National projects
The project “Thermal insulation materials based on alternative raw materials for modular building applications” (PB_Evotherm) is supported by a targeted grant from the President of the Lukasiewicz Center.
Total value of the project: 2 277 610,38 PLN
Funding: 2 049 849,34 PLN
The project concerns the development of a method and production of modern insulation materials in the form of flame-retardant polyurethane foams based on renewable or recycled raw materials. The material developed will find application in modular construction for thermal insulation of walls and roofs of newly constructed buildings. The subjects of the project include new, economically sustainable technologies for modular construction involving the diversification of the raw material base for polyurethane production. A key element of the project is lightweight thermal insulation based on polyurethane foams, which, among the available insulation materials, i.e. expanded polystyrene (EPS), mineral wool or cellulose, show the best thermal and sound insulation properties. Unfortunately, among the materials listed, they have the highest production cost and are not environmentally friendly. The objective of the Project is to develop 2 types of insulation materials: rigid foams for use as an insulating layer on walls and façades, and a spray formulation for insulating roofs or “re-insulating” old roof coverings with the elimination of thermal bridges. The selection of flame retardants to meet the flammability requirements of the materials under development is also a key element of the project. For the manufacture of rigid insulation foams, it is planned to use at least 30% of the polyether component derived from the depolymerisation of waste materials: pipe and duct thermal insulation and waste flexible foams from the furniture industry. This type of waste is difficult to treat by mechanical and chemical means. It is distinguished by very low density, which requires compression of the material and specialised shredding equipment. Currently, waste from the furniture industry is mechanically shredded and added during the foaming process, however, contaminated or dark-coloured materials cannot be added to upholstery foams. Therefore, chemical depolymerisation using alcohols with two hydroxyl groups, purification of the liquid depolymerisation product and development of formulations to match the quality of the resulting recycled polyol will be carried out to manage the wide range of polyurethane waste. One element of the project will also be the development of a universal method for the mechanical shredding of polyurethane waste, without the need to separate moulded, flexible and rigid plastics. The foams will be shredded to a grain size of 5-10mm, vacuum compressed and then transferred to the glycolysis process for chemical decomposition. The present results indicate that glycolysis of PUR plastics yields a product with a dark colour, a kinematic viscosity in the range of 200-1500 cSt. and a hydroxyl number in the range of 400-600 mg KOH/g, which is in line with the requirements for the polyether component used in rigid polyurethane foams. According to the art, it will be necessary to use polyethers with a hydroxyl number of approximately 50 mg KOH/g, and additives such as catalysts and surfactants to regulate the pore structure. A part project will also be the development of a two-component insulation formulation designed to be sprayed on site or in existing buildings. This type of insulation is currently in high demand, as polyurethane is distinguished by very good penetration properties and very high adhesion to the substrate which allows its application in any location, even difficult to access, ensuring tight thermal insulation and the elimination of thermal bridges. The aim of the project will be to develop bioplastics based on waste glycerine from the production of biodiesel and post-frying vegetable oils, which can replace the polyether component after appropriate modification. Key parameters of the foams obtained with the above polyols will be to maintain high adhesion to the substrate and to ensure the assumed thermal insulation thanks to their appropriate structure. An important element of this project is also the production of phosphate flame retardants, which will form a component of the thermal insulation materials obtained. Their role in the final product is extremely important, as it involves improving the fire performance of the resulting product, while maintaining the performance of the resulting foams. These phosphor antipirens will be chemically embedded in the structure of the insulating material, so that they will not become fugitive during long-term use. The final stage of the project will be the issuing of a National Technical Assessment for the developed foams, which will allow the innovative thermal insulation material to be marketed in the domestic market.
