Project Summary
Approved for funding through ERA’s Biological GHG Management Program in 2014, 1782815 Alberta Ltd aimed to develop a polyurethane (PU) spray foam with bio-polyol formula to replace conventional commercial petrochemical polyol formulas. By completion in 2015, the project developed and tested a spray foam insulation product that incorporated renewable materials from the agricultural sector, instead of using greenhouse gas (GHG) generating fossil fuels.
Bio-Based Spray Foam Insulation
Building insulation is an important material that can help reduce space heating energy demand. Spray polyurethane foam (SPF) is an attractive solution to replace conventional, lesser quality fibreglass batt (FGB) insulation; however, most SPF products are derived from fossil fuel materials. 1782815 Alberta Ltd partnered with Green Analytics and the Lipids Chemistry Group LCG at the University of Alberta to develop a novel bio-based SPF product utilizing local canola oil feedstock to produce a bio-polyol product that aims to reduce the carbon intensity of SPF insulation.
The project conducted an environmental life cycle assessment for a bio-polyol-based SPF product used as building envelope insulation material, estimated the relative building operational energy and GHG reductions when SPF insulation is used in place of FGB insulation, and estimated total GHG mitigation potential due to the utilization of SPF insulation in Alberta’s residential building sector.
Bio-SPF has Significant GHG Reduction Potential, Requires More Research
The results of the environmental LCA indicate that potentially substantial GHG reductions are possible by both 1) replacing conventional fossil fuel-based polyol, which makes up ~40% of the final SPF insulation product, with bio-polyol and 2) replacing the conventional blowing agent with the use of a methyl formate blowing agent with zero global warming potential (GWP).
The project evaluated the operational building performance of the SPF insulation, which has a lower energy demand compared to conventional insulation. Although the bio-SPF product has a higher carbon footprint, the evaluation determined a GHG payback period of less than one year before realizing benefits.
Lastly, the project developed several SPF market penetration scenarios, considering annual increase, GHG reductions from reduced operation building energy demand, and the price of carbon. A significant amount of revenue could be generated if the bio-SPF product is successfully commercialized and widely adopted in the province.
The project results indicate the bio-SPF being developed is a promising alternative to conventional spray foam and fibreglass insulations, if paired with a low GWP blowing agent. Preliminary results indicate the bio-SPF is an environmentally superior product; however, more empirical research is required to guarantee energy savings and GHG reductions.
What’s next?
1782815 Alberta Ltd. became OleoFoam Inc., which was later awarded funding by Alberta Innovates in 2016 to advance the production of canola-based rigid polyurethane foams, testing, and application for certification under the Canadian Construction Materials Council.
Post project, OleoFoam continued working with the University of Alberta Lipid Chemistry Group LCG to develop rigid foam insulation for construction. At the start of their multi-product oleochemical production project in 2017, LCG had developed plant oil-based chemicals (polyols) to be used in the production of polyurethane (PU) foam insulation. Although OleoFoam no longer exists, LCG found interest in the polyurethane PU foam product that was developed and was able to further develop the fire-retardant properties of the foam. Multiple pilot-scale batches of canola polyols were produced under this project for their evaluation.
In the past decade, other organizations have continued to develop eco-friendly spray foam insulations, which are now commercially available. For some, the higher cost of material and supply chain sustainability remains a challenge; however, ongoing research and development will advance performance and cost-effectiveness.