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<p>This study presents an innovative green intensification process for producing bio-polyurethane foams (PUFs) from waste cooking oil (WCO). By integrating ultrasonic atomization and high-shear mixing, critical limitations of WCO-based polyols, such as high viscosity and the low reactivity of secondary hydroxyl groups, are addressed. The developed experimental apparatus enhances water solubility in polyol through mist generation, enabling efficient foam formation with a 40% lower density (0.085&#xa0;g/cm³) and a finer, more uniform cellular structure compared to conventional methods. Dynamic mechanical analysis (DMA) reveals improved thermal stability, with the glass transition temperature (Tg) increasing by ~ 10&#xa0;°C. XRD and FTIR analyses confirm tailored crystallinity and enhanced crosslinking. This work advances sustainable polymer engineering by adhering to green chemistry principles, offering a scalable, and eco-friendly polyurethane production method with reduced fossil fuel dependency.</p>

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Green intensification of waste cooking oil-based bio-polyurethane foams: ultrasonic and high-shear mixing for enhanced performance and sustainability

  • 期刊论文

  • 出版模式：

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  • 发表日期：

    2026年7月2日

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  • Hendi Saryanto,
  • Anika Zafiah Rus,
  • Yazid Saif,
  • Hafizh Alamsyah,
  • M. R. Shaiqah

摘要

This study presents an innovative green intensification process for producing bio-polyurethane foams (PUFs) from waste cooking oil (WCO). By integrating ultrasonic atomization and high-shear mixing, critical limitations of WCO-based polyols, such as high viscosity and the low reactivity of secondary hydroxyl groups, are addressed. The developed experimental apparatus enhances water solubility in polyol through mist generation, enabling efficient foam formation with a 40% lower density (0.085 g/cm³) and a finer, more uniform cellular structure compared to conventional methods. Dynamic mechanical analysis (DMA) reveals improved thermal stability, with the glass transition temperature (Tg) increasing by ~ 10 °C. XRD and FTIR analyses confirm tailored crystallinity and enhanced crosslinking. This work advances sustainable polymer engineering by adhering to green chemistry principles, offering a scalable, and eco-friendly polyurethane production method with reduced fossil fuel dependency.