NOVEX Advances Sustainable Polyurethane Solutions for Construction under ZIRCON Project

The NOVEX Technology Centre, within the framework of Spain’s Science and Innovation Missions Programme (CDTI) and in collaboration with Ensatec laboratories and Geopannel, is completing the final stage of the ZIRCON project, focused on developing and validating sustainable polyurethane materials for the construction industry.

Running for one year from 1 November 2024 to 31 December 2025, the R&D&I initiative has been executed with a total budget of €1.66 million, supported by a public grant of approximately €0.86 million. The project has been led by NOVEX’s sustainability and advanced materials area, with a dedicated team of eight researchers working on innovative routes for recycling polyurethane foam waste.

Two complementary approaches have been explored: mechanical recycling, involving the shredding of waste foams for reuse in applications such as acoustic panels, and chemical recycling, which has enabled the recovery of polyols through glycolysis and the subsequent production of new polyurethane foams containing recycled content.

Recent progress includes the definition of demonstrators, with the selection of optimised processes and products suitable for scale-up and validation in real environments, including insulating panels, enclosures for livestock buildings and ornamental construction elements. In parallel, proof-of-concept and validation activities have been carried out under real operating conditions to ensure that the new materials meet the technical, safety and commercial requirements of the construction sector.

The project has also integrated bio-based and recycled polyurethanes, fire-retardant additives and innovative insulation systems, contributing to improved energy efficiency and reduced environmental impact.

Source: Fedit