Monument has begun the first US-based production of polyols from renewable carbon this month at its manufacturing facility in Brandenburg, KY.
The new product line of polycarbonate ether (PCE) polyols is based on a process from Econic Technologies that replaces fossil-based feedstocks with captured CO2 and reduces global warming potential by 20-30%.
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Overcoming formulation and processing challenges
Branded Poly-CO2, Monument’s new line of PCE polyols can be used to make high-performance polyurethanes for furniture and mattresses, automotive parts, apparel and footwear, coatings, adhesives, sealants, and elastomers.
Incorporating carbon at the molecular level can impart performance benefits in a range of polyurethane applications from foams to flame lamination to adhesives and elastomers. For example, Poly-CO2 can improve resilience in mattress foams and durability in coatings.
Poly-CO2 polyols also have several environmental benefits. In addition to reducing the carbon footprint of end products, they allow companies to design for circularity by keeping carbon in use and out of the atmosphere. Moreover, they can be used alone or together with recycled and bio-based polyols, and they are compatible with emerging recycling systems.
Thanks to Econic’s proprietary renewable carbon technology, Poly-CO2 products overcome some of the formulation, processing, storage, and handling challenges sometimes found in other CO2-based products. For example, foam manufacturers can continue using the same standard surfactants and catalysts used in traditional polyether and polyester polyols. Additionally, with Poly-CO2, carbon dioxide is more evenly distributed along the backbone of the polymer to ensure performance, quality, and stability.
The new product line will launch on the pilot scale, with commercial scale production coming to market in the coming years.
“This is a big step for Monument and the industry as a whole. Historically, the introduction of new technologies is met with several barriers to entry, including processing constraints, handling concerns, and application feasibility. Econic’s technology will allow us to upcycle waste carbon dioxide into polyols for high-performance materials, while eliminating a lot of those barriers to commercialization. We’re excited to be partnering with Econic and playing a role in moving the industry forward in innovation,” said Deb Schofner, Monument sales director.
“The entire industry is determined to drive toward net-zero, but given how traditionally standardized this industry is, not everyone is willing to take the first leap. Monument is always looking for new ways to innovate and expand our capabilities to better serve our customers. We saw this as an opportunity to be that role model for our industry and to show our customers that regardless of their needs, we can create new products and processes that meet them — and we can deliver positive change for the future while doing it,” explained Don Phillips, vice president, Oxides.
“Companies around the world are transforming their product portfolios to better serve society now and in the future. Monument is leading the way in sustainable polyols by being the first American company to commercialize this new product line based on renewable carbon, which will give their customers a competitive advantage,” said Keith Wiggins, CEO of Econic Technologies.
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