From Bioresources to Thermal Insulation Materials: Synthesis and Properties of Two-Component Open-Cell Spray Polyurethane Foams Based on Bio-Polyols from Used Cooking Oil
Open-cell spray polyurethane foams are widely used as highly efficient thermal insulation materials with vapor permeability and soundproofing properties. Unfortunately, for the production of commercial foams, mainly non-renewable petrochemical raw materials are used. The aim of this study was to det...
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| Format: | Article |
| Language: | English |
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MDPI AG
2023-09-01
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| Series: | Materials |
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| Online Access: | https://www.mdpi.com/1996-1944/16/18/6139 |
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| author | Krzysztof Polaczek Maria Kurańska Elżbieta Malewska Małgorzata Czerwicka-Pach Aleksander Prociak |
| author_facet | Krzysztof Polaczek Maria Kurańska Elżbieta Malewska Małgorzata Czerwicka-Pach Aleksander Prociak |
| author_sort | Krzysztof Polaczek |
| collection | DOAJ |
| description | Open-cell spray polyurethane foams are widely used as highly efficient thermal insulation materials with vapor permeability and soundproofing properties. Unfortunately, for the production of commercial foams, mainly non-renewable petrochemical raw materials are used. The aim of this study was to determine the possibility of completely replacing petrochemical polyols (the main raw material used in the synthesis of polyurethanes, alongside isocyanates) with bio-polyols obtained from used cooking oils, classified as waste materials. The research consisted of three stages: the synthesis of bio-polyols, the development of polyurethane foam systems under laboratory conditions, and the testing of developed polyurethane spray systems under industrial conditions. The synthesis of the bio-polyols was carried out by using two different methods: a one-step transesterification process using triethanolamine and a two-step process of epoxidation and opening oxirane rings with diethylene glycol. The obtained bio-polyols were analyzed using gel chromatography and nuclear magnetic resonance spectroscopy. The developed polyurethane foam formulations included two types of fire retardants: halogenated tris(1-chloro-2-propyl) phosphate (TCPP) and halogen-free triethyl phosphate (TEP). In the formulations of polyurethane systems, reactive amine catalysts were employed, which become incorporated into the polymer matrix during foaming, significantly reducing their emission after application. The foams were manufactured on both a laboratory and industrial scale using high-pressure spray machines under conditions recommended by commercial system manufacturers: spray pressure 80–100 bar, component temperature 45–52 °C, and component volumetric ratio 1:1. The open-cell foams had apparent densities 14–21.5 kg/m<sup>3</sup>, thermal conductivity coefficients 35–38 mW/m∙K, closed-cell contents <5%, water vapor diffusion resistance factors (μ) <6, and limiting oxygen indexes 21.3–21.5%. The properties of the obtained foams were comparable to commercial materials. The developed polyurethane spray systems can be used as thermal insulation materials for insulating interior walls, attics, and ceilings. |
| first_indexed | 2024-03-10T22:31:23Z |
| format | Article |
| id | doaj.art-bd9862786d7046ea92656607502b2b09 |
| institution | Directory Open Access Journal |
| issn | 1996-1944 |
| language | English |
| last_indexed | 2024-03-10T22:31:23Z |
| publishDate | 2023-09-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Materials |
| spelling | doaj.art-bd9862786d7046ea92656607502b2b092023-11-19T11:43:24ZengMDPI AGMaterials1996-19442023-09-011618613910.3390/ma16186139From Bioresources to Thermal Insulation Materials: Synthesis and Properties of Two-Component Open-Cell Spray Polyurethane Foams Based on Bio-Polyols from Used Cooking OilKrzysztof Polaczek0Maria Kurańska1Elżbieta Malewska2Małgorzata Czerwicka-Pach3Aleksander Prociak4Department of Chemistry and Technology of Polymers, Cracow University of Technology, Warszawska 24, 31-155 Cracow, PolandDepartment of Chemistry and Technology of Polymers, Cracow University of Technology, Warszawska 24, 31-155 Cracow, PolandDepartment of Chemistry