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CURRENT ISSUES IN THE BUILT ENVIRONMENT

Would recycled plastic insulation be a sustainable option as an alternative to

phenolic foam insulation boards used in UK homes?

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Introduction

Building insulation is a material or system that reduces heat transfer between the inside

and outside of a building. It is an important aspect of building construction because it

helps maintain a comfortable indoor temperature, saves energy, and reduces heating

and cooling costs (Sarika et al., 2021). Several insulation materials can be used in

buildings, including fiberglass, cellulose, foam, and mineral wool. Each type has its

unique properties and is best suited for certain applications. The R-value of insulation is

a quantification of how well it blocks the transfer of heat. With a greater R-value, the

insulation does a better job of retaining heat. The thickness of insulation required for a

building depends on the type of insulation used, the climate in which the building is

located, and the type of construction. Proper insulation installation is also important

(Sierra-Perez et al., 2016). This includes ensuring that there are no gaps or voids in the

insulation and that it is properly sealed. Insulation can be installed in the walls, floors,

ceilings, and insulating pipes, tanks, and other equipment.

The qualities of a building's envelope considerably influence its energy usage. The

exterior walls' thermal performance significantly contributes to the construction

industry's energy efficiency and the reduction of greenhouse gas emissions (Rad &

Fallahi, 2019). Installation of thermal insulation can reduce energy use for heating and

cooling. In this circumstance, insulation materials play a crucial role because they

guarantee satisfactory thermal comfort levels within a building and energy savings if the

right material, thickness, and location are chosen.

When designing a building envelope, it's also essential to consider important variables

like sound insulation, fire resistance, water vapor permeability, and the impact on the
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environment and human health. In addition to thermal qualities, there are several factors

to consider when choosing the right insulation for a building. These include the climate

in which the building is located, the type of construction, and the intended use of the

space. For example, a building in a colder climate may require more insulation to keep it

warm in the winter, while a building in a warmer climate may require less insulation to

keep it cool in the summer (Babenko et al., 2018). Similarly, the type of construction can

affect the amount and type of insulation needed. For example, a building with a metal

roof may require different insulation than a building with a flat roof.

In addition to the environmental benefits, insulation can provide economic benefits by

reducing energy costs. Proper insulation can help lower heating and cooling bills by

reducing the energy needed to maintain a comfortable indoor temperature (Rad &

Fallahi, 2019). This can be especially beneficial for commercial buildings and large

structures that use significant energy for heating and cooling.

This research aims to examine recycled plastic insulation's sustainability and insulating

properties to assess whether switching from phenolic foam insulation would be a

sustainable shift. Learning the origins of plastic waste is essential for addressing the

problem. To determine whether or not recycled plastic insulation may be utilized to

mitigate plastic pollution and waste, this article focuses on its material conductivity and

other physical and chemical qualities. The purpose of this study is to compare the

insulation sustainability properties of recycled plastic insulation to those of phenolic

insulation board and to analyze the environmental impact of this material through case

studies to see if it is suitable for reducing plastic pollution. Therefore, we will outline on
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building phenolic foam insulation boards used in UK homes, then discuss recycled

plastic insulation as a better sustainability option than phenolic foam insulation.

Phenolic insulation boards (PIB)

Phenolic foam is mostly used as insulation around pipes or in board form to increase

building thermal efficiency. To meet carbon emissions targets; existing building stock

thermal efficiency is crucial (Liu, 2018). External wall insulation can boost thermal

efficiency in solid-wall dwellings. Because of its poor heat conductivity and fire

resistance, phenolic foam is commonly used for exterior wall insulation. Retrofitting is

crucial to meeting 2050 emissions objectives, as 13,000 UK houses must be renovated

weekly. Consider the number of materials utilized and their environmental impact while

assessing the retrofit task.

Three basic constituents in making phenolic foam are phenolic resin, a blowing agent,

and an acid catalyst. Several additives can be used to tailor the foam's qualities

(Schroer et al., 2013.)

Chemical components

Phenolic foam is made from the following chemicals:

Phenolic resin; The major constituent in phenolic foam is a phenolic resin. The

ecoinvent database in SimaPro contains information on the product's potential

environmental impacts. For this reason, and because phenolic foam has a relatively

high embodied carbon content of 4–15 kg/kg CO2, e.g., it is expected that the final

product will include a sizable amount of embodied carbon (SimaPro, 2013).

