The goal of the POLDA project is to valorize polyurethane waste from WEEE recycling centers, by developing a mechanical recycling process as an alternative to traditional rebinding, which involves the use of hazardous binders like isocyanates.
The project proposes the use of airlay technology, a dry process in which pulverized polyurethane is pneumatically mixed with a risk-free thermoplastic binder. After thermosetting, the result is a re-agglomerated panel that is recyclable and eco-friendly.
A subsequent hot pressing phase makes the panel denser and more rigid, enabling its use in green furniture applications as a substitute for wood fiberboards such as MDF.
In electrical and electronic equipment (EEE) of Class R1 (e.g., refrigerators, freezers, air conditioners), rigid polyurethane (PU) is used as thermal insulation.
Previously, the blowing agents used in PU production were ozone-depleting, but following the Montreal Protocol, these were replaced by non-harmful gases like pentane.
In recycling centers, Class R1 WEEE is ground down to separate PU, plastic, and metals.
The PU is pelletized, reducing gas content to below 0.2%, and is then usually incinerated or landfilled.
Beneficiari
Objectives:
Expected results:
The recycling process will utilize 100% thermoplastic binders, optimized to meet application-specific requirements. Thanks to a collaboration with a technology provider specializing in airlay, the project will move from lab scale (TRL 3–4) to pilot scale (TRL 5), producing demonstrator panels to validate the recycling strategy for the intended use.
KEY PERFORMANCE INDICATORS (KPIs):
The market potential is significant. In 2022 alone, over 12 million cubic meters of MDF panels were produced in Europe (source: European Panel Federation), with furniture representing 50% of total end use.
KEY FIGURES
RESEARCHERS INVOLVED
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PROJECT DURATION
NUMBER OF WORK PACKAGES (WPS)
STARTING TRL
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Project n.: PE_00000004
MADE IN ITALY CIRCOLARE E SOSTENIBILE
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