WO2024036406A1 - Mousses de polyuréthane à base de lignine - Google Patents

Mousses de polyuréthane à base de lignine Download PDF

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Publication number
WO2024036406A1
WO2024036406A1 PCT/CA2023/051091 CA2023051091W WO2024036406A1 WO 2024036406 A1 WO2024036406 A1 WO 2024036406A1 CA 2023051091 W CA2023051091 W CA 2023051091W WO 2024036406 A1 WO2024036406 A1 WO 2024036406A1
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Prior art keywords
lignin
polyurethane foam
isocyanate
based polyurethane
catalyst
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PCT/CA2023/051091
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English (en)
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Adil MAZAR
Michael Paleologou
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Fpinnovations
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Publication of WO2024036406A1 publication Critical patent/WO2024036406A1/fr

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    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08H—DERIVATIVES OF NATURAL MACROMOLECULAR COMPOUNDS
    • C08H6/00—Macromolecular compounds derived from lignin, e.g. tannins, humic acids
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G18/00—Polymeric products of isocyanates or isothiocyanates
    • C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
    • C08G18/08—Processes
    • C08G18/16—Catalysts
    • C08G18/18—Catalysts containing secondary or tertiary amines or salts thereof
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G18/00—Polymeric products of isocyanates or isothiocyanates
    • C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
    • C08G18/28—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen characterised by the compounds used containing active hydrogen
    • C08G18/40—High-molecular-weight compounds
    • C08G18/64—Macromolecular compounds not provided for by groups C08G18/42 - C08G18/63
    • C08G18/6492—Lignin containing materials; Wood resins; Wood tars; Derivatives thereof
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G18/00—Polymeric products of isocyanates or isothiocyanates
    • C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
    • C08G18/70—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen characterised by the isocyanates or isothiocyanates used
    • C08G18/72—Polyisocyanates or polyisothiocyanates
    • C08G18/74—Polyisocyanates or polyisothiocyanates cyclic
    • C08G18/76—Polyisocyanates or polyisothiocyanates cyclic aromatic
    • C08G18/7657—Polyisocyanates or polyisothiocyanates cyclic aromatic containing two or more aromatic rings
    • C08G18/7664—Polyisocyanates or polyisothiocyanates cyclic aromatic containing two or more aromatic rings containing alkylene polyphenyl groups
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L97/00—Compositions of lignin-containing materials
    • C08L97/005—Lignin
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G2110/00—Foam properties
    • C08G2110/0041—Foam properties having specified density
    • C08G2110/005—< 50kg/m3
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G2110/00—Foam properties
    • C08G2110/0041—Foam properties having specified density
    • C08G2110/0058—≥50 and <150kg/m3
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G2110/00—Foam properties
    • C08G2110/0083—Foam properties prepared using water as the sole blowing agent

