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Chemical PU recycling

For some companies in the polyurethane processing trade their waste loads mean an enormous cost load (e.g. disposal fees), not to forget environmental damage caused by immense quantity of scrap on our landfills. There exist several ways to reuse this type of material through mechanical recycling - but there is a loss of mechanical properties in the final product that is present. ECOPUR stepped away from a traditional mechanical way of recycling microcellular foam and integral skin semi-rigid foam. Through a unique chemical process, without loosing mechanical properties of the material, we recycle the industrial PU and return it as a Co-system to the original formulated polyol. We provide our customer with the Know-how and the equipment to be able to do it as in-house solution.

Until now these polioles recycled starting off of polyurethane foam successful has been used in the following applications:

Microcellular and integral skin foam, like shoe soles or steering wheels

Flexible foam applications, like acoustic foam.

Elastomer coatings adhere for flooring or bed liners

Adhesive for the production of rebounded foams

These polyols maintain hydroxyl numbers between 50-80 mgKOH/g and viscosities between 2000-4000cp

The Co-system is a recycling polyol formulated and adapted to the specific application of each customer. It is mixable in different percentages with the polyol used and depending on that is the economical benefit of the reuse. This basic calculation below demonstrates the financial advantage of our process in work:

1.- Accumulated material cost:0.72usd/kg Recycled Polyol (base reagent, additive packages, PUR waste)

2.- Operating cost:                0.20usd/kg Recycled Polyol (Personal, energy, rent)

3.- Total cost for recycled       0.92usd/kg

Polyol blend:

Factors taken in consideration:      

1.   Total yearly PU scrap rising

2.   Nominal plant capacity

3.   Investment and financing for 2 years with nominal 6% of interest

4.   Price difference between the new Polyol blend and recycled Polyol blend

5.   Produced amount of Recycled Polyol

6.   Yearly profit without financing and tax considerations

*There are several other factors with input on the return on investment. As example; a fairly high market value of the PUR scrap will result in an extended return of investment time, whereas saved disposal costs would have a positive influence.