Chemical Recycling Recovers Building Blocks From Polyurethane Waste
Polyurethane (PU) is widely used in mattresses, furniture, insulation, automotive components and numerous other products. However, recycling this versatile polymer remains challenging, particularly when waste streams contain different types of PU. Belgian company Purtiso has developed a chemical recycling process designed to recover the original molecular building blocks from industrial and end-of-life polyurethane waste.
Recovering Polyol And Isocyanate
Purtiso is a spin-off from KU Leuven. Its patented PUR2ISO process breaks down PU waste into polyol and isocyanate, the main chemical components used to manufacture polyurethane. According to the company, the recovered substances offer a quality comparable to virgin raw materials and can replace up to 100% of conventional inputs in new PU production. Industry partners have independently verified these results.
The process does not require phosgenation, a conventional industrial step involving the highly toxic chemical phosgene. Omitting this stage could support safer and more decentralised recycling operations.
Processing Different PU Waste Streams
Although Purtiso initially optimised the technology for flexible polyurethane foams, PUR2ISO can reportedly process all major PU waste streams. These include TDI- and MDI-based flexible foams, rigid foams, polyisocyanurate (PIR) insulation and polyurethane made with polyester polyols.
This broad compatibility may be particularly valuable for handling mixed waste from mattresses, upholstered furniture, building insulation and industrial production. Such materials are often difficult to separate or recycle using mechanical methods.
Modular Recycling Close To Waste Sources
PUR2ISO is designed as a modular, continuous process that can operate at an industrial scale. Purtiso envisions recycling hubs located close to sources of PU waste. This approach could limit the transport of bulky, low-density foams while reducing associated costs and carbon emissions.
For PU manufacturers, the technology offers a route for converting production offcuts into reusable feedstocks. Waste management companies could use it to extract more value from end-of-life foam, while chemical producers could incorporate recovered polyol and isocyanate into existing manufacturing facilities.
Purtiso is currently working with industrial partners and technology investors to scale the process. The development of a pilot facility at the Brightlands Chemelot Campus in Geleen, the Netherlands, represents the next step towards commercial implementation. If successfully deployed, the technology could help reduce dependence on fossil-based raw materials and establish more circular material flows for polyurethane products.
Source: Purtiso