Definitions

  • This disclosure relates to the field of lignin-based polyurethane foams, and a process for making same.
  • Lignin is the second most abundant biological material on the planet after cellulose.
  • the lignin molecule provides opportunities for several high-value applications due to its high reactivity towards certain chemical reagents.
  • the presence of a significant number of functional groups in its structure such as phenolic, aliphatic and carboxylic hydroxyl groups as well as carbonyl groups and free aromatic ring positions provide opportunities for reacting lignin with different chemical reagents to produce the desired product(s). Because of its high content of hydroxyl groups (aliphatic, phenolic and carboxylic), lignin is considered a biopolyol.
  • lignin-based rigid polyurethane foams forthermal insulation purposes in the construction, refrigeration, automotive and other industries.
  • foam density and thermal conductivity it is important for the foam density and thermal conductivity to be relatively low, the closed cell content to be relatively high and for these foams to have reasonably good strength properties and water resistance.
  • the homogeneity issues are most likely due to the increasing viscosity of the petroleum-based polyol-lignin mixtures with increasing lignin content beyond the 20 wt. % substitution level, the limited solubility of lignin in petroleum-based polyols, the different reactivity of the various lignin hydroxyl groups towards isocyanate and the fact that a portion of these groups do not react at all because they are sterically hindered.
  • a lignin-based polyurethane foam comprising a polyurethane polymer having polymerized isocyanate and lignin, and wherein the lignin-based polyurethane foam comprises at least 30 % by weight of the lignin with respect to a total weight of the polyurethane foam.
  • the concentration of the lignin is at least 32 % by weight.
  • the polyurethane foam has a density of from 20 to 90 kg/m 3 .
  • the polyurethane foam has a thermal conductivity of from 17 to 33 mWm 1 K- 1 .
  • a maximum stress of the polyurethane foam is at least 100 kPa.
  • the polyurethane foam has less than 120 % water gain.
  • the polyurethane foam has a closed cell content of at least 90
  • the lignin-based polyurethane foam is a kraft lignin-based polyurethane foam.
  • the isocyanate is selected from hexamethylene diisocyanate (HDI), isophorone diisocyanate (IPDI), methylene bis(4-cyclohexylisocyanate) (H12MDI or Hydrogenated MDI), methylene diphenyl diisocyanate (MDI), toluene diisocyanate (TDI) or naphtalene diisocyanate (NDI).
  • HDI hexamethylene diisocyanate
  • IPDI isophorone diisocyanate
  • H12MDI or Hydrogenated MDI methylene bis(4-cyclohexylisocyanate)
  • MDI methylene diphenyl diisocyanate
  • TDI toluene diisocyanate
  • NDI naphtalene diisocyanate
  • a process for producing a lignin-based polyurethane foam comprising: dissolving or dispersing lignin in isocyanate to obtain an isocyanate-lignin solution or dispersion; adding to the isocyanate lignin solution or dispersion a mixture of lignopolyol, the mixture of lignopolyol comprising polypropylene glycol and oxypropylated lignin, to obtain a reaction mixture; and reacting the reaction mixture in the presence of a catalyst, a surfactant, and a foaming agent to obtain the lignin-based polyurethane foam.
  • the dissolving or dispersing the lignin in the isocyanate comprises dissolving or dispersing to a level close to a maximum solubility/dispersability of the lignin in the isocyanate.
  • the lignopolyol has a molecular weight of less than 2000 g/mol.
  • the lignopolyol has a viscosity at 25 °C, of less than 1 Pa.s.
  • the reaction mixture further comprises a blowing agent.
  • the blowing agent is water.
  • the kraft lignin is dried prior to dissolving in the isocyanate.
  • the kraft lignin is in acid form or in a base form.
  • the kraft lignin is in the base form.
  • the isocyanate lignin solution or dispersion further comprises at least one additive selected from a viscosity reducer, a surfactant, a flame retardant, a blowing agent or a combination thereof.
  • the catalyst is a metal catalyst or an amine catalyst.
  • the catalyst comprises dibutyltin dilaurate, stannous octoate, potassium octoate or a combination thereof.
  • the catalyst is selected from triethylenediamine (TEDA), enzyldimethylamine (BDMA), pentamethyl-diethylenetriamine (PMDETA), dimethylcyclohexylamine (DMCHA), dimethylethanolamine (DMEA), triethanolamine (TEA) or a combinations thereof.
  • the isocyanate lignin solution or dispersion comprises at least 20 wt. % of the lignin.
  • the lignopolyol mixture is obtained by oxypropylating lignin at weight ratio of from 15/85 to 30/70 of lignin to propylene oxide.
  • FIG. 1A is a bar graph showing the thermal conductivity as a function of the density for a traditional petroleum-based polyurethane foam (left side bar) compared to a kraft ligninbased polyurethane foam according to the present disclosure (right side bar).
  • FIG. 1B is a bar graph showing the maximal stress as a function of the density for a traditional petroleum-based polyurethane foam (left side bar) compared to a kraft lignin-based polyurethane foam according to the present disclosure (right side bar).
