molecules Article Physicochemical Properties of Jatropha Oil-Based Polyol Produced by a Two Steps Method Sariah Saalah 1 , Luqman Chuah Abdullah 2,3, *, Min Min Aung 3,4 , Mek Zah Salleh 5 , Dayang Radiah Awang Biak 2 , Mahiran Basri 4 , Emiliana Rose Jusoh 3 and Suhaini Mamat 2,6 1 2 3 4 5 6 * Chemical Engineering Programme, Faculty of Engineering, Universiti Malaysia Sabah, Jalan UMS, Kota Kinabalu 88400, Sabah, Malaysia; [email protected] Department of Chemical and Environmental Engineering, Faculty of Engineering, Universiti Putra Malaysia, Serdang 43400, Selangor, Malaysia; [email protected] (D.R.A.B.); [email protected] (S.M.) Higher Institution Centre of Excellence Wood and Tropical Fibre (HICoE), Institute of Tropical Forestry and Forest Products, Universiti Putra Malaysia, Serdang 43400, Selangor, Malaysia; [email protected] (M.M.A.); [email protected] (E.R.J.) Department of Chemistry, Faculty of Science, Universiti Putra Malaysia, Serdang 43400, Selangor, Malaysia; [email protected] Radiation Processing Technology Division, Malaysian Nuclear Agency, Kajang 43000, Selangor, Malaysia; [email protected] Universiti Kuala Lumpur, Malaysian Institute of Chemical and Bioengineering Technology (UniKL MICET), Alor Gajah 78000, Melaka, Malaysia Correspondence: [email protected] or [email protected]; Tel.: +60-3-8946-6288 Academic Editor: Derek J. McPhee Received: 10 February 2017; Accepted: 25 March 2017; Published: 29 March 2017 Abstract: A low cost, abundant, and renewable vegetable oil source has been gaining increasing attention due to its potential to be chemically modified to polyol and thence to become an alternative replacement for the petroleum-based polyol in polyurethane production. In this study, jatropha oil-based polyol (JOL) was synthesised from non-edible jatropha oil by a two steps process, namely epoxidation and oxirane ring opening. In the first step, the effect of the reaction temperature, the molar ratio of the oil double bond to formic acid, and the reaction time on the oxirane oxygen content (OOC) of the epoxidised jatropha oil (EJO) were investigated. It was found that 4.3% OOC could be achieved with a molar ratio of 1:0.6, a reaction temperature of 60 ◦ C, and 4 h of reaction. Consequently, a series of polyols with hydroxyl numbers in the range of 138–217 mgKOH/g were produced by oxirane ring opening of EJOs, and the physicochemical and rheological properties were studied. Both the EJOs and the JOLs are liquid and have a number average molecular weight (Mn ) in the range of 834 to 1457 g/mol and 1349 to 2129 g/mol, respectively. The JOLs exhibited Newtonian behaviour, with a low viscosity of 430–970 mPas. Finally, the JOL with a hydroxyl number of 161 mgKOH/g was further used to synthesise aqueous polyurethane dispersion, and the urethane formation was successfully monitored by Fourier Transform Infrared (FTIR). Keywords: jatropha oil; polyol; epoxidation; oxirane ring opening; polyurethane 1. Introduction The continuous depletion of fossil oil has led to the ever increasing price of such oil, which subsequently has contributed to the increasing price of polymer raw materials. There is a significant trend nowadays with regard to utilising products derived from natural molecules, such as vegetable oil, which is due to the lower cost and the fact that the source is renewable. In addition, bio-based products are more environmentally friendly due to possibility of being biodegradable [1]. Vegetable oils such as soybean oil, castor oil, rapeseed oil, rubberseed oil, palm oil, canola oil, and linseed oil are Molecules 2017, 22, 551; doi:10.3390/molecules22040551 www.mdpi.com/journal/molecules Molecules 2017, 22, 551 2 of 17 among the most important classes of renewable resources that have been utilised for the preparation of biopolymer products such as alkyd resins [2,3] and polyurethane [1,4,5]. Currently, polyol a 17 raw material Molecules 2017, 22, 551 derived from jatropha oil appears a promising candidate as2 of for polyurethane adhesives [6] and coatings [7,8]. Jatropha oil is a non-edible oil, and utilising such oils such as soybean oil, castor oil, rapeseed oil, rubberseed oil, palm oil, canola oil, and linseed oil an oil does not exploit or harm the market for edible vegetable oil. As shown in Table 1, jatropha are among the most important classes of renewable resources that have been utilised for the oil consists of 78.9% unsaturation percentage in resins its triglyceride structure, mainly corresponding to preparation of biopolymer products such as alkyd [2,3] and polyurethane [1,4,–5]. oleic and linoleic acid (Figure 1),from which provides an interesting platform chemical modification. Currently, polyol derived jatropha oil appears a promising candidate as for a raw material for polyurethane adhesives [6] and coatings [7,8]. Jatropha oil is a non-edible oil, and utilising such an The double bond group in the jatropha oil triglyceride molecules can be functionalised to a hydroxyl not exploit or harm the market for edible vegetable oil. As shown in Table 1, jatropha oil group byoiladoes two-step method; namely, epoxidation and oxirane ring opening. consists of 78.9% unsaturation percentage in its triglyceride structure, mainly corresponding to oleic and linoleic acid (Figure 1), which provides an interesting platform for chemical modification. The List ofoil fatty acid compositions in jatropha oil [9]. to a hydroxyl double bond group Table in the 1. jatropha triglyceride molecules can be functionalised group by a two-step method; namely, epoxidation and oxirane ring opening. Fatty Acid Unsaturates Saturates Table 1. List of fatty acid compositions in jatropha oil [9]. Palmitoleic (C16/1 ) Oleic (C18/ ) Linoleic (C18/2 ) Palmitic (C16/0 ) Stearic (C18/0 ) Unsaturates Saturates % Fatty Acid Palmitoleic 1.4 43.1 6.9 (C16/1) Oleic (C18/) Linoleic 34.4 (C18/2) Palmitic (C16/014.2 ) Stearic (C18/0) % 1.4 43.1 34.4 14.2 6.9 Total (%) 78.9 21.1 Total (%) 78.9 21.1 O a) Linoleic acid b) Oleic acid OH O OH Figure 1. Chemical structure of main fatty acids in jatropha oil. Figure 1. Chemical structure of main fatty acids in jatropha oil. Studies of the epoxidation of vegetable oils have become interesting as the products have become important oleochemicals for commercialisation. Despite being used as a starting material to produce Studies of the epoxidation of vegetable oils have become interesting as the products have become polyol, vegetable oils with epoxy groups are now accepted as an alternative to petrochemical based important oleochemicals for commercialisation. Despitestabilizers, being used as a starting feedstock to be used as plasticizers for polyvinyl chloride, and lubricants [10]. material to produce polyol, vegetable with epoxy are time, nowthe accepted as an alternative to petrochemical based Certainoils parameters such asgroups the reaction molar ratio of hydrogen peroxide to the oil double molar ratiofor of either formic chloride, or acetic acid as the peroxygen carrier to the oil feedstock to bebond, usedand as the plasticizers polyvinyl stabilizers, and lubricants [10]. double bond can be manipulated to obtain epoxidised oil with a different oxirane oxygen content Certain parameters such as the reaction time, the molar ratio of hydrogen peroxide to the oil (OOC). Higher amounts of peroxygen carrier and hydrogen peroxide as well as higher temperatures double bond, and the ratio ofbut either the peroxygen carrier to the will increase themolar reaction rate, it isformic difficultor toacetic controlacid the as temperature since the reaction is oil double bond can be manipulated obtain with ahas different oxirane oxygen (OOC). exothermic. The use of atolow percentepoxidised strong acid asoil a catalyst been reported [11], but, due tocontent the environmental issue of the waste sulphuric acid, the use