"Scaling Up Green-Based Polyol from Waste for Sustainable Production of Polyurethane Foams"

• Grant number: 24/23410-4
• Support Opportunities: Research Grants - Innovative Research in Small Business - PIPE
• Start date: February 01, 2025
• End date: January 31, 2027
• Field of knowledge: Engineering - Chemical Engineering - Chemical Technology
• Principal Investigator: Victor Saldanha de Carvalho
• Grantee: Victor Saldanha de Carvalho
• Pesquisadores principais: Brenno Santos Leite ; Juliana Marques Maique
• Associated researchers: Paulo César Pavan ; Sibele Augusta Ferreira Leite
• Associated research grant: 24/10399-2 - "Scaling Up Green-Based Polyol from Waste for Sustainable Production of Polyurethane Foams", AP.PIPE
• Associated scholarship(s): 25/01325-8 - Scaling up green-based polyol from waste for sustainable polyurethane foam production, BP.PIPE

Abstract

The proposal aims to elevate the technological and market maturity level in the production of the green polyol developed by BVS Green. The objective is to achieve characteristics equivalent to commercial polyols, especially those used in the manufacturing of polyurethanes such as rigid and flexible foams. Polyols are chemical inputs for forming polyurethanes, which are essential materials in products like upholstery, footwear, mattresses, and thermal insulators. While traditional polyols are derived from propylene oxide and ethylene, green polyols are typically derived from renewable sources such as carbohydrates, lignocellulosic material, and vegetable oils. Globally, the polyols market was estimated at $36.7 billion in 2022, with projections to grow to $49.3 billion by 2027. The green polyurethanes segment, in turn, represented $4.4 billion in 2021, with an expected annual growth rate of 9.5% until 2027, driven by environmental regulations. Brazil, despite having limited polyol production, has significant potential to lead in the production of green polyols, leveraging resources such as vegetable oils and agricultural residues like Citrus Pulp Pellet (CPP) and sausage casing, which are abundant in agribusiness. BVS Green stands out by using these residues to produce green polyol on a commercial scale, facing technological and market challenges. The PIPE proposal seeks to provide BVS Green with the necessary resources to achieve technological maturity, form a specialized team, and enter the market competitively.The main technological challenges to be overcome by BVS Green are: maintaining the reproducibility of the process and the characteristics of the green polyol at different scales; ensuring that the final product is compatible with market polyols in terms of properties such as viscosity, pH, and moisture; producing polyurethanes using green polyol (pure or in blends with petroleum-derived polyols), with adequate quality for their respective applications. In this regard, the main activities will include: optimization and scaling studies for green polyol production (from 3 liters to 7000 liters); characterization of green polyol and comparison with market-available polyols at various scales; process adjustments based on the results obtained; application of techniques to reduce pH and moisture; development of the MVP (Minimum Viable Product) for foam production and technology validation; characterization of the foams (or other polyurethanes produced) and evaluation of their performance (quality and environmental aspects). The main market challenges to be overcome by BVS Green are: improving the company's strategies based on market information and data; identifying direct and indirect competitors to position itself competitively; establishing connections, interacting with, and understanding customer demands to offer solutions that meet their expectations. To this end, BVS Green will collect and analyze information from market databases, reports, case studies, research articles, government data, websites, social media, and use competitive analysis tools. Additionally, it will seek to identify market trends through increased interaction with customers, including interviews, technical visits, and participation in fairs and events. The resources needed to advance from TRL 5 to TRL 7 include adequate infrastructure, acquisition of inputs and equipment, laboratory services for polyol and foam characterization, and partnerships for production scaling, as well as a specialized team. At the end of the proposal, it is expected that BVS Green will scale the green polyol technology, capable of producing high-quality polyurethanes that meet the market's environmental and performance requirements, consolidating its position in the sector (AU)