  • FIG. 1C is a bar graph showing the modulus as a function of the density for a traditional petroleum-based polyurethane foam (left side bar) compared to a kraft lignin-based polyurethane foam according to the present disclosure (right side bar).
  • FIG. 1D is a bar graph showing the water gain as a function of the density for a traditional petroleum-based polyurethane foam (left side bar) compared to a kraft lignin-based polyurethane foam according to the present disclosure (right side bar).
  • FIG. 2A is a scanning electron microscopy (SEM) image of a traditional petroleumbased polyurethane foam.
  • FIG. 2B is a SEM image of a kraft lignin-based polyurethane foam according to an embodiment of the present disclosure.
  • FIG. 3A is a graph illustrating the impact of lignin content on the viscosity of lignin- isocyanate mixtures.
  • FIG. 3B is a graph comparing the impact of lignin content on the viscosity of ligninpetroleum polyol mixtures and lignin-isocyanate mixtures expressed on a common basis (polyol replacement level).
  • a polyurethane-based foam that includes a concentration of at least 30 wt. % of lignin. It was surprisingly found that a PUF with 30 wt. % kraft lignin can be obtained by introducing lignin in the foaming process at two different stages. Kraft lignin is dissolved in isocyanate to yield an isocyanate-lignin solution/dispersion. Lignin is also provided in a lignopolyol mixture which comprises (or in some embodiments consists of) polypropylene glycol and oxypropylated lignin.
  • the isocyanate lignin solution is mixed with the lignopolyol mixture to obtain a reaction mixture.
  • the reaction mixture is reacted in the presence of a catalyst, a surfactant, and a foaming agent to obtain the PUF having at least 30 wt. % of lignin.
  • Polyurethanes are polymers that contain a chain of organic units joined by carbamate (urethane) linkages - these linkages are the result of a reaction between a hydroxyl group and an isocyanate group of two different chemical compounds (e.g. polyol and isocyanate).
  • the lignin comprises hydroxyl groups and reacts with isocyanate thereby acting as the polyol in the foam formation (more specifically a biopolyol).
  • the kraft lignin content dissolved in the isocyanate is close to a level of the maximal solubility or dispersibility limit of the kraft lignin in the isocyanate.
  • the kraft lignin can be dissolved/dispersed at least at 75 %, 80 %, 85 %, 90 % or 95 % ofthe solubility/dispersibility limit.
  • the solubility/dispersibility limit can differwith varying conditions of temperature and pressure.
  • the isocyanate lignin mixture comprises at least 20 wt. %, at least 25 wt. %, at least 30 wt. %, at least 35 wt. % or at least 40 wt.
  • the isocyanate lignin solution may comprise an upper limit of up to 50 wt. % of kraft lignin.
  • the isocyanate lignin solution may further comprise one or more additives which may be a viscosity reducer, a surfactant, a flame retardant, a blowing agent or any combination thereof.
  • the advantage of dissolving/dispersing kraft lignin in isocyanate is that the viscosity of the obtained mixture increases very slowly with increasing lignin content as compared to the case when the lignin is dissolved in the polyol. Moreover, it was surprisingly found that the isocyanate lignin solution can be mixed with a lignopolyol mixture itself containing additional lignin to yield a PUF having an advantageously elevated total lignin content.
  • the present process limits or preferably eliminates the need for the inclusion of any petroleum-based polyol.
  • the isocyanate is selected from hexamethylene diisocyanate (HDI), isophorone diisocyanate (IPDI), methylene bis(4-cyclohexylisocyanate) (H12MDI or Hydrogenated MDI), methylene diphenyl diisocyanate (MDI), toluene diisocyanate (TDI) or naphtalene diisocyanate (NDI).
  • the isocyanate lignin solution is free of a solvation solvent other than isocyanate (e.g. an organic solvent). Accordingly, in some embodiments, the isocyanate lignin solution consists of isocyanate, lignin and optional additives.
  • a partial chemical reaction between the lignin hydroxyl groups and the isocyanate may begin in the isocyanate lignin solution/dispersion. However, this reaction is limited and will generally only involve the hydroxyl groups that are sterically available.
  • the viscosity of the lignin isocyanate solution generally increases with time, and depends on the temperature, moisture content, and penetration level of the lignin particles and/or molecules into the isocyanate. Accordingly, once formed, the isocyanate-lignin solution generally should not be stored for a long time (e.g. not more than 2-3 days) and should be mixed with the lignopolyol mixture and then reacted to form the foam.
  • the lignopolyol mixture can be obtained by oxypropylation.
  • Oxypropylation is a reaction between lignin and propylene oxide (PO) with a catalyst to form oxypropylated lignin and polypropylene glycol (PPG).
  • the weight ratio of lignin to PO for the oxypropylation can be from 10/90 to 40/60, preferably from 15/85 to 30/70 or about 20/80.
  • the oxypropylation of lignin was surprisingly found to be compatible and complimentary to the incorporation of lignin in the isocyanate to achieve elevated final concentrations of lignin in the foam (e.g. at least 30 wt.%).
