Fully Funded EPSRC iCASE and TATA Steel PhD Scholarship: Development of Biomimetic Insulation Foams

Funding providers: EPSRC iCASE and TATA Steel UK

Subject areas: Chemistry, materials science, engineering

Project start date: 

• 1 October 2024 (Enrolment open from mid-September)

Project description: 

Tata Steel BSUK’s current sandwich panel insulation products offer an outstanding combination of light weight, low thermal conductivity and high fire resistance performance characteristics. However, the polyisocyanurate (PIR) rigid foam core that offers so many in-use benefits is currently made using chemicals derived largely from fossil fuels. Particularly problematic is the isocyanate component that makes up approximately 50% of the formulation but which is entirely fossil fuel-based. Hence, this project seeks to develop an alternative PIR foam that at least matches all the existing in-use performance characteristics of PIR foam but which is manufactured using either a bio-based isocyanate or is generated entirely without the use of an isocyanate. 

In seeking to develop a foam formulation containing a bio-based isocyanate, there will be a strong emphasis on generating the material from a biomass source that is cheap, readily available and relatively easy to make. Compatibility with the polyol component of the formulation is vital to foam quality and consistency and is an important aspect of the experimental work. The scaling potential of the biomass conversion process will also be considered and, if required, methods to improve the speed etc will be investigated. 

A few laboratory-scale examples of non-isocyanate polyurethane foam systems have been demonstrated in the literature and will form the starting point for the current work. This appears to be a relatively new field and offers great development scope but vital to a successful outcome will be the suitability of the kinetics to a foaming reaction. This unknown will be studied and, if necessary, methodologies will be developed to ensure compatibility. 

Analysis and testing of development materials will form a key part of the project and a range of state of the art characterisation facilities is available at Swansea University. These are further supported by performance testing facilities (e.g. fire) at BSUK’s manufacturing facility at Shotton in North Wales. 

Financial margins in the construction sector tend to be very tight so any new developments must offer outstanding performance at a competitive price. The cost implications and scale-up potential of any new insulation material are vital to product success and such considerations will form the basis of a technoeconomic analysis.

Eligibility

Candidates must hold an undergraduate degree at 2.1 level (or Non-UK equivalent as defined by Swansea University) in Engineering or similar relevant science discipline.

English Language: IELTS 6.5 Overall (with no individual component below 5.5) or Swansea University recognised equivalent.

This scholarship is open to candidates of any nationality.

Please visit our website for more information on eligibility.

Additional Funding Information

This scholarship covers the full cost of tuition fees and an annual stipend of £19,237 plus an additional set payment of £1,500 per year. 

Additional research expenses will also be available.

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