Mitsui Chemicals Partners with Microwave Chemical to Recycle Polyurethane Foam Using Microwave Technology
Views：974 Updated：2022-06-24
Mitsui Chemicals and Microwave Chemical have launched a new initiative to commercialize chemical recycling of flexible polyurethane (PU) foam through microwave technology. This project involves the direct synthesis of raw polyurethane raw materials by breaking down the scraps of foam used in the manufacture of mattresses and similar items. The two companies have previously collaborated on the development of recycling technology for automotive shredder residue (ASR). They are also jointly developing an eco-friendly carbon fiber manufacturing technology using microwaves.
Flexible polyurethane foams are mainly composed of polyols and isocyanates. Its softness and high elasticity have led to a wide range of applications ranging from industrial products and materials to everyday items including mattresses, car seats, seat cushions and kitchen sponges. However, in Japan, chemical recycling of flexible polyurethane foam and other polyurethane products has not reached a commercial level. Therefore, the development and commercialization of this technology is an urgent issue from the perspective of promoting a circular economy.
Using the PlaWave-based plastic decomposition technology developed by Microwave Chemical, the processing time for decomposing flexible polyurethane foam is expected to be reduced by at least half, and energy consumption is also expected to be significantly reduced compared to existing technologies. Microwave technology will also help reduce carbon dioxide emissions, as its efficiency will reduce costs and enable the process to be powered by electricity generated from renewable energy sources.
The PlaWave platform, which utilizes microwaves to decompose plastics, can be applied to both pyrolysis and solvents. According to the two companies, PlaWave enables faster response times and higher energy efficiency in a more compact device.
Due to the positive results of initial testing, the project will conduct a small-scale demonstration using Microwave Chemical's benchtop demonstration unit by March 2023, and continue with further research, with the goal of starting demonstration testing in March 2024 and in Commercialization of the technology by March 2026. In parallel with the demonstration tests, Mitsui Chemicals will establish a business model covering the entire value chain of flexible polyurethane foam recycling to achieve a circular economy.