  • the oxypropylation is helpful in overcoming the solubilization and homogeneity issues during the incorporation of lignin in PU foams.
  • This chemical conversion leads to the complete solubilization of lignin in polypropylene glycol (PPG) which is formed during the lignin oxypropylation reaction in addition to the oxypropylated lignin.
  • PPG polypropylene glycol
  • the obtained product from the oxypropylation reaction is referred to herein as a lignopolyol.
  • the lignopolyol is thus a mixture of PPO (homopolymer) and oxypropylated lignin.
  • PPG is formed by the homopolymerization of propylene oxide (PO) through an anionic grafting mechanism PO has a cost that is significantly less than petroleum-based polyols and a much greener environmental footprint.
  • the oxypropylation reaction can be performed with a catalyst (e.g. KOH) or optionally without catalyst, in the presence or absence of a solvent.
  • the oxypropylation is performed under heating (e.g. temperature of 200-250°C).
  • Oxypropylated lignin generally contains a similar amount of hydroxyl groups compared to the initial lignin before oxypropylation - however, these hydroxyl groups, are predominantly of the aliphatic type and more extended in space which makes them more readily available for reaction with isocyanate compared to the initial lignin.
  • the oxypropylation may form other products such as polypropylene oxide oligomers. These may be useful co-reactants in the foam formation process.
  • a petroleum-based polyol replacement level by lignin as high as 70 wt.% was achieved by the present process.
  • the remaining 30 wt.% replacement of petroleum polyol is provided by the PPG formed during the lignin oxypropylation reaction. Therefore, in some embodiments, the present process eliminates the need for petroleum-based polyols.
  • the only fossil-based major chemical reagent that may be required by the present process is propylene oxide (PO), a readily available and relatively inexpensive chemical.
  • the isocyanate-lignin dispersion/solution and the lignopolyol mixture are mixed to obtain a reaction mixture.
  • the reaction mixture is reacted with a catalyst which may be a metal catalyst or an amine catalyst (e.g. tertiary amine).
  • the catalyst is a metal catalyst and comprises mercury, lead, tin, bismuth, potassium or zinc catalyst or any combination thereof.
  • the catalyst comprises dibutyltin dilaurate, stannous octoate, potassium octoate or combinations thereof.
  • the catalyst is selected from triethylenediamine (TEDA), enzyldimethylamine (BDMA), pentamethyl-diethylenetriamine (PMDETA), dimethylcyclohexylamine (DMCHA), dimethylethanolamine (DMEA), triethanolamine (TEA) and combinations thereof.
  • the quantity of catalyst may be of from about 0.5 pphp to 10 pphp, where pphp is defined as parts per hundred parts of total polyol.
  • the reaction mixture may optionally be heated to a temperature of from 30°C to 90°C, or from 50°C to 70°C.
  • a surfactant and a blowing agent such as water are added to the reaction mixture.
  • Exemplary surfactants include: DabcoTM LK443 and DabcoTM DC 5598 from Evonik and SilstabTM 2100, a silicone surfactant available from Siltech Co.
  • Surfactants including organic surfactants and silicone based surfactants, are usually added to serve as cell stabilizers. It is important to use a small amount of a surfactant to stabilize the foaming reaction mixture until it cures thereby avoiding the collapse of cells and the formation of large uneven cells.
  • a surfactant total amount from about 0.2 to about 3 wt. %, based on the formulation as a whole, is sufficient for this purpose.
  • the kraft lignin-based polyurethane foam (PUF) obtained has an increased lignin content thanks to the combined addition of lignin in the isocyanate and in the lignopolyol.
  • the lignin content is polymerized and can be at least 30 % by weight of the PUF, at least 31 % by weight of the PUF, at least 32 % by weight of the PUF, at least 33 % by weight of the PUF or at least 34 % by weight of the PUF.
  • a maximal lignin content may be, in some embodiments, up to 40 % by weight of lignin.
  • the PUF of the present disclosure can be characterized as having a foam density of from 20 to 90 kg/m 3 , 20 to 80 kg/m 3 , 20-50 kg/m 3 , 30 to 40 kg/m 3 , of from 33 to 40 kg/m 3 or of from 35 to 40 kg/m 3 .
  • the PUF has a thermal conductivity of from 17 to 33 mWm' 1 K' 1 , of from 17 to 30 mWnrr 1 K’ 1 , of from 20 to 30 mWnrr 1 K’ 1 or of from 25 to 30 mWrir’K 1 .
  • the PUF has a max stress of at least 100 kPa, at least 102.5 kPa at least 105 kPa or at least 180 kPa. In some embodiments, the PUF limits the water gain to less than 120 %, preferably less than 110 %, more preferably less than 105 %.
  • the PUF can advantageously have a high closed cell content of at least 90 %, at least 93 % or least 95 %, for example from 90 to 98 %.
  • the PUF according to the present disclosure can have comparable strength properties and water resistance when compared to a traditional foam obtained with petroleum based polyol. In some embodiments, the PUF is a rigid foam.
