy through pricing, data, news and analysis.
Historical, current, and forecast prices, as well as comments, can help you track price fluctuations and understand price drivers and trends. Make quick and confident decisions and determine the best time to buy or sell. Talk to ICIS
An end-to-end perspective of the global petrochemical supply chain. It provides data on import and export volume, factory capacity, production, consumption, and chemical trade flows. Request a free demo
Our 24/7 news report keeps you informed of key events in the market-including market trends, analysis, data, etc. Talk to ICIS
Sign up for our ICIS newsletter to receive the latest market developments, headlines, and insights into chemical price changes and their impact on the market. Receive free market updates
Easy access to a series of ICIS chemical resources:
ICIS is part of the LexisNexis® Risk Solutions Group brand portfolio.
Copyright © 2021 LexisNexis Risk Solutions Group