and Technology of Polymers, Cracow University of Technology, Warszawska 24, 31-155 Cracow, PolandFaculty of Chemistry, University of Gdansk, Wita Stwosza 63, 80-308 Gdansk, PolandDepartment of Chemistry and Technology of Polymers, Cracow University of Technology, Warszawska 24, 31-155 Cracow, PolandOpen-cell spray polyurethane foams are widely used as highly efficient thermal insulation materials with vapor permeability and soundproofing properties. Unfortunately, for the production of commercial foams, mainly non-renewable petrochemical raw materials are used. The aim of this study was to determine the possibility of completely replacing petrochemical polyols (the main raw material used in the synthesis of polyurethanes, alongside isocyanates) with bio-polyols obtained from used cooking oils, classified as waste materials. The research consisted of three stages: the synthesis of bio-polyols, the development of polyurethane foam systems under laboratory conditions, and the testing of developed polyurethane spray systems under industrial conditions. The synthesis of the bio-polyols was carried out by using two different methods: a one-step transesterification process using triethanolamine and a two-step process of epoxidation and opening oxirane rings with diethylene glycol. The obtained bio-polyols were analyzed using gel chromatography and nuclear magnetic resonance spectroscopy. The developed polyurethane foam formulations included two types of fire retardants: halogenated tris(1-chloro-2-propyl) phosphate (TCPP) and halogen-free triethyl phosphate (TEP). In the formulations of polyurethane systems, reactive amine catalysts were employed, which become incorporated into the polymer matrix during foaming, significantly reducing their emission after application. The foams were manufactured on both a laboratory and industrial scale using high-pressure spray machines under conditions recommended by commercial system manufacturers: spray pressure 80–100 bar, component temperature 45–52 °C, and component volumetric ratio 1:1. The open-cell foams had apparent densities 14–21.5 kg/m<sup>3</sup>, thermal conductivity coefficients 35–38 mW/m∙K, closed-cell contents <5%, water vapor diffusion resistance factors (μ) <6, and limiting oxygen indexes 21.3–21.5%. The properties of the obtained foams were comparable to commercial materials. The developed polyurethane spray systems can be used as thermal insulation materials for insulating interior walls, attics, and ceilings.https://www.mdpi.com/1996-1944/16/18/6139spray polyurethane foamopen-cell foambio-polyolmunicipal wasteused cooking oilthermal insulation |
| spellingShingle | Krzysztof Polaczek Maria Kurańska Elżbieta Malewska Małgorzata Czerwicka-Pach Aleksander Prociak From Bioresources to Thermal Insulation Materials: Synthesis and Properties of Two-Component Open-Cell Spray Polyurethane Foams Based on Bio-Polyols from Used Cooking Oil Materials spray polyurethane foam open-cell foam bio-polyol municipal waste used cooking oil thermal insulation |
| title | From Bioresources to Thermal Insulation Materials: Synthesis and Properties of Two-Component Open-Cell Spray Polyurethane Foams Based on Bio-Polyols from Used Cooking Oil |
| title_full | From Bioresources to Thermal Insulation Materials: Synthesis and Properties of Two-Component Open-Cell Spray Polyurethane Foams Based on Bio-Polyols from Used Cooking Oil |
| title_fullStr | From Bioresources to Thermal Insulation Materials: Synthesis and Properties of Two-Component Open-Cell Spray Polyurethane Foams Based on Bio-Polyols from Used Cooking Oil |
| title_full_unstemmed | From Bioresources to Thermal Insulation Materials: Synthesis and Properties of Two-Component Open-Cell Spray Polyurethane Foams Based on Bio-Polyols from Used Cooking Oil |
| title_short | From Bioresources to Thermal Insulation Materials: Synthesis and Properties of Two-Component Open-Cell Spray Polyurethane Foams Based on Bio-Polyols from Used Cooking Oil |
| title_sort | from bioresources to thermal insulation materials synthesis and properties of two component open cell spray polyurethane foams based on bio polyols from used cooking oil |
| topic | spray polyurethane foam open-cell foam bio-polyol municipal waste used cooking oil thermal insulation |
| url | https://www.mdpi.com/1996-1944/16/18/6139 |
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