  • the black liquor was screened using a metal screen of 450 mesh (44 micron) in order to remove any suspended fibers and/or particles.
  • 100 L of black liquor was oxidized at 85-100 °C using oxygen (O2).
  • the oxidation was carried out in a 200-L reactor until the sulfide (S -2 ) concentration in black liquor reached the range of 0-1 g/L.
  • Table 2 Lignin chemical composition and properties.
  • LignoForceTM kraft lignin was oxypropylated using propylene oxide (PO) in the presence of a catalyst (potassium hydroxide).
  • the oxypropylation was carried out using a 1 ,8-L PARR reactor.
  • the formulation and operating conditions related to the oxypropylation of lignin are as follows: the Lignin/Propylene oxide (L/PO) (w/v) ratio and the Catalyst/Lignin ratio (w/w) were adjusted to 20/80 and 11.8/88.2, respectively.
  • a temperature of 230°C was chosen after some preliminary experiments at lower temperatures.
  • the reactor was charged with the appropriate amount of dry lignin followed by potassium hydroxide (KOH) in the form of commercial pellets and then by PO. The reactor was then closed and agitated at 550 rpm. When the reaction medium was heated, the pressure inside the reactor increased to a maximum value and then decreased progressively indicating the consumption of PO. At the end of the reaction, a viscous black solution was recovered and analyzed. This solution was composed of oxypropylated lignin dissolved in polypropylene oxide (this mixture is commonly referred to as a lignopolyol). The main features of the lignopolyol prepared in terms of weight-average molecular weight (Mw), viscosity and hydroxyl functional groups are shown in Table 4. Table 4: Main features of lignopolyol.
  • Lignin-based PU foams were made by first mixing dry lignin with isocyanate (p-MDI) in a 500-mL cup for 5 min using a high-speed mixer to get a homogenous mixture.
  • the desired amounts of polyol (petroleum-based or lignopolyol), surfactant, catalyst and blowing agent (water) were then mixed in a separate cup.
  • the former was then mixed with the latter mixture at 2000 RPM for 5-6 s.
  • the mixer was immediately removed, and the foam was left to rise in free expansion as a result of the carbon dioxide generated by the reaction between isocyanate and the water added.
  • the obtained foam was kept at room temperature for 24 h to ensure complete curing before characterization.
  • Lignin-based PU foams can also be made by first mixing dry lignin with isocyanate (p- MDI) in a 500-mL cup for 5 min using a high-speed mixer to get a homogenous mixture. The catalyst was then added and mixed with the lignin-isocyanate mixture. The desired amounts of polyol (petroleum-based or lignopolyol), surfactant and blowing agent (water) were then mixed in a separate cup. The former was then mixed with the latter mixture at 2000 rpm for 5-6 s. Subsequently, the mixer was immediately removed, and the foam was left to rise in free expansion as a result of the carbon dioxide generated by the reaction between isocyanate and the water added. The obtained foam was kept at room temperature for 24 h to ensure complete curing before characterization.
  • p- MDI isocyanate
  • water blowing agent
  • the produced PU foams were characterized for their apparent density, thermal conductivity, mechanical properties (maximum stress and modulus) and water absorption using standard methods. By adjusting the amount of water added from 0.5wt% to 2wt% of the foam weight added it was possible to produce lignin-based PU foams of a density ranging from 20 to 90 kg/m 3 .
  • Figs. 1A-1 D show the physical and mechanical properties of lignin-based PU foams as compared to the reference PU foam. At about the same density, the thermal conductivity of the lignin-based PU foams is somewhat better than the control while the strength properties and water absorption property of the lignin-based foams are comparable to the control.
  • Figs. 2A-2B show the morphology of the cells of the lignin-based PU foam (Fig. 2B) compared to the control (Fig. 2A). It can be seen from these figures that most of the cells are closed. This suggests that both PU foams produced (reference foam and lignin-based PU foam) are of high quality.
  • the cells of the lignin-based PU foam appear to be smaller and less uniform than the control. This suggests that the operating conditions to produce the lignin-based PU foam could be further optimized to achieve even better properties and/or higher replacement levels of the petroleum-based polyol by lignin.
  • Table 5 shows the potential savings in chemicals at different commercial polyol replacement levels by lignin in PU foams as described herein. It appears from the table that by incorporating lignin in PU foams, the chemical costs and carbon footprint can be reduced significantly with increasing lignin substitution level. For example, at 40% polyol replacement by lignin, the chemical costs can be reduced by about 12.1% while the renewable content can be increased from 0 to 17.4% which corresponds to a reduction in carbon footprint of 14.3%. In particular, in the case of 70% polyol replacement by lignin, the chemical costs were reduced by about 24% while the renewable content was increased to 30.6%. This corresponds to a reduction in carbon footprint of about 25%.

