Pheno-Recycle: Phenolic Resin Is Finally Recyclable
The result of a collaboration between researchers at the Charles Gerhardt Institute in Montpellier (ICGM) and Saint-Gobain, the Phéno-recycle project has led to the development of innovative processes for recycling phenolic resin—one of the most solid forms of waste in the chemical industry, which until now was destined for incineration or landfilling. Supported by the University Innovation Cluster in Montpellier, this virtuous partnership has been a resounding success.
They have overcome an industrial impasse in less than three years. Working hand in hand, researchers from the Charles Gerhardt Institute in Montpellier (UM/ENSCM/CNRS) and Saint-Gobain have finally found a way to recycle phenolic resin, one of the most resistant—and until now, non-compressible—wastes in the chemical industry. And to cap off this first successful collaboration, the two partners, bolstered by the support of the University Innovation Cluster, have just filed a patent application.
High-performance thermosetting polymers
The story begins in 2021. Saint-Gobain partnered with ICGM, which specializes in the synthesis of phenolic resins with reduced environmental impact (formaldehyde-free) and“places particular emphasis on recycling and the more responsible use of resources,” notes Vincent Ladmiral, a research director at the institute.
The industrial manufacturer Saint-Gobain uses these phenolic resins to develop insulation materials, such as glass wool, and to manufacture abrasives, such as sandpaper.
“There is an issue with these materials, which have an extremely long lifespan. They are thermosetting polymers, primarily composed of carbon-carbon bonds—one of the strongest bonds in chemistry. They are extremely resistant to aging and chemical attack. They also have high thermal stability. So by definition, they are not easy to recycle,” explains the researcher.
Small, reusable molecules
Specifically, through a research project funded by Saint-Gobain starting in November 2022 and conducted under the National Agency for Technological Research (ANRT), the teams have found a way to break down this resin into smaller, reusable molecules. After publishing an initial proof of concept in 2023, the team joined the“Companies & Campus”initiative, a tool developed as part of the University Innovation Cluster and designed to enhance collaboration between public research and the business world.
Thanks to the €50,000 grant awarded through this call for projects by the University Innovation Cluster, the team was able to hire an additional engineer for 12 months. “We had the process, we already had promising recycling pathways, but Companies&campus allowed us to go further in understanding the depolymerization mechanism and the structure of these oligomers,” says Morgane Petit, head of the eco-processes and innovations research and development group for chemistry at Saint-Gobain Research Paris and coordinator of the sustainable chemistry network at Saint-Gobain.
“A win-win situation”
Through their research, scientists have succeeded in turning these resins into valuable byproducts. They have also managed to transform them into vitrimers, which have reversible properties. Invented in 2011, this new class of polymers consists of materials that can be melted down and recycled as often as needed… A godsend at a time when an ecological transition is essential. “It’s a win-win situation, ”says Vincent Ladmiral.
If Saint-Gobain implements this technology, it could enable the use of these recycled materials in the manufacture of new products, thereby helping to minimize the use of global resources. “We have high hopes for these materials, which could prevent the accumulation of thermosetting polymers that currently have no recycling solution. Until now, their end-of-life options were limited to incineration or landfilling.… So from both a scientific and industrial standpoint, this is a tremendous success, ” summarizes the ICGM researcher.