of an ion exchanger catalyst has become the Higher amounts of peroxygen carrier and hydrogen peroxide as well as higher temperatures will preferred approach [12]. In addition, an ion exchanger is preferred because sulphuric acid is reported to increase the reaction rate, but it is difficult to control the temperature since the reaction is exothermic. be unsuitable for certain oils due to the low yield of epoxide [13]. In some studies, the use of a The use of a low percent strongbutacid as a catalyst hashydrogen been reported [11], due to together the environmental catalyst is even eliminated, the more concentrated peroxide has to but, be employed higher sulphuric loading of formic andexchanger co-workers [15] reported thatbecome epoxidised issue of with the awaste acid,acid the[13,14]. use ofMeyer an ion catalyst has the preferred jatropha could achieve OOC of up tois 4.75% at a reaction temperature of 50 °Cacid and 10 of approach [12]. oil In(EJO) addition, an ionanexchanger preferred because sulphuric is hreported to be reaction time. By increasing the reaction temperature to 65 °C, the reaction time can be reduced to unsuitable for certain oils due to the low yield of epoxide [13]. In some studies, the use of a catalyst is 5 h with OOC reduced to 4.3% [15]. even eliminated, but polyol the more hydrogen peroxide has to together with a Producing from concentrated epoxidised vegetable oil involves the opening of be the employed oxirane group to produce of a hydroxyl group.[13,14]. A higherMeyer OOC value favourable if[15] a high hydroxylthat value of polyol is jatropha oil higher loading formic acid and isco-workers reported epoxidised expected. The hydroxyl value refers to average distribution of OH of groups (EJO) could achieve an OOC of of uppolyol to 4.75% atthe a reaction temperature 50 ◦present C andin10theh of reaction triglycerides [16], which will determine the properties◦ of the polyurethane. However, a systematic time. By increasing the reaction temperature to 65 C, the reaction time can be reduced to 5 h with study of the effect of the epoxidation condition on the properties of polyol derived from jatropha oil OOC reduced to 4.3% [15]. is not available. The aim of this studyepoxidised is to investigate the effectoil of the molar ratio, temperature, and Producing polyol from vegetable involves the reaction opening of the oxirane group to on the OOC of EJO.A During the OOC epoxidation less concentrated peroxide value will be of polyol is producetime a hydroxyl group. higher valuestep, is favourable if ahydrogen high hydroxyl utilised and the reaction will be performed without using a strong acid catalyst. It is intended to expected. The hydroxyl value of polyol refers to the average distribution of OH groups present in the establish the relationship between the hydroxyl value of the polyol and the oxirane oxygen content triglycerides [16], which will determine the properties of the polyurethane. However, a systematic study of the effect of the epoxidation condition on the properties of polyol derived from jatropha oil is not available. The aim of this study is to investigate the effect of the molar ratio, reaction temperature, and time on the OOC of EJO. During the epoxidation step, less concentrated hydrogen peroxide will be utilised Molecules 2017, 22, 551 3 of 17 and the reaction will be performed without using a strong acid catalyst. It is intended to establish the relationship between the hydroxyl value of the polyol and the oxirane oxygen content of the epoxidised oil. Other Molecules 2017, 22, 551physico-chemical properties of the EJOs and JOLs, such as the molecular 3 of 17weight Molecules 2017, 22, 551 3 of 17 and rheology, will be investigated as part of the required information for handling and processing of the epoxidised oil. Other physico-chemical properties of the EJOs and JOLs, such as the molecular purposes. the potential of producing polyurethane dispersion from synthesised of theFurthermore, epoxidised oil. Other of the EJOs and JOLs, suchfor as handling thethe molecular weight and rheology, will physico-chemical be investigated asproperties part of the required information and jatropha oil-based polyol will weight and rheology, willbe beinvestigated. investigated as part of the required information for handling and processing purposes. Furthermore, the potential of producing polyurethane dispersion from the processing purposes. Furthermore, of producing polyurethane dispersion from the synthesised jatropha oil-based polyolthe willpotential be investigated. 2. Results and Discussion synthesised jatropha oil-based polyol will be investigated. 2. Resultsoil-based and Discussion Jatropha polyols were produced by the epoxidation and oxirane ring opening route, 2. Results and Discussion as shown Jatropha in Figure 2. In the jatropha triglyceride, the oil double bond in theopening linoleic and oleic oil-based polyols were oil produced by the epoxidation and oxirane ring route, Jatropha oil-based wereoil produced by the epoxidation and in oxirane opening route, as shown in Figure 2. In polyols the jatropha triglyceride, the oil double bond the linoleic and oleic fatty fatty acid was transformed to epoxy, which was then opened to incorporate a ring hydroxyl and methoxy as shown in Figure 2. to In epoxy, the jatropha oil triglyceride, thetooil double bond in the linoleic and oleic fatty acid was transformed which was then opened incorporate a hydroxyl and methoxy group. group. The resulting jatropha oil-based polyol contained a secondary hydroxyl group. The formation acid was transformed to oil-based epoxy, which was then opened to incorporate a hydroxyl and methoxy group. The resulting jatropha a secondary hydroxyl group. The formation ofepoxy of epoxidised jatropha oil and polyolpolyol werecontained confirmed by FTIR analysis. On the other hand, the The resulting jatropha oil-based polyol contained a secondary hydroxyl group. The formation of epoxidised jatropha oil and polyol were confirmed by FTIR analysis. On the other hand, the epoxy groupsepoxidised in the epoxidised oil were reported as oxirane oxygen content (OOC), while theepoxy amount of jatropha oil and polyol were confirmed by FTIR analysis. On the other hand, the groups in the epoxidised oil were reported as oxirane oxygen content (OOC), while the amount of hydroxyl groups in the polyol was reported as oxygen theOH OHnumber. number. Photographs ofjatropha the jatropha groups ingroups theformed epoxidised oilthe were reported as oxirane content (OOC), while of thethe amount of hydroxyl formed in polyol was reported as the Photographs hydroxyl groups formed in the polyol was reported as the OH number. Photographs of the jatropha oil andoil the resulting polyol are shown in Figure 3. Jatropha oil is a golden yellow oil, while the and the resulting polyol are shown in Figure 3. Jatropha oil is a golden yellow oil, while thepolyol oil and resulting polyol are shown in Figure 3. Jatropha oil is a golden yellow oil, while the is slightly yellow. polyol isthe slightly yellow. polyol is slightly yellow. O O O O O O O O O O O O Jatropha oil Jatropha oil Temperature: 50°C /60 °C Temperature: 50°C /60/5h °C Time: 2h/ 3h /4h/ 4.5h Time: 2h/ 3h /4h/ 4.5h /5h O O O O CHCOOH, CHCOOH, H 2O2 H2O2 O O O O O O O O O O O O O O Epoxidised jatropha oil (EJO) Epoxidised jatropha oil (EJO) CH3OH, CH 3OH, H 2O H2O Temperature: 64 °C Temperature: Time: 30 min 64 °C Time: 30 min OH OH OCH3 OCH3 O O O O O O O O O O OH OCH3 OH OCH3 OCH3 OH OCH3 OH O O polyol (JOL) Jatropha oil-based Jatropha oil-based polyol (JOL) Figure 2. Synthesis of jatropha oil-based polyol via the epoxidation and oxirane ring opening method. FigureFigure 2. Synthesis of jatropha polyolvia via epoxidation and oxirane ring opening 2. Synthesis of jatrophaoil-based oil-based polyol thethe epoxidation and oxirane ring opening method. method. Figure 3. Appearance of jatropha oil-based polyol (b); compared with the starting jatropha oil (a). 