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Acid catalysts; Acid catalysts like toluene or xylene sulfonic acid are needed for

synthesizing phenolic foam, as stated by Odian (1991, p.127). Because a new patent

offers to employ both acids together, all three options will be researched. Since there is

no available LCI data for toluene sulfonic acid or xylene sulfonic acid in SimaPro, we

had to make educated guesses about their environmental effects (Gordiziella et al.,

2000, pp. 158–169; Schroer et al., 2013).

Toluene sulfonic acid; The acid toluene sulfonic is produced when toluene is reacted

with strong sulfuric acid. In a perfect reaction, one mole of toluene and one mole of

sulfuric acid would produce two moles of toluene sulfonic acid. The resultant toluene

sulfonic acid contains benzene, methyl, and sulfonate groups.

Xylene sulfonic acid; It is recommended that a molar ratio of 1:1.4–1:1.9 be used when

reacting xylene with sulfuric acid to produce xylene sulfonic acid. Due to the larger

environmental impact and increased material requirements of increasing sulfuric acid

levels, the lowest concentration ratio (1:4) within this range is chosen. The yield of

xylene sulfonic acid will decrease, but the reaction will still occur, even at lower ratios

(ChemSpider, 2013a).

Blowing agents; Among the various blowing agents used in producing modern phenolic

foam, pentane is most frequently noted (Schroer et al., 2013). For the best results,

however, the latest patent recommends using 85:15 mixtures of isopropyl chloride and

pentane as the blowing agent. Therefore, we shall compare the two possibilities to

understand better how they will affect the natural world. Isopropyl chloride information is

currently lacking in SimaPro, so that an initial estimate will be made.

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Comparison of the environmental impact of blowing agent alternatives

Since 21 g of blowing agent alternatives are needed for the most recent patent, their

environmental effects are compared. Including isopropyl, chloride enables a direct

comparison between pentane's environmental effects and those of the substance.

However, when employed alone as a blowing agent, it produces an unfavorable foam

structure with bigger cells. Pentane is the most influential solvent in seven areas,

whereas isopropyl chloride is the most influential in nine. The gas mixture, not

surprisingly, lies somewhere in the middle.

Additives; To make a phenolic foam; four chemicals are recommended for use: a

surfactant (castor oil-ethylene oxide adduct), a plasticizer (polyester polyol), an organic

modifier (urea), and an inorganic filler (Kingspan Holdings Limited, 2006). (calcium

carbonate).

Plasticizer: It is advised to use a polyester polyol as a plasticizer; it should be combined

with phenolic resin and let to stand for two to twenty-four hours (Kingspan Holdings

Limited, 2006). Although SimaPro does not have LCI data for polyester polyol, PU

Europe (the Polyurethane Insulation Industry group) has developed an eco-profile

(Schindler et al., 2010). The eco-profile provides specific input materials, and emissions

entered into SimaPro to calculate the aromatic polyester polyol's potential

environmental effects. In this investigation, aromatic polyester polyols are employed

since they are used in producing PIR and PUR foams (Invista, 2013).

Organic modifier: urea; The phenolic resin is combined with powdered urea. The use of

urea can strengthen the foam and reduce its heat conductivity. Fertilizer farmers
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typically employ industrial urea, which is created by reacting ammonia with carbon

dioxide (Copplestone and Kirk, 2013)

Surfactant: castor oil–ethylene oxide adducts. Before the surfactant is added, the

phenolic resin is mixed with the blowing agent and acid catalyst. It is intended to

stabilize the phenolic foam's cells, lowering the risk of cell wall cracks (Zeggelarr, 2010).

The surfactant is synthesized from castor oil and ethylene oxide with a mole ratio of 21–

38:1.

Inorganic modifier (calcium carbonate); When making phenolic foam, Calcium

carbonate, when mixed with phenolic resin, urea, and polyester polyol, serves both as

an inorganic filler and a means of regulating the foam's pH. The recommended particle

size is 170 mm. LCI values for calcium carbonate (. 63 mm) are available and

representative of Europe (ELCD 3.0, 2013). To calculate the environmental

consequences, these have been entered into SimaPro 7.

Recycled plastic insulators (polyurethane)

Recycled plastic insulators are made from recycled plastic materials collected,

processed, and used to manufacture new insulators. Different insulators and production

methods can result in recycled plastic insulators with slightly different ingredient lists.

Recycled plastic insulators can be made from various plastic materials, including

polyethylene, polypropylene, and polyvinyl chloride (PVC). In this section, we'll focus on

polyurethane board insulators.

Due to its superior stability, resistance to corrosion, low density, and thermal

conductivity, polyurethane is frequently utilized in the building sector (Godinho et al.,

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2021). Flexible foams, rigid foams, and shells are the three main categories that

polyurethanes fall under (coatings, adhesives, sealants, and elastomers). Wastes made

of polyurethane foam have multiplied throughout production and consumption.

