Bio-based monomers for epoxy resins from waste oils

Technological Overview

A Polish research organisation has developed an innovative technology for the synthesis of high-performance epoxy monomers and resins derived from renewable resources and industrial oily waste streams, mainly used cooking oil converted into biodiesel.

The solution addresses the challenge of replacing petrochemical-based thermosets with bio-based alternatives without compromising technical performance. By using vegetable oils and fatty acid residues as primary feedstocks, it provides a resource-efficient route to functionalised epoxy precursors. The process is based on the epoxidation of biodiesel obtained from oil and is designed to be scalable and environmentally friendly.

The bio-based molecules are engineered to be fully miscible with conventional epoxy systems, which facilitates their integration into existing industrial manufacturing lines. Formulations containing the bio-based monomers exhibit thermal stability and mechanical strength comparable to commercial resins. So far, 30% of petrochemical epoxy monomers have been successfully replaced with the renewable alternative, which means a significant reduction in the use of Bisphenol A based components.

Advantages and innovations

The proposed technology offers the following advantages and innovative aspects:

• 30% of petrochemical epoxy monomers already replaced with a renewable alternative;

• significant replacement of Bisphenol A based components with bio-derived functional building blocks;

• use of renewable feedstocks and industrial oily waste streams, mainly used cooking oil, supporting circular economy and resource efficiency;

• scalable synthesis process;

• full miscibility and chemical compatibility with existing epoxy systems;

• easy integration into existing industrial manufacturing lines;

• comparable thermal stability and mechanical strength of the formulations to petrochemical benchmarks;

• suitability for further laboratory and pilot-scale validation and technology transfer towards industrial applications.

Our Organization

Poznan Science and Technology Park (PPNT) is the first science and technology park in Poland, established in 1995 and operating within the Adam Mickiewicz University Foundation. We bridge the gap between academic breakthroughs and industrial application. As a research and technology organisation, we work in organic chemistry, advanced materials development and agrochemistry.

Our expertise includes:

• Synthesis of bio-based epoxy monomers and resins: from waste oily streams (including used cooking oil) and other renewable feedstocks.

• Waste valorisation: use of industrial oily waste streams as feedstocks for polymer precursors.

• Application-oriented formulation: optimisation of epoxy systems with partial replacement of petrochemical, BPA-based components, including miscibility and compatibility with commercial epoxy resins.

• Basic material characterization: curing behaviour and thermal and mechanical properties of cured materials.

• Scale-up excellence: laboratory-scale synthesis and scale-up of production up to 100 kg per batch.

• SSbD contribution: support for safe-and-sustainable-by-design polymer development, laboratory- and pilot-scale validation and technology transfer towards industrial applications.

• Science dissemination and popularization: organizing conferences, workshops and trade fairs.

Collaboration

We are looking for projects to join as research institution and consortium partner.