Comparative Study on Selected Properties of Modified Polyurethane Foam with Fly Ash

Abstract

The aim of the article is to compare two types of fly ash (from the fluidized and pulverized coal combustion process) as a filler for rigid polyurethane foam. Pulverized fly ash (PFA) is widely used in building materials, while fluidized fly ash (FFA) is not currently recycled, but landfilled. The produced rigid polyurethane foams were reinforced with 5 and 10% by weight addition of fly ash from two different types of boilers. The foaming process, physical properties, morphologies and thermal degradation were subject to comparative analysis. The research indicated that fly ash intensifies the reactions of foam synthesis, most commonly, polyurethane (PU) foam with an addition of 10% PFA. What is interesting is that both ashes can be used in PU foam technology as they do not cause deterioration of the physical parameters. As shown, the addition of filler affects the morphology and impairs the brittleness. Additionally, the use of fly ash from coal combustion in the technology of polyurethane materials complies with the guidelines of the circular economy stated in the European Union legislation. Partial replacement of petrochemical components with waste filler also reduces the total energy consumption in the production of PU composites.

Impact of Sunflower Press Cake and Its Modification with Liquid Glass on Polyurethane Foam Composites: Thermal Stability, Ignitability, and Fire Resistance

“…The first stage involved the degradation of urethane bonds at approximately 150–220 °C (the total weight loss was around 20%). Furthermore, the substantial weight loss due to the decomposition of soft polyol segments and the SFP as well as the SFP/LG fillers was observed at a temperature range of 220–400 °C [ 2 , 42 ]. In this temperature range, the percentage weight loss was found to be up to 50% [ 43 ].…”

“…Polyurethane (PUR) foams are an important group of polymers with many advantageous applications in various industries, such as for furniture, consumer bedding, automotive seats, cushioning, medicine, thermal insulation, sound absorption, and in specific locations where other materials would not be suitable because of the versatile chemistry of these products [ 1 , 2 ]. PUR is generally developed through the polyaddition reaction between isocyanates and polyols with other additives to improve the cellular structure and foaming [ 3 ].…”

Fire-resistant bio-based polyurethane foams designed with two by-products derived from sugarcane fermentation process

“…In the gure, the SEM micrographs the rst visible feature was the irregular structure revealed by both (PF and PFA) conditions, with the latter presenting apparent damage of cells probably caused by ash presence [49,50]. In addition to surface heterogeneity, PFA samples displayed micro-holes, in this case, due to the introduction of solid particles into the polyol premix that might signi cantly alter bubble nucleation conditions, which directly affects the size, shape, and number of pores, as well as pore wall thickness in the nal materials [51].…”

Synergistic effects of fly ash on thermal, combustion, and mechanical properties of polypropylene including intumescent flame retardant

“…FAs have been used in the production of composite materials using various polymer matrices, including polyester, polyethylene, polypropylene (PP), epoxy, and polyurethane 15–19 . However, due to the different chemical compositions and physical properties of FAs arising from different coals and combustion systems, diverse findings have been reported regarding the impact of FA additions on mechanical, thermal, and combustion properties of composite materials.…”

“…FAs have been used in the production of composite materials using various polymer matrices, including polyester, polyethylene, polypropylene (PP), epoxy, and polyurethane. [15][16][17][18][19] However, due to the different chemical compositions and physical properties of FAs arising from different coals and combustion systems, diverse findings have been reported regarding the impact of FA additions on mechanical, thermal, and combustion properties of composite materials. While FAs can be directly utilized in polymers without any surface modification, 20 it is worth noting that reducing particle size and modifying the surface of FAs can greatly enhance their compatibility with polymer interfaces.…”