Polyurethane foam also has negative environmental effects because of its low pile-up

density (approximately 30 kg/m3) and its difficulties in degrading naturally.

Incineration holds a significant role in the treatment of polyurethane foam. Waste

polyurethane is burned at an incinerator to recover energy. In actuality, the combustion

of polyurethane can provide the same amount of heat as coal. However, many

polyurethane foams also contain flame retardants, which significantly reduce

polyurethane's ability to burn (Wu et al., 2016). The incomplete burning of polyurethane

will contaminate the atmosphere and release harmful pollutants (such as CO and NOx).

Recycling will therefore be the most effective technique to deal with polyurethane foam.

Physical and chemical polyurethane foam recycling are currently available. Physical

recycling preserves chemical structure. Powdered polyurethane foam can be reshaped

with adhesives or filler (Tantisattayakul et al., 2018). Crushed rigid polyurethane foam

into particles to improve PUF and phenolic foam mechanical characteristics (PF). PUF

and PF compressive strength increase by about 20% at 5 wt% particle polyurethane

foam (PPU). Gama et al. used MDI at 100-200 °C and 30-200 psi pressure to shape

PUF waste particles. Carpets, furniture, and insulating panels are all made using this

technology.

Moon et al. (2019) powder flexible polyurethane foam via low-temperature pulverization.

The original polyurethane foam is blended with ultrasonic-treated powder to make

mixed PUF. Physical recycling is cheap and easy, but its potential has not been fully
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explored. Polyurethane foam is broken down into oligomers and smaller molecules

through alcoholysis, hydrolysis, glycolysis, acidolysis, etc. Recovering raw resources for

polyurethane foam and other goods is done chemically. Castor oil is used by Valle et al.

(2020) to break down flexible polyurethane foam.

When decomposed polyurethane (DP) is present in a greater quantity, the material's

tensile strength, elongation at break, and cell size all decrease. Heiran et al. (2021)

utilized different glycols and catalysts to glycolyze waste polyurethane foam. Factors

like temperature and material ratio are made decisions. New polyurethanes can be

made using recycled raw materials, which can then be employed as boiler insulation

and protective coatings. Succinic acid is used by Gama et al. (2020) to depolymerize

flexible polyurethane foam and produce recyclable polyol. To create polyurethane foam;

recycled polyol will be used in place of some of the original polyol. The density and

shape of the polyurethane foam are unaffected by the addition of 30% recycled polyol.

The ideal way for recycling polyurethane foam, in theory, is the chemical recycling

approach, which adheres to the degradation principle.

To chemically react solid reactants without a solvent and alter their chemical structure,

Mechanochemistry absorbs mechanical and thermal energy by prolonged mechanical

force action. Chemical recovery is an example of a mechanochemical technique that

can disrupt the network crosslinking structure, reduce crosslinking degree, and increase

recycled powder activity but cannot convert thermosetting polymers to raw materials.

(Hu et al., 2020) regenerated thermosetting phenolic resin using mechanochemical

methods, which increased its tensile strength.

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In conclusion, the mechanical approach may recycle thermosetting plastics, but it

prioritizes mechanical qualities above thermal insulation, which wastes polyurethane

foam. This section shows how to reuse polyurethane foam as insulation for buildings.

Without glue, a mechanochemical technique is used to recover recycled polypropylene

as a matrix and polyurethane foam as filler. Particle size, ratio, and heat pressing

parameters were only changed.

Materials and Methods

Materials

A rigid polyurethane insulation board served as the study's source of used polyurethane

foam (Deng et al., 2021). This board has hard polyurethane foam in the middle, a non-

woven cloth layer, and an inorganic paste that can withstand flames. The most popular

kind of construction insulation material is this board. Recycled polypropylene serves as

the matrix material.

The process of PUF Crushing

In a homemade crusher created specifically for long-term laboratory crushing, used

polyurethane foam waste is broken down. The fireproof layer is kept to match the actual

recovery circumstances (Stachack et al., 2021). It can increase the economic benefit

and strength of the recycled wide. The polyurethane foam is roughly crushed into

particles smaller than 5 mm after being manually chopped into minute pieces measuring

2 square centimeters. Finally, a self-made crushing step into a low crosslinking powder.

The homemade crusher has two grinding discs and three sets of cutting teeth. The
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grinding process involves various mechanical forces, including shear, grinding,

extrusion, and others (Prestes et al., 2019).

