Polyurethanes are an important class of polymers because of their wide industrial applications in automobiles, construction, household appliances, medicine, packaging, furniture, thermal, and electrical/vibration insulations. There is a global effort to replace petrochemicals with compounds from renewable resources. We propose to use soybean oil for the preparation of non-isocyanate polyurethanes using a cost-effective method that can be used for consumer as well as industrial applications. We plan to synthesize non-isocyanate polyurethanes using soybean oil-based compounds as a substitute for petrochemical-based polyols. Soybean oil-based non-isocyanate polyurethanes will be used for foams, coatings, and adhesives industries.

Traditional polyurethane synthesis stems from the polyaddition reaction of diisocyanates and diols, both of which are largely derived from fossil fuel sources. The isocyanates are produced from hazardous and toxic phosgene gas by the phosgenation process. Phosgene is an extremely toxic gas. Additionally, the isocyanates are toxic and moisture-sensitive and cannot be prepared without sophisticated safety devices, thus posing serious environmental and human health risks. Consequently, a strong thrust has been directed to polyurethanes that avoid diisocyanates and have a reduced carbon footprint.
This proposal provides a solution to both problems. We propose to synthesize non-isocyanate polyurethanes using soybean oil-based compounds as a substitute for petrochemical-based polyols. We will also use carbon dioxide during the synthesis of non-isocyanate polyurethanes which is a global warming gas. The conversion of carbon dioxide into value-added and safe chemicals is very attractive to industries and environmental protection agencies. Non-isocyanate polyurethane-based foams, coatings, and adhesives will be developed for industrial applications.

There has been increased demand for the utilization of renewable materials for industrial applications. Soybean oil will be applied for value-added applications in polyurethanes, coating, and adhesive industries. The global polyurethane market size was estimated at over $72 billion in 2021, exhibiting a CAGR of 4.3% over the forecast period of 2022-2030. The market is driven by the presence of stringent environmental regulations designed by various regulatory bodies. Environmental concerns are likely to continue playing a key role in the formulation and use of these materials. The proposed research on soybean oil-based value-added materials will provide new pathways to utilize a large quantity of soybean oil providing greater value for the soybean farmers. The initial seed money from the Kansas Soybean Commission will help us to develop technology for commercialization. The societal impact of this project is significant as this proposal provides an opportunity for students to be involved in research, education, and product development. The outcome of this research will be used for business development, which will provide economic development to the State of Kansas. We expect to have a patent, two graduate thesis, and three peer-reviewed publications. The outcome of the project will be presented in seminars at Pittsburg State University and at conferences (after protecting intellectual properties). These seminars will be opened to the public to enhance community involvement in science and education. This will be a great platform to create public awareness regarding the value-added applications of soybean oil.

Polyurethanes are used in the production of flexible foams (39%), rigid foams (26%), coatings (13%), binders (4%), elastomers, and adhesives. The global polyurethane market size was valued at USD 72.82 billion in 2021 and is expected to expand at a compound annual growth rate (CAGR) of 4.3% from 2022 to 2030. Over 24 million metric tons of polyurethane were used globally in 2021. Utilizing soybean oil for such a huge industry will generate a demand of ~ 15 million metric tons of soybean oil (over 3 billion soybean bushels) per year. Kansas ranked 10th in soybean production among US states. Soybeans will provide a good source of raw material for the polyurethane industry. Creating advanced materials and technologies using soybean oil will provide financial benefits to soybean growers.