A second life for discarded hard foam (Circular Foam)

Polyurethane (PU) hard foam is often used as an insulation material in refrigerators and freezers. It is also common in the building industry, where it is applied for insulation and integrated into backings on laminate flooring, ceiling panels and wall panels. ‘Recycling of this material can be very valuable, both from a sustainablity and a financial perspective. It can reduce waste and decrease the need for petroleum-based primary goods in manufacturing,’ stresses David Lemiski, Senior Researcher at the Amsterdam University of Applied Sciences. A typical refrigerator has approximately 8 euros of value in its PU hard foam insulation. In Europe alone, in 2019 approximately 30 million refrigerators and freezers were discarded. ‘However, a process dedicated to recycling PU hard foam does not exist,’ says Lemiski. The project Circular Foam is the first in the world to investigate how to develop such a recycling process.

Three regions in Europe

The research takes place in three regions across Europe: the Rhineland in Germany, Silesia in Poland, and the Amsterdam region. In each of these areas, the consortium will investigate current recycling practices as well as infrastructural, logistical and regulatory issues. For example, can the PU be recovered to the specifications required, stored and transported to a central location for recycling it back to the molecular level? In addition to technical aspects, the consortium will also consider social aspects: how does industry look at current recycling practices and how can it increase awareness in the industry of the importance of recycling PU hard foams?

Creating a circular process

Circular Foam will deliver a small-scale (but scalable) demonstration plant to prove that recycling can be done in an efficient, economical, and environmentally safe way, and that the end product can re-enter the process as new input. In other words, it will show that the loop can be closed to create a circular process. The project will create awareness, among governments and industry, of the importance of and the opportunities for recycling PU hard foam. It will also deliver insights that can be applied in other regions in Europe, opening the door to large-scale recycling programmes.

Education

Undergraduate students from the Faculty of Technology of the Amsterdam University of Applied Sciences specializing in Urban Studies and Logistics can do an internship or graduation project with one of the consortium partners. Best practices and insights from the project will be shared in lectures for minor students.

Partners

The Circular Foam consortium, initiated by PU hard foam producer Covestro , includes over 20 academic and research organizations, industry associations, and corporations, from four different countries. These include the Netherlands, Germany, Poland, and Switzerland. The Amsterdam University of Applied Sciences is responsible for the research in the Amsterdam region and will consult the local government to increase awareness and develop tailor-made solutions.