3. Appearance of jatropha oil-basedpolyol polyol (b); with thethe starting jatropha oil (a).oil (a). FigureFigure 3. Appearance of jatropha oil-based (b);compared compared with starting jatropha Molecules 2017, 22, 551 Molecules 2017, 22, 551 4 of 17 4 of 17 2.1.2.1. FTIR Analysis of JO, EJO, andand JOL FTIR Analysis of JO, EJO, JOL The FTIR spectra forfor thethe jatropha oiloil (JO), epoxidised jatropha oiloil (EJO), and jatropha oil-based The FTIR spectra jatropha (JO), epoxidised jatropha (EJO), and jatropha oil-based polyol (JOL) areare shown in in Figure 4. 4. From thethe spectra of of thethe jatropha oil,oil, thethe absorbance band at at polyol (JOL) shown Figure From spectra jatropha absorbance band − 1 −1 3007 cmcmcorresponds to the double bond group. TheThe disappearance of the double bond and 3007 corresponds to the double bond group. disappearance of the double bond and − 1 the −1 in appearance of of new peaks at at 840 and 819 cmcm spectra of the epoxidised jatropha oiloil confirms appearance new peaks 840 and 819 in the spectra of the epoxidised jatropha confirms thethe conversion of of thethe double bond to to anan epoxy group during thethe epoxidation reaction. After thethe conversion double bond epoxy group during epoxidation reaction. After oxirane ring was opened, thethe polyol was formed, and thisthis was confirmed by by thethe existence of aofbroad oxirane ring was opened, polyol was formed, and was confirmed existence a broad 1 , which −1, − absorbance band at 3425 cmcm which waswas attributed to the hydroxyl group in the JOLJOL spectra. absorbance band at 3425 attributed to the hydroxyl group in the spectra. 1 attributed −1 − From thethe EJO spectra, thethe weak and broad shoulder around 3425 cm attributed to the OHOH group From EJO spectra, weak and broad shoulder around 3425 cm to the group was observed, instead of of a remarkable peak, as as reported in in other studies [14,15]. This indicates thatthat thethe was observed, instead a remarkable peak, reported other studies [14,15]. This indicates minimum side reaction associated with the the ringring opening of epoxy withwith water/acid during epoxidation. minimum side reaction associated with opening of epoxy water/acid during epoxidation. (a) JO 3007 1464 2922 722 1743 2853 1160 %T (b) EJO 3h 840 819 (c) JOL 217 3425 4000 3500 3000 2500 2000 1500 1000 500 -1 Wavenumber (cm ) Figure 4. (Fourier Transform Infrared) FTIRFTIR spectra of jatropha oil (JO), jatropha oil (EJO), Figure 4. (Fourier Transform Infrared) spectra of jatropha oilepoxidised (JO), epoxidised jatropha oiland (EJO), jatropha oil-based polyol (JOL). and jatropha oil-based polyol (JOL). 2.2.2.2. Effect of Molar Ratio, Temperature, and Reaction Time onon thethe Oxirane Oxygen Content Effect of Molar Ratio, Temperature, and Reaction Time Oxirane Oxygen Content Figures 5 5and the oxirane oxiraneoxygen oxygencontent, content, OOC relative conversion to Figures and66 present present the OOC (%),(%), andand relative conversion to oxirane oxirane of epoxidised jatropha oil prepared by different molar ratios of formic acid to the oil double of epoxidised jatropha oil prepared by different molar ratios of formic acid to the oil double bond and bond and reaction temperature. The epoxidation reaction 50 °C was conducted 5 h, the while the reaction temperature. The epoxidation reaction at 50 ◦ Catwas conducted over 5 over h, while reaction reaction at 60 °C was conducted over 4 h. Overall, increasing the mole ratio of formic acid to the oil ◦ at 60 C was conducted over 4 h. Overall, increasing the mole ratio of formic acid to the oil double double bond from 0.4 to 0.6 increased the OOC from 2.42% to 4.49% and from 3.26% to 4.64% for the bond from 0.4 to 0.6 increased the OOC from 2.42% to 4.49% and from 3.26% to 4.64% for the reactions reactions conducted 50 °C 60 °C, respectively. However, the increase in the OOC becomes less ◦ C, respectively. conducted at 50 ◦ Catand 60 and However, the increase in the OOC becomes less significant significant when there is a 20% excess of formic acid in the mixture. About 80% relative conversion when there is a 20% excess of formic acid in the mixture. About 80% relative conversion to oxirane to was oxirane was achieved moleand of acid anddouble the oilbond double bond were equal. achieved when thewhen molethe of acid the oil were equal. Molecules 2017, 22, 551 5 of 17 Molecules2017, 2017,22, 22,551 551 Molecules of17 17 55of Figure 5. Effect of molar ratio and reaction temperature on the oxirane oxygen content (OOC) of Figure 5. Effect of molar ratio andreaction reaction temperature temperature on oxygen content (OOC) of of Figure 5. Effect of molar ratio and onthe theoxirane oxirane oxygen content (OOC) epoxidisedjatropha jatrophaoil. oil. epoxidised epoxidised jatropha oil. Relative Relativeconversion conversionto tooxirane oxirane(%) (%) 100.0 100.0 50⁰C, ⁰C,55hh 50 80.0 80.0 60.0 60.0 58.3 58.3 60⁰C, ⁰C,44hh 60 75.0 75.0 65.4 65.4 80.8 78.280.8 78.2 81.4 81.4 42.2 42.2 40.0 40.0 20.0 20.0 0.0 0.0 0.4 0.4 0.6 0.6 11 1.2 1.2 Molarratio ratioof offormic formicacid acidto toC=C C=C Molar Figure Effect of the the molar ratio andreaction reactiontemperature temperature on on relative conversion to oxirane oxirane of of Figure 6. Effect of the molar ratio and onrelative relative conversion to oxirane Figure 6.6. Effect of molar ratio and reaction temperature conversion to of epoxidised jatropha oil. epoxidised jatropha epoxidised jatropha oil. oil. The reaction reaction at at 60 60 °C °C resulted resulted in in aa better better OOC OOC with with aa reduced reduced reaction reaction time, time, compared compared to to the the The ◦ resulted in a better OOC with a reduced reaction time, compared to The reaction at 60 reaction conducted ataaC lowertemperature. temperature.ItItwas wasinteresting interestingthat thataa4.3% 4.3%OOC OOCwith withaarelative relativeconversion conversion reaction conducted at lower the reaction conducted at a lower temperature. It was interesting that a 4.3% OOC with to oxirane of 75% could be achieved with a molar ratio of 0.6, a reaction temperature of 60 °C, and hof of to oxirane of 75% could be achieved with a molar ratio of 0.6, a reaction temperature of 60 °C, and aa4a4hrelative reaction time. This was about same value as obtained by Goud and co-workers [12] with the application conversion to oxirane of 75% could be achieved with a molar ratio of 0.6, a reaction temperature reaction time. This was about same value as obtained by Goud and co-workers [12] with the application of ofand anion ion exchanger or22time. wt.% %This sulphuric acidcatalyst catalyst after10 10 ofreaction reaction atGoud 50°C. °C.The Theresults resultswere were [12] 60 ◦ C,of a 4exchanger h of reaction was about same after value ashhobtained by and co-workers an or wt. sulphuric acid of at 50 comparable with the findings of Hazmi and co-workers [14] for 5 h epoxidation assisted by more with of thean findings of Hazmi or and co-workers [14] foracid 5 h catalyst epoxidation assisted byreaction more at with comparable the application ion exchanger 2 wt. % sulphuric after 10 h of concentrated hydrogen peroxidewith (50%)the ataafindings temperature of65 65°C °C and higherformic formic acid peroxide (50%) at temperature of and higher 50 ◦ C.concentrated The results hydrogen were comparable of Hazmi and co-workers [14]acid for loading. 