When polyurethane foam is ground, the material's network structure is broken, releasing

heat energy that can then be used to create active groups. The crusher's speed is set to

1500 rpm, and the crushing takes 40 minutes. The crushing impact will be enhanced by

moving at a faster rate for a longer period, but the efficiency will suffer, and more

mechanical energy will be used. Polyurethane foam offers the highest cost performance

and can be successfully degraded at 1500 r/min and 40 min.

Process of Heat Press

The flat vulcanizing machine is used to mold the polyurethane foam powder. The base

of the mold is covered with a layer of PET film to help with demolding. Because PET

has a melting point over 250 degrees Celsius, the melt may not be able to adhere to the

mold. Mix the recycled PP material and waste polyurethane foam powder uniformly,

then Cover the press mold with a second layer of PET film once you've added the

mixture. Pre-heat the mold for each experiment for 10 minutes at 175°C (Yuan et al.,

2017). Then, the heat pressing is done for the allotted time and temperature. After the

exhaust has been heated and pressed for 10 minutes, it is kept warm for another 10

minutes before being released. At this point, you can take out the mold and set it

somewhere cool to let it cool to room temperature before demolding.

Testing Thermal Conductivity

The primary factor relating to the practical use of polyurethane foam has long been

considered thermal conductivity. A heat flow meter is employed to measure the board's
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thermal conductivity (Kemona et al., 2020). Choose Two Heat Flow Meter

Configurations following ISO 8301, then adjust the pressure to 80 N, the hot surface to

40°C, and the cool surface to 25°C. The formula used to calculate thermal conductivity;

is k = λ / (ρ x Cp).

PUF's structure and molecular composition following mechanochemical grinding of

discarded polyurethane foam. Therefore, more time is spent crushing, allowing more

thermal and mechanical energy to be stored. The activity of PUF powder is much

increased due to the disruption of the C-O bond and the resulting damage to the

network crosslinking structure (Yuan et al., 2017). Heat pressing can remold PP and

polyurethane foam powder into composite products. Mesh, percentage, temperature,

and time are used as variables in the orthogonal test design approach, whereas thermal

conductivity, tensile strength, and density are used as indices.

Thermal conductivity and tensile strength are most significantly influenced by

polyurethane foam powder percentage, mesh size, and to a lesser extent, temperature

and time (Stachack et al., 2021). The materials with the highest tensile strength, 0.133

Mpa, and the lowest thermal conductivity, 0.037 W/mK, are obtained when the mesh

number is 40, and the percentage is 80%. At the age of 40, the polyurethane foam

powder still has a fairly complete bubble structure, but 20% polypropylene melting does

not fill it; instead, it creates new, smaller bubbles. When the percentage is set to 50, and

the mesh size is 120, the maximum tensile strength is 9.913 Mpa, and the thermal

conductivity is 0.1253 W/mK. Although it is only 54% as thermally conductive as pure

polypropylene board, which is 0.23 W/mK thermally conductive, the value of 0.1253
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W/mK has also met the standards for materials used in thermal insulation (Gama et al.,

2020).

Comparison of phenolic insulation boards and renewable plastic insulators

As discussed above, recycled polyurethane plastic is a type of recycled plastic

insulation made from recycled polyurethane foam. It is often considered more

sustainable than phenolic board insulation because it has several environmental

benefits. Below I discuss some reasons why recycled polyurethane plastic may be

considered more sustainable than phenolic board insulation:

Firstly, recycled plastic insulators are made from sustainable materials. Recycled

polyurethane plastic is made from recycled polyurethane foam, which diverts waste

from landfills and reduces the demand for new virgin materials. Phenolic board

insulation, on the other hand, is typically made from new, virgin materials, which can

have a greater environmental impact (Tingley et al., 2017). Secondly, energy-efficient,

recycled polyurethane plastic typically has a high R-value, which means it is very

effective at insulating and preventing heat loss. This can result in energy savings, as

buildings with recycled polyurethane plastic insulation require less energy to heat and

cool. On the other hand, phenolic board insulation may also have a high R-value, but it

may not be as effective at insulating as recycled polyurethane plastic.

Thirdly, under carbon emissions, the production of recycled polyurethane plastic

insulation typically generates fewer carbon emissions compared to the production of

phenolic board insulation. This is because the production of recycled polyurethane

plastic insulation requires less energy and raw materials compared to the production of
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phenolic board insulation (Alam et al., 2017). In addition, on durability, recycled

polyurethane plastic insulation is typically very durable and long-lasting. This means

that it may need to be replaced less frequently, reducing the overall environmental

impact of insulation over time. On the other hand, phenolic board insulation may also be

durable but not as long-lasting as recycled polyurethane plastic insulation.

