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Environmentally friendly vegetable oils and their derivatives represent alternatives to mineral-based lubricants. Vegetable oils have high biodegradability and low production costs. Their poor thermo-oxidative stability and poor low temperature properties are disadvantages in their use as lubricant basestocks. In our study we used corn oil and diester mixtures, which become lubricants when additives are introduced. These mixtures of corn oil and di-2-ethylhexyl-adipate (DOA) and di-2-ethylhexyl-sebacate (DOS) offer a wide range of kinematic viscosities, pour points lower than -39°C and flash points over 218°C. The diameters of wear scars measured under four-ball testing (40 daN) are less than 0.90 mm and the copper strip corrosion test result is 1a. The differential scanning calorimetry study and thermogravimetric study under nitrogen atmosphere and in synthetic air are reported. From these studies a higher thermal stability was observed for corn oil than for diester oils. The thermo-oxidative instability occurred at temperatures higher than 350°C. The low production cost of corn oil and its mixtures with diesters makes them an attractive alternative to mineral oil lubricants.

Ester polyurethane (PU) foam waste was reacted at atmospheric pressure in an autoclave and using microwaves with diethylene glycol (DEG) at different PU/DEG ratios in the presence of diethanolamine as a catalyst to find the glycolysis conditions that allow for the improved recovery of the PU foam waste and enable the recycling of the whole glycolysis product in foam formulations suitable for industrial application. The recycled polyol was characterized by dynamic viscosity, hydroxyl number, water content, and density, while thermal stability was assessed using thermogravimetric analysis. In the PU foam formulation, 1% and 5% of the glycolyzed material was reused. The relationship between the reuse level of the recycled polyol and the physical properties of the foam was thoroughly investigated. It was observed that both hardness and air flow decreased with increasing recycled polyol content, particularly for the polyester type foam, while tensile strength and compression strength increased. Depending on the amount of recycled polyol and catalyst used, polyether-based foams could be obtained with a low air permeability, needed in special applications as sealed foams, or with higher air permeability desirable for comfort PU foams. The results open the way for further optimization studies of industrial polyurethane foam formulations using a glycolysis process without any separation stage.

An industrially manufactured recycled polyol, obtained by acidolysis process, was for the first time proved to be a possible replacement of the reference fossil-based polyol in a low-density formulation suitable for industrial production of flexible polyurethane foams. The influence of increasing recycled polyol amounts on the properties of the polyurethane foam has been studied, also performing foam emission tests to evaluate the environmental impact. Using 10 pbw recycled polyol in the standard formulation, significant differences of the physical properties were not observed, but increase of the recycled polyol amount to 30 pbw led to a dramatic decrease of the foam air flow and a very tight foam. To overcome this drawback, N,N′-bis[3-(dimethylamino)propyl]urea was selected as tertiary amine catalyst, enabling the preservation of foam properties even at high recycled polyol level (30 pbw). Foam emission data demonstrated that this optimized foam formulation also led to an important reduction of volatile organic compounds. The results open the way for further optimization studies in low-density flexible polyurethane foam formulations, to increase the reutilization of the polyurethane waste and reduce the amount of petroleum-based raw materials.