5loading. h epoxidation Agreater greaterconcentration concentrationof ofhydrogen hydrogenperoxide peroxide wasalso also employedby byMeyer Meyerand and co-workers[15] [15]at at A assisted by more concentrated hydrogen peroxide was (50%) atemployed a temperature of 65 ◦co-workers C and higher formic prolonged reaction times of up to 10 h, which resulted in a %OOC of 4.75 at a temperature of 50 °C. prolonged reaction times of up to 10 h, which resulted in a %OOC of 4.75 at a temperature of 50 °C. acid loading. These results results suggest suggest that that aa reaction reaction temperature temperature of of 60 60 °C °C can can be be employed employed to to achieve achieve aa higher higher These Aconversion greater concentration of ahydrogen peroxide waswithout also employed by Meyer and co-workers to oxirane over shorter reaction period the application of a catalyst or more [15] conversion to oxirane over a shorter reaction period without the application of a catalyst or more at prolonged reaction times of up to 10 h, which resulted in a %OOC of 4.75 at a temperature of concentrated hydrogen peroxide. concentrated hydrogen peroxide. 50 ◦ C. These results suggest that a reaction temperature of 60 ◦ C can be employed to achieve a higher 2.3.Effect Effect Oxiraneover Oxygen Contenton onOH OHNumbers Numbers JatrophaOil-Based Oil-Based Polyol(JOL) (JOL) conversion toofof oxirane a shorter reaction period without the application of a catalyst or more 2.3. Oxirane Oxygen Content ofofJatropha Polyol concentrated hydrogen peroxide. A reaction reaction parameter of 60 60 °C °C and and aa molar molar ratio ratio of of 0.6 0.6 were were selected selected for for the the preparation preparation of of A parameter of epoxidisedjatropha jatrophaoil oilto tobe befurther furtherconverted convertedto topolyol polyolby byoxirane oxiranering ringopening. opening.For Forthis thispurpose, purpose, epoxidised 2.3. Effect of Oxirane Oxygen Content on OH Numbers of Jatropha Oil-Based Polyol (JOL) A reaction parameter of 60 ◦ C and a molar ratio of 0.6 were selected for the preparation of epoxidised jatropha oil to be further converted to polyol by oxirane ring opening. For this purpose, the Molecules 2017, 22, 551 Molecules 2017, 22, 551 Molecules 2017, 22, 551 6 of 17 6 of 17 6 of 17 the JO g. 77 shows the effect of times with amount of JOof scaled up toup 400to Figure 7 shows the effect varying reactionreaction times with respect the amount amount ofwas JO was was scaled scaled up tog.400 400 g. Figure Figure shows theof effect of varying varying reaction times with respect to the OOC. Increasing the reaction time increased the OOC in the epoxidised JO. It can be to the OOC. Increasing the reaction time increased the OOC in the epoxidised JO. It can be seen respect to the OOC. Increasing the reaction time increased the OOC in the epoxidised JO. It canthat be seen that the OOC obtained at 4 h was lower than the results found in the previous work, in which aa the 4 h was at lower thanlower the results found in the previous in which a small scale seenOOC that obtained the OOCat obtained 4 h was than the results found in thework, previous work, in which small scale sample was used. This is due to the low mass transfer coefficient in a larger scale of sample was used. This is due to This the low masstotransfer coefficient in a larger scale ofinpreparation, as the small scale sample was used. is due the low mass transfer coefficient a larger scale of preparation, as the other factors such as the heat transfer area are not well considered. At this stage, other factors such as the heat transfer area are not well considered. At this stage, all the epoxidised JO preparation, as the other factors such as the heat transfer area are not well considered. At this stage, all epoxidised JO to by oxirane method was converted to polyol the oxirane ring opening using methanol. all the the epoxidised JO was wasbyconverted converted to polyol polyol by the the method oxirane ring ring opening opening method using using methanol. methanol. Figure oil. Figure 7. 7. Effect Effect of of reaction reaction time time on on OOC OOC of of epoxidised epoxidised jatropha jatropha jatropha oil. oil. The relationship between %OOC and OH number is in Figure 8. The relationship relationship between between %OOC %OOC and and OH OH number number is is expressed expressed in in Figure Figure 8. 8. As As expected, expected, higher higher The expressed As expected, higher OH numbers of polyol were obtained by increasing the %OOC. Polyol with increasing OH numbers OH numbers of polyol were obtained by increasing the %OOC. Polyol with increasing OH numbers OH numbers of polyol were obtained by increasing the %OOC. Polyol with increasing OH numbers from 138–217 mgKOH/g successfully produced from epoxidised jatropha oil with an increase from 138–217 138–217 mgKOH/g mgKOH/g was was an OOC OOC increase increase from was successfully successfully produced produced from from epoxidised epoxidised jatropha jatropha oil oil with with an OOC from 3.56 to 4.32. These values are comparable with other vegetable oil based polyols synthesised from from 3.56 to 4.32. These values are comparable with other vegetable oil based polyols synthesised from from 3.56 to 4.32. These values are comparable with other vegetable oil based polyols synthesised soybean oil, castor oil, linseed oil, and palm oil [16–18]. The OH numbers will determine the amount of soybean oil, castor oil, linseed oil, andoil, palm oilpalm [16–18]. OH numbers determine the amountthe of from soybean oil, castor oil, linseed and oil The [16–18]. The OH will numbers will determine diisocyanate required for polyurethane synthesis. Depending on the application, vegetable oil-based diisocyanate required for polyurethane synthesis. Depending on the application, vegetable oil-based amount of diisocyanate required for polyurethane synthesis. Depending on the application, vegetable polyols relatively high OH are desired for of rigid polyurethane [19]. polyols with with relatively OH numbers numbers are generally generally for production production rigid polyurethane [19]. oil-based polyols withhigh relatively high OH numbersdesired are generally desiredoffor production of rigid However, polyols with low OH numbers are advantageous in terms of bio-based content, as they However, polyols with low OH numbers are OH advantageous in advantageous terms of bio-based content, as they polyurethane [19]. However, polyols with low numbers are in terms of bio-based require less diisocyanate as aa hard segment in the polyurethane [20]. The combination of the OH require less diisocyanate as hard segment in the polyurethane [20]. The combination of the OH content, as they require less diisocyanate as a hard segment in the polyurethane [20]. The combination numbers and hard segment content was reported as a key role in controlling the structure and the numbers and hard segment content was reported as a key role in controlling the structure and the of the OH numbers and hard segment content was reported as a key role in controlling the structure thermophysical and mechanical properties of the polyurethane film [16–20]. thermophysical and mechanical properties of the polyurethane film [16–20]. and the thermophysical and mechanical properties of the polyurethane film [16–20]. Figure Figure 8. 