Chemical Recycling of PEF into Polyols for PUR/PIR Hard Foams
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Solution Overview
Problem
Current recycling methods for polyethylene furanoate (PEF) are limited, primarily focusing on material recycling which results in low-quality regranulates unsuitable for high-grade products like PUR/PIR hard foams, and lack chemical recycling solutions, leading to inefficiencies and high costs in processing PEF waste streams.
Innovation Solution
A method for chemical recycling of PEF that converts PEF polymer into low-molecular compounds through solvolysis, specifically glycolysis, followed by transesterification to produce recycling polyols suitable for manufacturing high-grade PUR/PIR hard foams, allowing for the closed-loop recycling of PEF and reducing the need for petroleum-based materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If material recycling of PEF is performed to produce regranulates, then PEF waste can be recovered and reused, but the regranulates have low quality and cannot be used for high-grade products like PUR/PIR hard foams
Solution Approach 1:
The patent applies chemical transformation parameters to convert PEF polymer into different molecular forms. Through glycolysis and transesterification reactions, the polymer is broken down and reformed into polyols with specific molecular weights and functional groups, transforming the material from a recyclable plastic into a chemical feedstock suitable for high-grade foam production
Solution Approach 2:
The patent recovers valuable chemical components from PEF waste through systematic chemical processing. Instead of simply reprocessing the plastic mechanically, the method discards the original polymer structure and recovers monomeric and oligomeric compounds that can be re-polymerized or directly used as polyols, achieving both high recycling rates and high product quality
2Adaptability or versatility
If chemical recycling methods are developed for PEF, then high-grade products like PUR/PIR hard foams can be produced from PEF waste, but no chemical recycling methods are currently known for PEF
Solution Approach 1:
The patent makes PEF waste applicable to multiple high-grade applications through chemical recycling. The produced polyols can be used not only for PUR/PIR hard foams but potentially for other polyurethane products, demonstrating the versatility of the chemical recycling approach in transforming a single waste stream into multiple valuable products
Solution Approach 2:
The patent replaces mechanical recycling methods with chemical recycling processes. Instead of physically reprocessing PEF through grinding and melting, the invention uses chemical reactions (glycolysis, transesterification) to break down and reconstruct the polymer, enabling the production of high-grade chemical products that mechanical methods cannot achieve
3Manufacturing precision
If PET regranulates are processed to remove impurities using hot sodium hydroxide solution, then purity requirements for foodstuffs industry can be met, but the process is expensive and rarely economically viable
Solution Approach 1:
The patent extracts and removes impurities from PEF waste through chemical reactions during glycolysis and transesterification. The chemical process selectively breaks down the polymer chains and separates contaminants, allowing impurity removal as part of the value-added transformation process rather than as a separate costly purification step
Solution Approach 2:
The patent uses chemical intermediates (glycols, catalysts, solvents) to mediate the transformation of PEF waste into high-purity polyols. These intermediates facilitate the chemical reactions that simultaneously degrade the polymer structure and remove impurities, achieving purification as an integrated part of the chemical recycling process
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Facilitates the production of high-quality PUR/PIR hard foams with improved sustainability and properties comparable to those made from traditional petroleum-based materials, while minimizing the use of finite resources and reducing greenhouse gas emissions.
Implementation Method 1
conversion of the PEF polymer into the at least one low-molecular compound takes place by means of solvolysis
Implementation Method 2
conversion of the PEF polymer into the at least one low-molecular compound takes place by means of solvolysis, in particular by means of glycolysis
Implementation Method 3
The low-molecular compound is converted into a recycling polyol by transesterification in the presence of at least one polyhydric alcohol
Data Source
AI summary
A method for the chemical recycling of polyethylene furanoate (PEF), wherein a PEF polymer is converted into at least one low-molecular compound.