Fourthly, considering water resistance, recycled polyurethane plastic insulation is

typically resistant to water, making it suitable for use in damp or humid environments.

This can be beneficial in terms of sustainability, as it can help to prevent mold and other

moisture-related issues that can contribute to the deterioration of building materials (He

et al., 2021). Phenolic board insulation, on the other hand, is not as resistant to water

and may not be suitable for use in damp or humid environments. In addition, recycled

polyurethane plastic insulation is typically classified as a Class 1/Class A building

material, meaning it has excellent fire resistance properties. This can be beneficial in

terms of sustainability, as it can help to prevent fires and the associated carbon

emissions and air pollution (Yuan et al., 2017). Phenolic board insulation is also typically

classified as a Class 1/Class A building material, but it may not offer the same level of

fire resistance as recycled polyurethane plastic insulation.

Lastly, recycled polyurethane plastic insulation is made from non-toxic materials and

does not emit any volatile organic compounds (VOCs). This may improve indoor air

quality and reduce air pollution's potential negative health impacts. Phenolic board

insulation may also be made from non-toxic materials, but it may emit VOCs, which can

negatively impact indoor air quality (Kim et al., 2020).

Comparison of thermal conductivity

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The ability of a material to conduct heat is measured by its thermal conductivity. In the

context of insulation, materials with a lower thermal conductivity are generally

considered more effective at insulating and preventing heat loss. Some reasons why

recycled polyurethane plastic insulation may be preferred over phenolic board insulation

in terms of thermal conductivity:

Higher R-value: Recycled polyurethane plastic insulation typically has a higher R-value,

which means it is more effective at insulating and preventing heat loss. A material's

thermal resistance is measured by its R-value, and materials with a higher R-value are

typically better insulators. Phenolic board insulation may also have a high R-value, but it

may not be as effective at insulating as recycled polyurethane plastic insulation. In

addition, to higher R-value, recycled polyurethane plastic insulation typically has a lower

thermal conductivity than phenolic board insulation. This means it is less effective at

conducting heat, making it a better insulator. Phenolic board insulation may also have a

low thermal conductivity, but it may not be as effective at insulating as recycled

polyurethane plastic insulation.

Conclusion

This study analyzes the environmental implications of phenolic foam insulation across

various impact areas, with a special focus on the entire production process, from raw

materials to finished goods. It is hoped that by describing the techniques and the

assumptions used, the information given would be sufficiently accessible to enable

others to use it in other LCA studies, filling the gap in the body of knowledge on the

environmental effect that is currently available. The effects have been analyzed and

depicted visually to use the information in individual case studies to examine impacts
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and payback times for 1 kilogram of phenolic foam. The presented data should make it

straightforward to evaluate phenolic materials against recyclable plastic insulators.

One major advantage of recycled plastic polyurethane plastic insulators is their

sustainability. These insulators are made from recycled materials, which divert waste

from landfills and reduce the demand for new, virgin materials. In contrast, phenolic

board insulators are typically made from new, virgin materials, which can have a greater

environmental impact. Recycled polyurethane plastic insulators also tend to be more

energy efficient than phenolic board insulators. These insulators have a high R-value,

which effectively insulates and prevents heat loss. As a result, buildings with recycled

plastic polyurethane plastic insulators require less energy to heat and cool, leading to

energy savings and reduced carbon emissions. Phenolic board insulators may also

have a high R-value, but they may not be as effective at insulating as recycled plastic

polyurethane plastic insulators.

In addition to their energy efficiency, recycled plastic polyurethane insulators offer other

environmental benefits. For example, these insulators are resistant to water and are

suitable for use in damp or humid environments. This can help to prevent mold and

other moisture-related issues that can contribute to the deterioration of building

materials. On the other hand, Phenolic board insulators are not as resistant to water

and may not be suitable for use in damp or humid environments. Considering these

environmental benefits, recycled plastic polyurethane insulators also offer practical

advantages. For example, they can help reduce noise transmission between rooms and

floors in a building, improving overall acoustic performance. They are also made from

non-toxic materials and do not emit any volatile organic compounds (VOCs), which can
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help to improve indoor air quality. Phenolic board insulators may offer some of these

benefits, but they may not be as effective as recycled plastic polyurethane insulators.

Overall, recycled plastic polyurethane insulators offer numerous environmental and

practical benefits compared to phenolic board insulators. Their sustainability, energy

efficiency, water resistance, fire resistance, and impact on indoor air quality make them

preferable for insulation in many applications.

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