8. Effect Effect of of %OOC %OOC of of EJO EJO on on the the OH OH number number of JOL. number of of JOL. JOL. Molecules 2017, 22, 551 Molecules 2017, 22, 551 7 of 17 7 of 17 Molecular Weight Weight and Rheology of Epoxidised Jatropha Oil (EJO) 2.4. Molecular The molecular weights of the jatropha oil (JO) and epoxidised jatropha oil (EJO) were determined using gas permeation chromatograpy (GPC). The analysed GPC results (Table 2) for JO and the three 4 h, and 4.54.5 h, are presented as number average (Mn )(M and EJOs produced produced at atvarious variousreaction reactiontimes, times,3 3h,h, 4 h, and h, are presented as number average n) weight average (Mw )(M molecular weight. A higher polydispersity index (PDI) was was observed for EJO and weight average w) molecular weight. A higher polydispersity index (PDI) observed for 3 h and EJOEJO 4 h,4indicating a broad whichisisaatypical typical characteristic EJO 3 h and h, indicating a broadmolecular molecularweight weight distribution, distribution, which characteristic of of jatropha (JO). The EJO producedusing usinga alonger longerreaction reactiontime timeshowed showedaa significantly significantly higher jatropha oiloil (JO). The EJO 4.54.5 produced of 1457 1457 with with aa narrow molecular molecular weight weight distribution distribution (Figure (Figure 9), 9), suggesting suggesting the the formation formation of of a Mnn of dimer. Dimerisation Dimerisation(or (oroligomerisation) oligomerisation)isisanan epoxy ring opening side reaction that occurs when epoxy ring opening side reaction that occurs when the the epoxy group reacts with acid water,followed followedbybythe thedimerisation dimerisationof ofthe the already already formed epoxy group reacts with thethe acid or or water, first step, the attack of aa proton proton on an an epoxy epoxy group group leads hydroxyl compound. In the case at issue the first to the formation of hydroxyl and acetyl or formyl groups. If the reaction stops at that stage, a polyol A hydroxyl hydroxyl group may react further with an epoxy group to give internal is formed (Figure 10) [21]. A ethers or oligomeric ethers (dimers) formation of of epoxidised jatropha oil oligomeric ethers (dimers)[21]. [21].The Theschematic schematicofofdimer dimer formation epoxidised jatropha is shown in Figure 11. In11. addition to increasing molecular weight,weight, dimerisation typically will cause oil is shown in Figure In addition to increasing molecular dimerisation typically willa significant increaseincrease of viscosity[21]. cause a significant of viscosity[21]. Table 2. Molecular weight of epoxidised jatropha oil. Table Sample Sample n MM n JO JO EJO 3EJO h 3h EJO 4EJO h 4h EJO 4.5 h 4.5 h EJO MwM w 1630 1630 1666 1666 1516 1516 1566 1566 1083 1083 995 995 834 834 1457 1457 PDI =PDI Mw= /M Mnw /M n 1.51 1.51 1.67 1.67 1.82 1.82 1.07 1.07 5 EJO 4.5h dwt/d(logM) 4 3 2 1 0 500 1000 1500 2000 2500 3000 3500 Molecular weight (Daltons) Figure 9. The The molecular molecular weight weight distribution of EJO 4.5 h. The functionalisation of double bonds to the epoxy groups leads to a significant increase in The functionalisation of double bonds to the epoxy groups leads to a significant increase in viscosity. As shown in Figure 12, the viscosity of EJO 4.5 h at 25 °C◦ is 180 mPas, while the viscosity of viscosity. As shown in Figure 12, the viscosity of EJO 4.5 h at 25 C is 180 mPas, while the viscosity the starting jatropha oil is 55 mPas. Both JO and EJO 4.5 h exhibit Newtonian behaviour in the of the starting jatropha oil is 55 mPas. Both JO and EJO 4.5 h exhibit Newtonian behaviour in the measured shear rate ranges. Increasing the temperature causes a significant reduction of viscosity, as measured shear rate ranges. Increasing the temperature causes a significant reduction of viscosity, shown in Figure 13. Although having a dimer structure, the viscosity of the EJO 4.5 h is still low and as shown in Figure 13. Although having a dimer structure, the viscosity of the EJO 4.5 h is still low and comparable to completely epoxidised soybean oil (ESO), as reported by Petrovic and co-workers [21]. comparable to completely epoxidised soybean oil (ESO), as reported by Petrovic and co-workers [21]. It is worth noting that a low viscosity ESO produced commercially has been receiving attention for It is worth noting that a low viscosity ESO produced commercially has been receiving attention for use as a reactive diluent to reduce the viscosity of a petroleum-based epoxy, thus improving the use as a reactive diluent to reduce the viscosity of a petroleum-based epoxy, thus improving the processibility of the resin [22]. processibility of the resin [22]. 8 of 17 Molecules 2017, 22, 551 Molecules 2017, 22, 551 Molecules 2017, 22, 551 8 of 17 8 of 17 8 of 17 1 11 RR R OO O 2 22 HH H 2 22 1 11 RR R HH H OO O OO O CC C HH H 2 22 2 22 2 22 1 11 2 22 OO O 2 22 HH H RR R HH H OO OHH H OO C OCC HH H C OO OCC HH H 1 11 HH H OO O OO O OO O CC C HH H OO ORR R RR R H H H C 2 22 CC OHH HH H H OO CC C OCC C OO HH H CC C OO C OCC HH H RR R O O O RR R 1 11 RR R + ++ HH H 2 22 RR R 1 11 RR R HH H CC C OO O HH H CC C 2 22 RR R RR R O O O HH H CHH H HH HHH H CC C C C O OO OCC C OO HH H HH H OO C C O C OO C H OCC H H HH H Molecules 2017, 22, 551 Figure 10. Side reaction of epoxy groups [21]. Figure 10. Side reaction reaction of epoxy groups Figure 10. 10. Side Side of epoxy epoxy groups groups [21]. [21]. Figure reaction of [21]. O O O O OO O O O O O O O O O O O O O O O O OO O O O O OO O O O O O O O O O O OO O O O O O O O O O O O O O O O O O O OO O O OO O O O O O O + + + O O O RO RO RO O O O OH OH OH O O O O O O O O O O O O RO RO RO O O O O O O OH OH OH O O O O O O Figure 11. Schematic representation of dimer formation. Figure 11. 11. Schematic Schematic representation representation of dimer formation. Figure of dimer formation. Viscosity (Pa.s) Viscosity (Pa.s) Viscosity (Pa.s) 0.25 0.25 0.25 JO JO EJO 4.5 h JO EJO 4.5 h EJO 4.5 h 0.20 0.20 0.20 0.15 0.15 0.15 0.10 0.10 0.10 0.05 0.05 0.05 0.00 0.00 0.00 10 10 10 100 100 Shear100 rate (1/s) Shear rate (1/s) Shear rate (1/s) 1000 1000 1000 Figure 12. Viscosity curve of jatropha oil (JO) and epoxidised jatropha oil (EJO) at 25 °C. Figure 12. Viscosity Viscosity curve curve of jatropha oil (JO) and epoxidised jatropha jatropha oil oil (EJO) (EJO) at at 25 25 °C. Figure 12. of jatropha oil (JO) and epoxidised jatropha oil (EJO) at 25 ◦°C. C. Molecules 2017, 22, 551 9 of 17 Molecules 2017, 22, 551 9 of 17 Figure 13. Viscosity of jatrophaoil oil(JO) (JO)and and epoxidised epoxidised jatropha (EJO) at various temperatures. Figure 13. Viscosity of jatropha jatrophaoiloil (EJO) at various temperatures. 2.5. Molecular Weight, Physicochemicaland andRheological Rheological Properties Oil-based Polyol (JOL) 2.5. Molecular Weight, Physicochemical PropertiesofofJatropha Jatropha Oil-based Polyol (JOL) The molecular weight of JOL is presented in Table 3. It is obvious that the molecular weight is The molecular weight of JOL is presented in Table 3. It is obvious that the molecular weight is higher than the starting EJO. With Mn increased from a range of 834–1457 for EJO to 1439–2129 for higher than the starting EJO. With Mn increased from a range of 834–1457 for EJO to 1439–2129 for JOL, it is believed that oligomerisation also occurred during the ring opening step with methanol. JOL, The it is newly believed that oligomerisation also occurred during theepoxy ring opening with methanol. formed OH groups tend to react with the existing groups tostep form a higher The newly formed OHdimer groups tend to react with the existing epoxy groupsin toJOL form a as higher molecular molecular weight or oligomer. Oligomerisation is more pronounced 217 a result of weight or oligomer. Oligomerisation is more pronounced in JOL 217 as a result of reported the relatively thedimer relatively high epoxy content of the starting EJO. The formation of oligomers was also Caillol and co-workers [23] for soybean oil-based polyol (44–63%was oligomers) produced ring and high by epoxy content of the starting EJO. The formation of oligomers also reported byby Caillol opening with carboxylic acid. co-workers [23] for soybean oil-based polyol (44%–63% oligomers) produced by ring opening with carboxylic acid. Table 3. Molecular weight of JOL. Molecular weight of PDI JOL.