Polyurethane Sustainability: Production of CO2-Based NIPUs

Non-isocyanate polyurethanes (NIPUs) are an advanced polymer solution leading to a safer and more sustainable alternative to traditional polyurethanes. The conventional production methods involve the usage of so-called toxic isocyanates such as MDI, TDI, etc.  

The polyurethanes produced via NIPU technology eliminate the usage of isocyanates entirely. The most common route of commercial production is via the reaction of cyclic carbonates and amines to form polyhydroxyurethanes (PHU). In this process, the cyclic carbonates are obtained via reacting epoxide and captured CO₂. This process utilizes carbon dioxide—a renewable, non-toxic, and abundantly available resource—and boasts 100% atom efficiency, ensuring that all reactants are fully incorporated into the final product.  

Another method of production involves the usage of harmless dicarbamate synthesized directly from CO₂. Methanol and CO₂ are reacted with diamines at a pressure of 50 bar to synthesize dicarbamates, which then replace isocyanates as building blocks in thermoplastic polyurethanes. 

IAL Insights: 

Non-isocyanate polyurethanes (NIPUs) have experienced growing research and commercial interest over the last two decades, driven by tightening regulations and sustainability-driven demands across several industries.  

Despite this scientific progress, NIPUs remain largely absent from global markets, constrained by immature production technologies, elevated manufacturing costs, and the absence of established industrial infrastructure. Their core advantage over traditional polyurethanes — the elimination of toxic isocyanates — makes them inherently safer for both workers and the environment, yet widespread adoption continues to be slowed by performance shortfalls, scalability hurdles, and limited compatibility with existing raw material supply chains.

Nevertheless, the long-term outlook for NIPUs remains encouraging: regulatory restrictions on isocyanates are intensifying, consumer and corporate appetite for sustainable materials is rising, and investment from industrial players in greener polymer chemistries is accelerating. As research matures and manufacturing capabilities expand, NIPUs are well-positioned to capture a meaningful share of the global polyurethane market in the years ahead. 

The graph below shows the substantial forecast growth in the production of NIPUs from 2030 onwards.  

   Source: IAL Consultants 

The current market therefore points to considerable growth within this segment as the underlying technology continues to mature. The segment is further projected to expand at a compound annual growth rate exceeding 90% through to 2035. 

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Research for this study was carried out in late 2025 and early 2026. Data are provided from 2021 to 2035, with the base year 2025.

To learn more about the report, please follow the link:

Global Overview of Sustainability in the Polyurethane Market 2026

For more information, please contact ial@brggroup.com

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