Synthesis of Lipid Based Polyols from 1-Butene Metathesized Palm Oil for Use in Polyurethane Foam Applications
Total Page:16
File Type:pdf, Size:1020Kb
Synthesis of Lipid Based Polyols from 1-butene Metathesized Palm Oil for Use in Polyurethane Foam Applications A Thesis Submitted to the Committee on Graduate Studies in Partial Fulfillment of the Requirements for the Doctor of Philosophy in the Faculty of Arts and Science TRENT UNIVERSITY Peterborough, Ontario, Canada © Copyright by Prasanth Kumar Sasidharan Pillai 2015 Materials Science PhD. Graduate Program January 2016 Abstract Synthesis of Lipid Based Polyols from 1-Butene Metathesized Palm Oil for Use in Polyurethane Foam Applications Prasanth Kumar Sasidharan Pillai This thesis explores the use of 1-butene cross metathesized palm oil (PMTAG) as a feedstock for preparation of polyols which can be used to prepare rigid and flexible polyurethane foams. PMTAG is advantageous over its precursor feedstock, palm oil, for synthesizing polyols, especially for the preparation of rigid foams, because of the reduction of dangling chain effects associated with the omega unsaturated fatty acids. 1-butene cross metathesis results in shortening of the unsaturated fatty acid moieties, with approximately half of the unsaturated fatty acids assuming terminal double bonds. It was shown that the associated terminal OH groups introduced through epoxidation and hydroxylation result in rigid foams with a compressive strength approximately 2.5 times higher than that of rigid foams from palm and soybean oil polyols. Up to 1.5 times improvement in the compressive strength value of the rigid foams from the PMTAG polyol was further obtained following dry and/or solvent assisted fractionation of PMTAG in order to reduce the dangling chain effects associated with the saturated components of the PMTAG. Flexible foams with excellent recovery was achieved from the polyols of PMTAG and the high olein fraction of PMTAG indicating that these bio-derived polyurethane foams may be suitable for flexible foam applications. PMTAG polyols with controlled OH values prepared via an optimized green solvent free synthetic strategy provided flexible foams with lower compressive strength and ii higher recovery; i.e., better flexible foam potential compared to the PMTAG derived foams with non-controlled OH values. Overall, this study has revealed that the dangling chain issues of vegetable oils can be addressed in part using appropriate chemical and physical modification techniques such as cross metathesis and fractionation, respectively. In fact, the rigidity and the compressive strength of the polyurethane foams were in very close agreement with the percentage of terminal hydroxyl and OH value of the polyol. The results obtained from the study can be used to convert PMTAG like materials into industrially valuable materials. Keywords Cross Metathesis; Metathesized Triacylglycerol (MTAG); Fractionation; Polyols; Hexol; Tetrol; Diol; Olein; Stearin; Glycerol Composition; Polyurethane Foams; Compressive Strength; Recovery. iii Acknowledgements Its extreme pleasure to thank all the good hearted people who showered immense support and help in achieving this milestone. I would never be able to finish this Ph.D without the kind contributions from many of the wonderful people. In this pleasant occasion I would like to thank all these wonderful people from my heart. I would like to express my sincere thanks and respect to my supervisor, Prof. Suresh S. Narine for giving me this wonderful opportunity. At this time I thank him for his magnificent guidance and immense support throughout the program. He is a brilliant mentor as well as a good friend who cares a lot about the welfare of the people who depended on him. Without the priceless learning and incalculable experience obtained from him, I would not be able to finish this work. I would like to thank Dr. Laziz Bouzidi and Dr. Shaojun Li for their kind advices and valuable suggestions during my Ph.D. Also I take this opportunity to thank my supervisory committee members Dr. Andrew Vreugdenhil and Dr. Ghaus Rizvi for their kind advices and motivations. I would like to thank Professor Sabu Thomas for their immense and generous help showered one me on all my difficult times. I am also Thankful to Dr. Laly A. Pothen and Abraham Mathew for their immense support and motivation all the time. I have a million thanks for Ms. Athira Mohanan for her incredible and selfless support throughout the Ph.D. Without her unconditional support and valuable advices, I would not be able to finish my Ph.D. I am thanking all my colleagues Ms. Latchmi Regunanan, Ms. Shegufa Merchant, Mr. Michael Floros, Mr. Avinaash Persaud and Dr. Jesmy Jose for their kind help and valuable iv suggestions throughout my Ph.D. Also I am grateful to our Lab managers and technicians Ali Mahdevari, Carolyn Payne, John Breukelar, Peter Andreas for their valuable supervision and support during this period. I would like to thank Rekha Singh, the administrative secretary of our group for her kind support on all difficult times during my Ph.D. I would like to thank the Grain Farmers of Ontario, Elevance Renewable Sciences, Trent University, the GPA-EDC, Ontario Ministry of Agriculture, Food and Rural Affairs, Industry Canada and NSERC for their financial support I thank all my friends for their valuable suggestions throughout my life. A special thanks to Mr. Tino Justin, Hassan Damji, Mohammed Jawad Nathoo and Mike Harrison Charles, who were always there with me on all my difficulties. I am also grateful to Dr. Swaroop Sasidharan Pillai, Dr. Dinesh T. Sreedharan for their precious support. Finally my appreciation goes to my family for their selfless support. Exclusively, I am always grateful to my parents, Sasidharan Pillai and Prasanna Kumari. I would like to thank my sister Sree Lekshmi. P and brother in law Sarath S. Kurup for their unconditional support and taking care my parents Sasidharan Pillai and Prasanna Kumari while I am miles away from home. Also I am so thankful to my uncle B. Sivan Pillai for his support and advices throughout my life. v Table of Contents Abstract ........................................................................................................................... ii Keywords ...................................................................................................................... iii Acknowledgements ....................................................................................................... iv Table of Contents .......................................................................................................... vi List of Figures ............................................................................................................... xii List of Schemes ........................................................................................................... xvi List of Tables ............................................................................................................... xix List of Abbreviations ................................................................................................ xxiii 1 Introduction............................................................................................................ 1 1.1 Motivation and Objectives .................................................................................... 1 1.2 Background ........................................................................................................... 4 1.2.1 Polyurethanes ............................................................................................... 4 1.2.2 Polyurethane foams ..................................................................................... 5 1.2.3 Polyols ......................................................................................................... 6 1.2.4 Petroleum Polyols ........................................................................................ 6 1.2.5 Vegetable Oil Based Polyols ....................................................................... 8 1.3 Factors Determining the Properties of PU Foams............................................... 14 1.3.1 Effect of Polyol Structure .......................................................................... 14 1.3.2 Effect of Isocyanate ................................................................................... 15 1.3.3 Effect of Catalyst ....................................................................................... 16 1.3.4 Effect of Blowing Agent ............................................................................ 17 1.3.5 Effect of Surfactant .................................................................................... 18 1.4 Problems of Vegetable oil Derived PU Foams ................................................... 19 vi 1.5 Rectification of Dangling Chain Issue ................................................................ 19 1.5.1 Olefin Metathesis ....................................................................................... 19 1.5.2 Fractionation by Crystallization ................................................................ 22 1.6 Hypotheses .......................................................................................................... 23 1.7 Thesis Outline ..................................................................................................... 26 1.8 References ........................................................................................................... 27 2 1-Butene Metathesized Palm Oil & Polyol Derivatives: Structure, Chemical Composition and Physical Properties.................................................................