Aerogels are synthetic lightweight materials with extraordinary properties, including high porosity and low density. They are made by replacing the liquid in a gel with air, while preserving the structure of the solid. Aerogels are excellent thermal insulators because air conducts heat very poorly. Capiworld has led a research team to develop an innovative aerogel insulation using recycled polyethylene terephthalate (PET) plastic, the material used to make water bottles and other containers.
In the lab, we developed a process to cross-link recycled PET fibers into an aerogel structure with pores largely filled with air. We found that by carefully controlling the chemistry, we were able to create a material with the density of air but the strength of an insulating foam. Our PET-based aerogel, named POLYCYCLE, achieved a thermal conductivity of around 0.035 W/mK, which is competable to fiberglass and on par with other aerogel materials.
To scale up the process, we built a small pilot plant that can produce POLYCYCLE panels at a rate of 200 square meters per day. The key steps are: 1) Seperating and layering recycled PET fibers to prepare the raw material. 2) Cross-linking the PET fibers in a chemical solvent to form a gel. 3) Removing the solvent from the gel by drying in ambient condition.
For manufacturing, we developed a continuous production process and constructed the world’s first plant to produce POLYCYCLE on a large scale. Our manufacturing line can produce over 10,000 square meters of POLYCYCLE panels per day, enough to insulate dozens of homes. The aerogel is formed into pre-fabricated panels for easy installation.
In summary, we have successfully turned recycled plastic waste into a sustainable and high-performance insulation material. POLYCYCLE keeps more heat in compared to other insulations, reducing energy usage. It is also moisture-resistant, rot-proof, and durable. This novel material provides an environmentally-friendly solution to better insulate homes and buildings. With further cost reduction, POLYCYCLE promises to make a significant impact on improving energy efficiency and comfort.
(2) Progress in Recycled PET Aerogels
Our research team has been developing innovative aerogel materials using recycled polyethylene terephthalate (PET) plastic. We started by producing PET-based aerogels, called POLYCYCLE, for building insulation, as described in our previous article. With its low density and high porosity, aerogel is an excellent insulator and sound dampener.
We have since expanded the applications of POLYCYCLE to include absorption and filtration. For absorption, we have developed oil spill cleaning aerogels that can absorb up to 30 times their own weight in oils and organic solvents. The hydrophobic and oleophilic properties of the aerogels enable them to absorb oils and repel water. POLYCYCLE can play an important role in remediating oil spills and other leaks with minimal secondary waste.
For filtration, we have produced POLYCYCLE with pores of specific sizes that can efficiently filter out particles, colloids, and molecules. They have a high surface area and porosity, making them suitable for air, water and wastewater filtration. The properties of POLYCYCLE can be tailored based on the application. They represent a low-cost and sustainable alternative to traditional filters.
Scaling up has been an important part of our progress. We have improved our manufacturing techniques to produce POLYCYCLE at high volumes and low cost. We built the world’s first large-scale plant dedicated to POLYCYCLE, with a capacity of 10,000 square meters per day. This has allowed the commercialization of our insulation, absorption and filtration aerogel products.
POLYCYCLE demonstrate the potential of plastics after use. Turning recycled plastic bottles into high-performance, value-added materials helps build a circular economy. Our research has shown that plastics need not be treated as waste, but rather, a renewable resource for sustainable solutions. With continued innovation, POLYCYCLE are poised to impact a wide range of industries in the coming decades. They represent a new generation of recycling and upcycling, transforming waste into products that make a difference.
In summary, we have turned a discarded plastic—PET—into a versatile set of aerogel materials for insulation, absorption and filtration. From sustainability to commercial impact, POLYCYCLE show the benefits of thinking beyond single-use in plastics. They give new purpose to used plastic bottles, making recycling and beyond.
(3) POLYCYCLE: A Sustainable Insulation from Recycled Plastic
POLYCYCLE is an innovative insulation material made of 100% polyester fibers. It is produced using an environmentally-friendly process that turns plastic waste into a high-performance insulation product. With 80% recycled polyester content, POLYCYCLE promotes sustainability by reducing waste and energy usage.
POLYCYCLE has a thermal conductivity of 0.035 to 0.042 W/mK, giving it excellent insulating properties for building insulation. It helps improve energy efficiency by keeping more heat in. POLYCYCLE may not be suitable for all fire regulation applications, so fire engineers should be consulted for specifications. However, POLYCYCLE itself is non-flammable and non-toxic.
POLYCYCLE also has acoustic insulation properties by reducing noise transmission in wall cavities and floor spaces. It is naturally resistant to moisture, rot, and corrosion, with no loss of R-value over time. The material is chemically inert and considered non-allergenic and non-irritating, with no hazardous materials.
At the end of its useful life, POLYCYCLE is 100% recyclable. It can be re-dissolved and re-fabricated into new insulation, completing the recycling loop. This sustainable feature minimizes waste and maximizes resource efficiency.
POLYCYCLE represents an eco-friendly solution for residential, commercial and industrial insulation. It helps companies and homeowners improve energy efficiency, lower costs, and reduce environmental impacts. With its combination of cutting-edge performance and sustainability, POLYCYCLE is set to make a significant difference in the building insulation industry. Its use of recycled material and recyclability provides substantial sustainability benefits for a greener future.
