Manufacturing of polyols out of alternative sources. chemistry and engineering aspects ABSTRACT

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Manufacturing of polyols out of alternative sources chemistry and engineering aspects Dr. Frank Dürsen, RAMPF Holding GmbH & Co.KG, D-72661 Grafenberg Christian Giesker, KEIL Anlagenbau GmbH & Co.

1 Manufacturing of polyols out of alternative sources chemistry and engineering aspects Dr. Frank Dürsen, RAMPF Holding GmbH & Co.KG, D Grafenberg Christian Giesker, KEIL Anlagenbau GmbH & Co. KG, D Bohmte-Hunteburg ABSTRACT The presentation includes the different polyols that are provided by RAMPF Eco Solutions including standard polyols and new developments and describes the modular concept for recycling plants of KEIL Anlagenbau. The presentation is completed by an economic calculation for production of polyols out of alternative sources. INTRODUCTION The company RAMPF Eco Solutions GmbH & Co. KG is specialized in the manufacturing of polyols out of different kinds of polymers. It is known that solid polyaddition polymers like polyurethane could be depolymerized by chemolysis. Also RAMPF Eco Solutions is using this process but in contrast to others RAMPF is doing that on industrial scale since CHEMICAL CONVERSION OF PU AND PET WASTE BACK TO POLYOL The Glycolysis is used for the chemical recovery of rigid and integral foams. The converted polyols could be used again in the original product to gain a closed loop recycling or in other applications. Figure 1: Closed loop recycling of PU scrap back in the original application

Figure 2: Polyols gained by chemical recycling of PU production residues could be used for production of rigid or

MANUFACTURING OF POLYOLS FROM PU FLEXIBLE FOAM WASTE In 2012 the world's first industrial plant for the

2 Figure 2: Polyols gained by chemical recycling of PU production residues could be used for production of rigid or semi rigid integral skin PU foams In cooperation with DKR a method for the chemical recycling of PET was developed in The recovered polyols (Petol ) could be used to manufacture rigid foams with high mechanical strength and advanced fire retarding properties. Figure 3: PET based polyols used for production of insulation boards out of PIR foam INDUSTRAIL SCALE PLANT FOR MANUFACTURING OF POLYOLS FROM PU FLEXIBLE FOAM WASTE In 2012 the world's first industrial plant for the manufacturing of polyols from PU flexible foam waste using the Acidolysis process was installed in Pirmasens at the manufacturing site of RAMPF. The plant was designed and completed as part of a project funded by the German Federal Ministry of Education and Research to develop industrial-scale acidolysis for flexible slabstock foams.

Figure 4: Recycling plant for the manufacturing of polyols from PU flexible foam waste installed by KEIL

approaches were tested as RAMPF is involved in several R&D project like ProLignin and Lignoplast for the

which could be used in the manufacturing of polyols and polyurethanes.

R&D projects PROLIGNIN and GREASE were funded by the Federal Ministry of Food and Agriculture in Germany) RAMPF

3 Figure 4: Recycling plant for the manufacturing of polyols from PU flexible foam waste installed by KEIL Anlagenbau at RAMPF site in Pirmasens DEVELOPMENT OF BIOBASED POLYOLS AND POLYURETHANES In the last years new approaches were tested as RAMPF is involved in several R&D project like ProLignin and Lignoplast for the material use of lignin or GREASE dealing with the utilization of fatty acids or fatty acid based building blocks which could be used in the manufacturing of polyols and polyurethanes. Figure 5: Integral skin foam with lignin and PU rigid foam using fatty acids extracted from wood bark (European R&D projects PROLIGNIN and GREASE were funded by the Federal Ministry of Food and Agriculture in Germany) RAMPF Eco Solutions has different business areas. Development and production of polyols, recycling concepts for customers and the design and sale of tailor-made PU-recycling plants.

MODULAR CONCEPT FOR RECYCLING PLANTS To provide also recycling plants RAMPF is working together with the engineering partner KEIL Anlagenbau GmbH & Co. KG.

4 MODULAR CONCEPT FOR RECYCLING PLANTS To provide also recycling plants RAMPF is working together with the engineering partner KEIL Anlagenbau GmbH & Co. KG. KEIL is specialized in planning, assembling and maintaining of storage tank farms, production equipment as well as special devices and customized equipment since For these recycling plants KEIL is using a modular concept with different units for storage, dosing, mixing, filtration, control technology and peripheral equipment. This modular concept has many advantages like easy adjustment to the companies needs of production amount and existing local conditions and a short installation time on side caused by pre-fabrication of the units at KEIL. Figure 6: Modular concept for recycling plants FURTHER DEVELOPMENT AND PERSPECTIVES To improve existing and new plants KEIL occupies with different further developments. These developments are divided into energy savings, for example heat recovery use and tiein of combined heat and power units (CHP) or micro gas turbines and process improvement like amendment of the distillation process by fractionation of the condensate and a vacuum distillation. In order to recycle also PU residues out of composite materials KEIL is working on a special refinement equipment at the moment. The challenge for this project is the high amount of impurities like aluminum and paper in the raw material.

CONCLUSION Though the recycling plants are tailor-made designed on the needs of the customer they could also be used for the manufacturing of PET based polyols, NOP s or other polyester polyols.

Petersburg who is going to produce PET based polyols. Please also visit RAMPF Eco Solutions and KEIL Anlagenbau at booth 871. BIOGRAPHIES Dr.

5 CONCLUSION Though the recycling plants are tailor-made designed on the needs of the customer they could also be used for the manufacturing of PET based polyols, NOP s or other polyester polyols. And finally there is also an economic benefit by using these kind of plants directly at the manufacturing site of a customer. Currently such a plant is built for a customer in St. Petersburg who is going to produce PET based polyols. Please also visit RAMPF Eco Solutions and KEIL Anlagenbau at booth 871. BIOGRAPHIES Dr. Frank Dürsen Frank Dürsen received his PhD in Chemistry from the University of Stuttgart, Germany, in He started his career in the R&D of Akzo Nobel Faser AG in Obernburg/Main. In 2008 he took responsibility for Quality Assurance at Sika Deutschland GmbH, Bad Urach. Since 2011 he is Director of R&D Future and Sustainability at RAMPF Holding GmbH & Co. KG, Grafenberg. He is responsible for the development of new products (polyurethanes and epoxies) based on sustainable raw materials. Christian Giesker Christian Giesker received his Master in Process Engineering from the University of Stuttgart, Germany, in He started his career as a project manager at Hans-Jürgen Keil Anlagenbau GmbH & Co. KG. Since 2014 he is deputy division manager for the engineering at KEIL. He is also responsible for construction of the recycling-plants and the development of the process technology.

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