= Mw/Mn Sample Table 3.M n M w JOL 161 1572 2121 1.35 Sample JOL 188 M1439 n 2110 M w 1.47 PDI = M w /M n 2129 2231 2121 1.05 JOL 161 JOL 217 1572 1.35 JOL 188 1439 2110 1.47 JOL 217 2231in Table 4. The polyols 1.05 produced were Other physico-chemical properties2129 of the JOL are given slightly yellow in colour, and all of them were liquid at room temperature. A polyol of industrial importance is commonly required to have low viscosity and a high hydroxyl value. From our Other physico-chemical properties of the JOL are given in Table 4. The polyols produced were previous work, waterborne polyurethane film synthesised from JOL 138 was soft and tacky with slightly yellow in colour, and all of them were liquid at room temperature. A polyol of industrial poor structural rigidity [20]. For this reason, only JOL 161, JOL 188, and JOL 217 were analysed in importance commonly low viscosity and a viscosity high hydroxyl value. From our as previous terms ofisviscosity and required rheology.to Inhave polyurethane production, is an important criterion it work,determines waterborne polyurethane film synthesised from JOL 138 was soft and tacky with poor structural the ease of pouring and pumping the polyol into the machine to be mixed with rigidity [20]. For this only 161, 188, andof JOL analysed viscosity diisocyanates [18].reason, As shown in JOL Figure 10,JOL the viscosity the217 JOLwere increased from in 430terms to 940ofmPas and rheology. polyurethane production, viscosity an important determineswith the ease when the In OH number increased from 161 to 217ismgKOH/g. The criterion viscosity as is itcomparable soybean oil-based polyol a lower OH number, a viscosity of 2500 to 35,000 mPas was of pouring and pumping the [24,25]. polyol With into the machine to be mixed with diisocyanates [18]. As shown in reported for polyol derived from crude palm oil [18]. A commercial polyol is available in various Figure 10, the viscosity of the JOL increased from 430 to 940 mPas when the OH number increased ranges from as low 230 mPas to above 10,000 depending onpolyol the OH[24,25]. number, from viscosity 161 to 217 mgKOH/g. Theasviscosity is up comparable with mPas, soybean oil-based With a functionality, production routes, and its vegetable oil origin types [26]. lower OH number, a viscosity of 2500 to 35,000 mPas was reported for polyol derived from crude palm The JOL exhibits Newtonian behaviour similar to the rheological behaviour of the starting EJO, oil [18]. A commercial polyol is available in various viscosity ranges from as low as 230 mPas up to as shown in Figure 14. With increasing temperature, the viscosity decreased significantly (Figure 15). aboveBased 10,000 the OH number, functionality, routes, and its vegetable onmPas, these depending results, the on processing temperature of the JOLproduction could be easily correlated with oil origin types [26]. viscosity. For example, the JOL has to be heated to a temperature above 70 °C to achieve a viscosity The JOL exhibits Newtonian similar to the rheological behaviour of the of less than 100 mPas (see inset behaviour in Figure 15). In waterborne polyurethane production, the starting reaction EJO, as shown in Figure 14. With increasing temperature, the viscosity decreased significantly (Figure 15). temperature is usually in the range of 65 °C to 90 °C [16,27,28]. Based on these results, the processing temperature of the JOL could be easily correlated with viscosity. For example, the JOL has to be heated to a temperature above 70 ◦ C to achieve a viscosity of less than 100 mPas (see inset in Figure 15). In waterborne polyurethane production, the reaction temperature is usually in the range of 65 ◦ C to 90 ◦ C [16,27,28]. Molecules 2017, 22, 551 Molecules Molecules 2017, 2017, 22, 22, 551 551 10 of 17 17 10 10 of of 17 Table 4. Physicochemical properties of the JOL. Table 4. Physicochemical Physicochemical properties properties of of the the JOL. JOL. Table 4. OH OH Number Number OH Number Sample (mgKOH/g) (mgKOH/g) (mgKOH/g) JOL 138 JOL 138 138 138 JOL 138 138 JOL 161 JOL 161 161 161161 JOL 161 JOL 188 JOL 188 188 188188 JOL 188 JOL 217 217 JOL 217 JOL 217 217217 Sample Sample Acid Acid Value Value Acid Value (mgKOH/g) (mgKOH/g) (mgKOH/g) 29.92 29.92 29.92 26.09 26.09 26.09 26.66 26.66 26.66 15.95 15.95 15.95 EW EW ** EW * 407 407 Physical Density Physical Density ** ** Density Physical 3 Appearance (kg/m 3) f ** ) Appearance (kg/m (kg/m3 ) Appearance --liquid liquid - 4.51 - 965.5 liquid liquid 4.51 965.5 4.51 965.5 liquid liquid 4.82 971.9 liquid 4.82 4.82 971.9971.9 liquid liquid 8.24 975.5 8.24 8.24 975.5975.5 liquid liquid liquid 407348 348348 298 298298 259259 259 ** Equivalent weight, ** functionality. * Equivalent weight, weight, ** Equivalent **functionality. functionality. 1.4 1.4 JOL JOL 161 161 JOL JOL 188 188 JOL JOL 217 217 EJO EJO 4.5h 4.5h Viscosity(Pa.s) (Pa.s) Viscosity 1.2 1.2 1.0 1.0 0.8 0.8 0.6 0.6 0.4 0.4 0.2 0.2 0.0 0.0 10 10 100 100 Shear Shear rate rate (1/s) (1/s) 1000 1000 Figure 14. Viscosity curves of jatropha oil-based polyol with different OH numbers at 25 Figure oil-based polyol polyol with with different different OH OH numbers numbers at at 25 25 ◦°C. °C. Figure 14. 14. Viscosity Viscosity curves curves of of jatropha jatropha oil-based C. As As shown shown in in Figure Figure 16, 16, the the viscosity viscosity plotted plotted against against the the reciprocal reciprocal temperature temperature obeyed obeyed the the As shown in Figure 16, the viscosity plotted against the reciprocal temperature obeyed the Arrhenius Arrhenius dependence dependence (Equation (Equation 1): 1): Arrhenius dependence (Equation (1)): E (1) = (1) (1) η= = ηo e RT reference viscosity, the viscous-flow activation energy, the gas constant, and T where where is is the gas constant, and T is is aa reference reference viscosity, viscosity,EE Eisis isthe theviscous-flow viscous-flowactivation activationenergy, energy,R R R is the gas constant, and T where ηη ηooo is is absolute temperature From slopes of straight lines, activation energy of the absolute temperature (K).(K). From thethe slopes of these straight lines, the the activation energy of flow can is the the absolute temperature (K). From the slopes of these these straight lines, the activation energy of flow flow can be is in be and and this this is presented in Table 5. 5. cancalculated, be calculated, calculated, and this is presented presented in Table Table 5. of 250 ss−1 −1s..− 1 . Figure 15. Viscosityof ofjatropha jatrophaoil-based oil-basedpolyol polyol(JOL) (JOL)at varioustemperatures temperaturesat shearrate rate 250 15. Viscosity Viscosity of jatropha oil-based polyol (JOL) atatvarious various temperatures atataa ashear shear rate ofof 250 Molecules 2017, 22, 551 Molecules 2017, 22, 551 11 of 17 11 of 17 9 8 7 ln η 6 JO EJO 4.5 h JOL 161 JOL 188 JOL 217 5 4 3 2 1 2.6 2.8 3.0 3.2 3.4 3.6 1/T *1000 Figure 16. The viscosity–temperature relationship for jatropha oil-based polyols (JOLs). (JOLs). The viscous-flow viscous-flow activation activation energies energies for for jatropha jatropha oil oil and and EJO EJO are are also also included. included. The The activation activation The energy of of flow flow is is related related to to the the flexibility flexibility of of the the molecular molecular chains chains and and the the interaction interaction between between energy molecules [29]. The activation energies of the polyols were significantly higher than those of EJO and and molecules [29]. The activation energies of the polyols were significantly higher than those of EJO jatropha oil. These confirmed the hydrogen bonding present in all the JOLs, increasing according to jatropha oil. These confirmed the hydrogen bonding present in all the JOLs, increasing according hydroxyl numbers. The activation energy values soy to hydroxyl numbers. The activation energy valuesobtained obtainedare arecomparable comparabletotothose those values values of of soy polyols reported by Dai and co-workers [25]. Vegetable oil contains a cis C=C double bond that polyols reported by Dai and co-workers [25]. Vegetable oil contains a cis C=C double bond