Development of Breathable Bio-Based Polyurethane Foam from Indigenous Irish Biomass for Energy-Efficient Building Insulation

Project Description

Space heating accounts for 55–60% of energy use in Irish homes and schools, highlighting the urgent need for high-performance insulation as Ireland progresses toward Nearly Zero Energy Building (NZEB) standards. While insulation is critical to improving Building Energy Ratings (BER), existing fossil-based materials face limitations in terms of sustainability, breathability, and regulatory acceptance. Notably, open-cell polyurethane (PU) foam, used in over 100,000 Irish homes, still lacks CE certification and has faced concerns over indoor air quality and moisture management. This project proposes the development of breathable, bio-based polyurethane (BPU) insulation foams derived from two abundant yet underutilized Irish biomass sources: Ascophyllum nodosum (seaweed) and wheat straw. These feedstocks will be converted into bio-polyols through green chemical processes such as hydrothermal liquefaction and transesterification. The resulting polyols will be formulated into BPU foams optimized for thermal insulation, moisture permeability, mechanical integrity, dimensional stability, and fire resistance. Performance will be benchmarked against conventional petrochemical PU foams to assess commercial viability. By using indigenous renewable resources, the project supports Ireland’s bioeconomy strategy and Sustainable Energy Authority of Ireland (SEAI) objectives to reduce carbon emissions in the built environment. The initiative also contributes to rural development through the valorisation of marine and agricultural residues. Final outputs will include a lab-scale proof-of-concept and preliminary pilot data, supported by life cycle assessment (LCA) and techno economic analysis. These results will inform scalable solutions for energy efficient retrofitting and construction, helping to meet Ireland’s Climate Action Plan and retrofit targets through the development of CE-ready, low carbon insulation materials.