How Bio-based Polyurethanes are Produced
Key Pathways:
- Bio-based Polyols + Fossil Isocyanates
- Most common commercial route today. Polyols are made from vegetable oils (soy, castor, palm), sugars, or lignocellulosic biomass.
- Isocyanates (MDI, TDI) remain fossil-based but are under bio-development.
- Bio-based Polyols + Bio-based Isocyanates (Emerging)
- Includes biogenic aromatic amines converted to isocyanates using phosgene or green alternatives.
- R&D ongoing into non-isocyanate polyurethane (NIPU) pathways using cyclic carbonates and diamines.
- CO₂-Based Polyols
- Captured CO₂ is polymerized with epoxides to form polyether carbonate polyols, offering partial renewable content and carbon utilization.
Feedstocks: Castor oil, soybean oil, palm kernel oil, sugar alcohols, CO₂, glycerol, and biomass-derived diacids.
Case Study: Covestro’s Cardyon® CO₂-based Polyol Platform
Highlights:
- Utilizes CO₂ as a raw material to produce polyether carbonate polyols used in foams and textiles.
- Reduces fossil input by up to 20% while maintaining performance.
- Partnered with companies like Recticel and Puma for bio-based PU products.
Timeline & Outcome:
- 2016: First commercial plant in Dormagen, Germany operational.
- 2019: Launched first PU-based sports flooring and mattress foams.
- 2022–2024: Extended Cardyon use into coatings and textile applications with bio-based content validation.
Global Startups Working on Bio-based PU
- Ecovia Renewables (USA) – Develops bio-polyols from sugar fermentation for foams and coatings.
Link - Puratex (Germany) – Specializes in castor-oil-derived polyurethanes for footwear and coatings.
- Reverdia (France/Netherlands) – Focused on biosuccinic acid and derivatives for PU intermediates.
- Futuramat (France) – Develops NIPUs using lignin and vegetable oils for insulation panels.
India’s Position
India has access to plentiful renewable feedstocks — castor oil, glycerol, jatropha, and sugar-derived polyols. Companies such as:
- Jubilant Ingrevia and Godrej Chemicals are working on bio-polyols.
- PU foam manufacturers like Sheela Foam and Flexible Foam have shown interest in renewable inputs.
While commercial scale bio-PU is yet limited, bio-polyol production is active, and India is well-positioned for downstream expansion.
Commercialization Outlook
Market & Demand
- Global PU market: ~$80 billion (2024), projected to reach ~$110 billion by 2030.
- Bio-based PU accounts for ~7–10% today, growing at CAGR >7%.
- Key sectors:
- Furniture & bedding
- Footwear
- Automotive (seating, interiors)
- Paints and adhesives
Key Drivers
- Rising demand for bio-based foams in mattresses, sportswear, and packaging.
- Extended producer responsibility (EPR) and green building codes.
- Automotive OEMs moving toward net-zero interior materials.
- Fashion and footwear brands adopting castor-oil-based PUs.
Challenges to Address
- Isocyanate Bottleneck: Bio-isocyanate tech is at early stage; current systems still rely on fossil MDI/TDI.
- Price Premium: Bio-based PUs are 15–30% more expensive than conventional ones.
- Performance Matching: Some bio-based PUs show softness or hydrolysis limitations in high-stress applications.
- Certification & Scaling: Need for consistent bio-content verification and global LCA validation.
Progress Indicators
- 2016: Covestro launches CO₂-based Cardyon® polyols.
- 2020–2023: Bio-polyol and CO₂-based PU adoption in footwear, foam mattresses, and automotive trials.
- 2023: Puma launches RE:SUEDE sneakers using Cardyon®.
- India: CSIR-IICT develops jatropha- and glycerol-derived PU systems; startups in Gujarat explore castor-oil polyols.
- 2025: Projected scale-up of bio-isocyanate pilot tech and increased brand-side procurement of bio-PUs.
Bio-based polyols are at TRL 9 (fully commercial); CO₂-based polyols are TRL 7–9 depending on end-use. Bio-isocyanates and non-isocyanate PUs (NIPU) are at TRL 4–6 (lab to pilot stage).
Conclusion
Bio-based polyurethanes are emerging as a leading solution for decarbonizing foams, footwear, coatings, and interior materials. Companies like Covestro and Ecovia are scaling platforms that integrate CO₂ and vegetable oils into high-performance, low-impact PU systems. In India, strong feedstock availability and R&D progress on polyols create a strong foundation for local bio-PU value chains. As bio-isocyanate tech matures and brand demand grows, bio-based polyurethane will play a central role in climate-smart, circular materials for industry and consumers alike.
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