Scaled-up and economic assessment approach of the split-phase glycolysis process for the recycling of flexible polyurethane foam wastes

The economic viability of the split-phase glycolysis process for the recycling of any kind of flexible polyurethane foam waste employing crude glycerol as cleavage agent has been demonstrated. First, experiments at pilot plant scale were carried out to check that the process can be extrapolated to larger scales. With the goal of scaling-up the process from laboratory scale to pilot plant, geometric similarity criteria were applied together with dynamic similarity for laminar flow in agitated tank reactors. Hence, a pilot plant installation was designed with geometrically similar equipment to those used for lab scale, obtaining analogous results in terms of recovered polyol properties. Then, the basic design of a split-phase glycolysis industrial plant with a capacity for treating 270 Tm per year of flexible PU foams scraps was proposed. Finally, the economic feasibility of such recycling process was confirmed because of the obtention of a Net Present Value (NPV) of 1,464,555€, with an Internal Rate of Return (IRR) of 27.99%, and a payback time between 4 and 5 years.