that created a defect in theofpacking of the triglycerides. The lower viscosity of the oil to is acreated defect in the packing the triglycerides. The lower viscosity of the vegetable oil isvegetable comparable comparable to animal fat [30].energy The activation energy of jatropha oilreported is similar that reported animal fat [30]. The activation of jatropha oil is similar to that fortosoybean oil [29].for soybean oil [29]. Table 5. Viscosity at 45 ◦ C and activation energy of viscous flow (Ea ) for the jatropha oil-based polyols. Table 5. Viscosity at 45 °C and activation energy of viscous flow (Ea) for the jatropha oil-based polyols. Sample Sample JO JO EJO EJO JOL 161 JOL JOL 161 188 JOL JOL 188 217 JOL 217 ◦ Viscosity at 45 C (mPas) Activation Energy (kJ/mol) Viscosity at 45 °C (mPas) Activation Energy (kJ/mol) 25.7 28.7 28.7 25.7 77.2 32.3 77.2 32.3 154.8 39.1 154.8 241.0 39.1 40.5 241.0 289.0 40.5 46.0 289.0 46.0 2.6. Monitoring Polyurethane Synthesis by FTIR 2.6. Monitoring Polyurethane Synthesis by FTIR The polyurethane synthesis was monitored by FTIR analysis, as shown in Figure 17. At 1 h of − 1FTIR Thetime, polyurethane synthesis was monitored by shown in Figure 17. At 1 h of reaction a strong absorbance peak at 2270 cm was analysis, observed,aswhich indicated a high amount −1 was observed, which − 1 reaction time, a strong absorbance peak at 2270 cm indicated a high amount of free isocyanate. The formation of an absorbance peak at 3324 cm confirmed the formation of of free isocyanate. The formation of an absorbance peak at and 3324polyol cm−1 confirmed the formation of urethane by the reaction of dimethylol propionic acid (DMPA) with isophrene diisocyanate urethane by the reaction of dimethylol propionic acid (DMPA) and polyol with isophrene diisocyanate (IPDI). At the early stage of polymerisation, it is believed that the DMPA reacted rapidly with IPDI (IPDI). At the stage of of the polymerisation, it is believed that the DMPA reacted rapidly with IPDI due to the highearly reactivity primary hydroxyl in the structure. due to the high reactivity of the primary hydroxyl in the structure. The consumption rate of free isocyanate is high during the first two hours of reaction and becomes The consumption rate toofa free isocyanate is high during theand first of reaction and slower as time proceeds due decreasing amount of NCO groups thetwo lowhours reactivity of secondary becomes slower time proceeds to a decreasing amount of NCO(HEMA) groups and lowtoreactivity OH groups in theas JOL. After 3 h of due reaction, hydroxyethyl methacrylate wasthe added end-cap of secondary OH groups in the JOL. After 3 h of reaction, hydroxyethyl methacrylate (HEMA) was the terminal NCO groups. After 3 h and 35 min, the NCO peak almost disappeared, thus indicating added to end-cap the terminal NCO groups. After 3 h and 35 min, the NCO peak almost disappeared, that most of the isocyanate groups were involved in polymerisation. An absorbance peak at 1707 cm− 1 thus indicatingwith that carbonyl most of the isocyanate groups in polymerisation. An absorbance corresponded group stretching, andwere the involved –NH bending observed at 1531 cm− 1 was −1 corresponded with carbonyl group stretching, and the –NH bending observed peak at 1707 cm evidence of polyurethane formation. at 1531 cm−1 was evidence of polyurethane formation. Molecules 2017, 22, 551 12 of 17 Molecules 2017, 22, 551 12 of 17 100 (b) 95 100 90 95 85 90 85 12 of 17 % Transmittance % Transmittance % Transmittance % Transmittance (a) 100 Molecules 2017, 22, 551 98 100 (b) (a) JPU 1 h JPU 2 h JPU 2 h 45 min JPU 3 h 35 min JOL N=C=O JPU 1 h JPU 2 h JPU 2 h 45 min 2320 2280 2240 JPU 3 h 35 min -1 Wavenumber (cm ) JOL N=C=O 2320 2280 2240 100 (c) Wavenumber (cm-1) 2200 2200 96 98 94 96 4000 94 4000 O-H JPU 1 h JPU 2 h JPU 2 h 45 min JPU 3 h 35 min N-H JOL O-H JPU 1 h JPU 2 h 3800 3600 3400 3200 JPU 2 h 45 min -1 JPU 3 h 35 min N-H) Wavenumber (cm JOL 3800 3600 3400 3200 3000 3000 Wavenumber (cm-1) 90 % Transmittance % Transmittance 100 80 90 70 (c) N-H JPU 1 h 80 JPU 2 h 60 N-H JPU 2 h 45 min 70 JPU 3 h 35 min JOL 1 h C=O JPU 50 JPU 2 h 60 JPU 2 h 45 min 1800 1750 1700 1650 1600 JPU 1550 1500 3 h 35 min 1450 -1 C=O Wavenumber (cmJOL ) 50 Figure FTIR spectra of (a) isocyanate group1650 in polyurethane, (b) the hydroxyl andthe urethane groupand 1800 1750 1700 1600 in 1550 1500 1450 (b) Figure 17.17. FTIR spectra ofthe (a) the isocyanate group polyurethane, hydroxyl -1 in polyol and polyurethane respectively, and (c) Wavenumber the carbonyl(cm and urethane group in polyurethane. ) urethane group in polyol and polyurethane respectively, and (c) the carbonyl and urethane group in polyurethane. Figure 17. FTIR spectra of (a) the isocyanate group in polyurethane, (b) the hydroxyl and urethane group 2.7. Physical Properties of the Aqueous Polyurethane (JPU) Dispersion in polyol and polyurethane respectively, and (c) the carbonyl and urethane group in polyurethane. The Properties aqueous JPU synthesised in this Dispersion work has a solid content of 25 wt. % and 2.7. Physical of thedispersion Aqueous Polyurethane (JPU) 2.7. Physical Properties the Aqueous Polyurethane (JPU) Dispersion appears milky white inofcolour. The dispersion has a low viscosity of 12.5 mPas, with a zeta potential aqueous JPU 18 dispersion synthesised in this work hasdispersion, a solid content of 25 wt. % and appears ofThe −56.6 mV. Figure shows a particle size distribution of the demonstrates theand low The aqueous JPU dispersion synthesised in this work has a solidwhich content of 25 wt. % milky white in colour. The dispersion has a low viscosity of 12.5 mPas, with a zeta potential of particle size with a modal peak at 13.5 nm. From the point of view of colloidal stability, the dispersion appears milky white in colour. The dispersion has a low viscosity of 12.5 mPas, with a zeta potentialis −56.6 mV.asFigure 18 shows a particle sizethan distribution of the dispersion, which demonstrates the low stable the average particle is less 100 nm [31]. particle size is andemonstrates important parameter of −56.6 mV. Figure 18 showssize a particle size distribution of The the dispersion, which the low particle size size with a modal peak at 13.5 nm. From the point of view of colloidal stability, the dispersion inparticle deciding the industrial applications of a waterborne polyurethane dispersion [32], in which with a modal peak at 13.5 nm. From the point of view of colloidal stability, the dispersion isa small particle size is particle essential for deep of[31]. the dispersion into aissubstrate [33]. parameter is stable as the average is than100 100nm nm [31]. The particle isimportant an important parameter stable as the average particlesize size is less lesspenetration than The particle sizesize an in deciding the industrial applications of aofwaterborne polyurethane dispersion in deciding the industrial applications a waterborne polyurethane dispersion[32], [32],ininwhich whichaasmall particle size is essential for deepfor penetration of the of dispersion into into a substrate [33]. small particle size is essential deep penetration the dispersion a substrate [33]. Figure 18. Particle size distribution of the JPU dispersion. Figure Particlesize size distribution distribution ofofthe dispersion. Figure 18.18.Particle theJPU JPU dispersion. Molecules 2017, 22, 551 13 of 17 3. Materials and Methods 3.1. Materials Reagent grade hydrogen peroxide 30% and methanol were supplied by Merck (Darmstadt, Germany). Isophrene diisocyanate (IPDI), dimethylol propionic acid (DMPA), n-methyl pyrollidone (NMP), hydroxyethyl methacrylate (HEMA), phtalic anhydride, and dibutyltin dilaurate (DBTDL) were supplied by Sigma Aldrich (Milwaukee, WI, USA). Ethyl methyl ketone (MEK), triethylamine (TEA), formic acid, magnesium sulphate anhydrous, pyridine, and sodium hydroxide were reagent grade, supplied by Classic Chemicals (Shah Alam, Malaysia). The crude jatropha oil was supplied by Biofuel Bionas Sdn Bhd, Kuala Lumpur, Malaysia. It is a non-food grade material and was used as received. All chemicals were used without further purification. 