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Abstract

L'invention concerne une mousse de polyuréthane à base de lignine comprenant un polymère de polyuréthane ayant un isocyanate polymérisé et de la lignine, et la mousse de polyuréthane à base de lignine comprenant au moins 30 % en poids de lignine par rapport au poids total de la mousse de polyuréthane.
PCT/CA2023/051091 2022-08-19 2023-08-17 Mousses de polyuréthane à base de lignine WO2024036406A1 (fr)

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Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CA2918686A1 (fr) * 2013-08-13 2015-02-19 Enerlab 2000 Inc. Procede de preparation de produits de polyurethanne a base de lignine
WO2018205020A1 (fr) * 2017-05-09 2018-11-15 Fpinnovations Dépolymérisation de lignine pour la production de polyols et de phénols d'origine biologique et de résines/mousses de pf/pu/époxy à base de lignine

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CA2918686A1 (fr) * 2013-08-13 2015-02-19 Enerlab 2000 Inc. Procede de preparation de produits de polyurethanne a base de lignine
WO2018205020A1 (fr) * 2017-05-09 2018-11-15 Fpinnovations Dépolymérisation de lignine pour la production de polyols et de phénols d'origine biologique et de résines/mousses de pf/pu/époxy à base de lignine

Non-Patent Citations (2)

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Title
BERRIMA BESMA, MORTHA GERARD, BOUFI SAMI, EL ALOUI ELIMAM, NACEUR BELGACEM MOHAMED, BELGACEM M N: "OXYPROPYLATION OF SODA LIGNIN: CHARACTERIZATION AND APPLICATION IN POLYURETHANE FOAMS PRODUCTION", CELLULOSE CHEMISTRY AND TECHNOLOGY, vol. 50, no. 9-10, 1 January 2016 (2016-01-01), pages 941 - 950, XP093141903 *
CATETO, C.A. ET AL.: "O ptimization Study of Lignin Oxypropylation in View of the Preparation of Polyurethane Rigid Foams", INDUSTRIAL & ENGINEERING CHEMISTRY RESEARCH, vol. 48, 2009, pages 2583 - 2589, XP055076453, DOI: 10.1021/ie801251r *

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