3.2. Preparation of Jatropha Oil-Based Polyol (JOL) Polyols were synthesised by a two-step process; namely epoxidation followed by oxirane ring opening (Figure 2). 3.2.1. Epoxidation The reaction parameters for the epoxidation step are presented in Table 6. The epoxidation parameters are divided into three groups; reaction temperature at 50 ◦ C with varied molar ratio, reaction at 60 ◦ C with varied molar ratio, and the molar ratio fixed in 1:0.6:1.7 with varied reaction times. Briefly, a mixture of jatropha oil and formic acid was placed in a 1 L flask and heated to 40 ◦ C under continuous stirring. Hydrogen peroxide 30% was then added dropwise for 30 min before increasing the temperature to a specified reaction temperature. After a prescribed time, the mixture was cooled to room temperature. The aqueous layer was discarded, and the remaining acid was removed by washing the oil layer with an excessive amount of water. Magnesium sulphate was then added to the EJO as a drying agent. Table 6. Reaction parameters for the epoxidation step and the acid values of epoxidised jatropha oil (EJO). No. Molar Ratio a Reaction Temperature (◦ C) Reaction Time (h) Acid Value (mgKOH/g) 1 2 3 4 5 6 7 8 9 10 11 1.0:0.4:1.7 1.0:0.6:1.7 1.0:1.0:1.7 1.0:0.4:1.7 1.0:0.6:1.7 1.0:1.0:1.7 1.0:1.2:1.7 1.0:0.6:1.7 1.0:0.6:1.7 1.0:0.6:1.7 1.0:0.6:1.7 50 50 50 60 60 60 60 60 60 60 60 5 5 5 4 4 4 4 2 3 4 4.5 14.49 14.76 16.27 15.10 15.20 16.40 14.43 15.95 a Double bond: Formic acid: Hydrogen peroxide. 3.2.2. Oxirane Ring Opening The reactions were carried out in a four-necked flask equipped with a mechanical stirrer, condenser, dropping funnel, and thermometer. For this reaction, the molar ratio of methanol to water is 5:1, while the amount of water is 10% (w/w) of epoxidised jatropha oil. Briefly, a calculated amount of methanol, water, and sulphuric acid catalyst (0.3 wt. %) were poured into a 1 L flask and heated to 64 ◦ C under continuous stirring. Epoxidised jatropha oil was then added, and the reactions proceeded for 30 min, followed by adding sodium bicarbonate to quench the reaction. After being Molecules 2017, 22, 551 14 of 17 cooled to room temperature, the deposit was discarded. Methanol and water were removed by vacuum distillation. Only to Molecules 2017, 22,the 551 third series of epoxidised jatropha oil was selected to be further converted 14 of 17 polyol using the same oxirane ring opening conditions. Four types of polyol with different hydroxyl 10 1.0:0.6:1.7 60 4 numbers were produced. 11 1.0:0.6:1.7 60 4.5 15.95 Double bond: Formic acid: Hydrogen peroxide. 3.3. Preparation of Aqueous Polyurethane Dispersion a The reactions were carried out in a four-necked 3.3. Preparation of Aqueous Polyurethane Dispersion flask equipped with a mechanical stirrer, dropping funnel, condenser, and thermometer. The jatropha oil-based polyol (JOL 161) and DMPA (dissolved The reactions were carried out in a four-necked flask equipped with a mechanical stirrer, in NMP) werefunnel, charged into theand flask and heatedThe to ajatropha temperature of polyol 80 ◦ C (JOL for 30161) min. mixture dropping condenser, thermometer. oil-based andThe DMPA ◦ C and the IPDI was slowly dropped for 30 min. DBTDL was used as a catalyst. was then cooled to 60 (dissolved in NMP) were charged into the flask and heated to a temperature of 80 °C for 30 min. The The reaction wasthen reheated a temperature ofdropped 80 ◦ C for h,min. followed theused addition mixture was cooled and to 60reached °C and the IPDI was slowly for330 DBTDLby was as a of HEMA for a The chain termination step. About 20 g of MEK was added batch to reduce catalyst. reaction was reheated and reached a temperature of 80 °C for 3by h, batch followed by the the addition of system HEMA for a chain termination step. About 20 gg). of The MEKreaction was added by batch to the viscosity of the (the total amount of MEK was 100 wasbatch complete when reducespectra the viscosity of the system (the total amount of MEK g). The reaction was complete that ATR-FTIR showed that the NCO peak at 2270 cm− 1was had100 disappeared, thus indicating −1 had the ATR-FTIR spectra showed that the NCO 2270 to cm40 disappeared, thus ◦ C and all thewhen diisocyanate was consumed. The reactants werepeak then at cooled neutralised by the indicating that all the diisocyanate was consumed. The reactants were then cooled to 40 °C and addition of TEA (1.2 equiv. per DMPA), followed by dispersion at high speed with distilled water to neutralised by the addition of TEA (1.2 equiv. per DMPA), followed by dispersion at high speed produce the JPU dispersions with a solid content of ∼25 wt.% after removal of the MEK under vacuum. with distilled water to produce the JPU dispersions with a solid content of ∼25 wt.% after removal of The formulation of waterborne is shownofinwaterborne Table 7, using NCO/OH of 0.8/1.0, while the chemical the MEK under vacuum. TheJPU formulation JPU is shown in Table 7, using NCO/OH of reaction is shown in Figure 19. 0.8/1.0, while the chemical reaction is shown in Figure 19. H3CO OH O O O OCH3 O O CH3 CH3 OCH3 + CH3 O C N + HO OH N C O O COOH IPDI O DMPA JOL O DBTDL ( catalyst ) O HO CH2 O HEMA CH3 N O O H3CO O O O O OCH3 O O TEA N H OCH3 H N O O O COO O N H NH O Water O O Aqueous polyurethane dispersion Figure 19. Synthesis of aqueous polyurethane dispersion. Figure 19. Synthesis of aqueous polyurethane dispersion. O H N O O O CH2 CH3 Molecules 2017, 22, 551 15 of 17 Table 7. The recipe of aqueous polyurethane (JPU) dispersions. Ingredient Functional Group Mass (g) Mol JOL DMPA HEMA IPDI OH OH OH NCO 60.0 7.3 4.3 29.0 0.172 0.111 0.033 0.260 3.4. Characterisation The oxirane oxygen content measurement of the epoxidised jatropha oil was determined according to AOCS Tentative Method Cd 9-57, revised in 1963. The theoretical maximum oxirane oxygen content, OOCt was determined to be 5.74% according to Equation (2): OOCt = {( IV0 /2Ai )/[100 + ( IV0 /2Ai ) A0 )]} × A0 × 100 (2) where IV0 (96.06) is the initial iodine value of the oil, Ai (126.9) is the atomic weight of iodine, and A0 (16.0) is the atomic weight of oxygen [13]. The oxygen oxirane content was used to determine the relative conversion to oxirane, according to Equation (3): Relative conversion to oxirane = OOCc /OOCt (3) where OOCc is an experimental oxirane oxygen content. The determination of the hydroxyl number of the jatropha-based polyol followed ASTM D4274-99 Test Method C (reflux phthalation) standard practice. The equivalent weights (EW) of the polyols were calculated using Equation (4) [18]: EW = (Molecular weight of KOH × 1000) OH number = 56100 OH number (4) The acid number measurements of the epoxidised jatropha oil and the polyol were determined according to ASTM D4662-03 Test Method A standard practice. The FTIR spectra were recorded on a Perkin-Elmer Spectrum 2000 spectrometer (Perkin Elmer, Norwalk, CT, USA), equipped with a horizontal germanium attenuated total reflectance (ATR) accessory. The spectra were recorded in the range of 4000–500 cm− 1 with a nominal resolution of 4 cm− 1 . The molecular weight of the samples was determined using Gel Permeation Chromatography (Waters Co., Milford, MA, USA) with a series of Styragel® columns. Calibration was performed using a polystyrene standard, whereby tetrahydrofuran (THF) was used as the eluent with a flow rate of 1.0 µL/min at 35 ◦ C. The sample injection volume was 50.0 µL. The rheological properties of the samples were analysed on an ARG2 rheometer (TA Instruments, DE, USA). The rheometer was equipped with a 40 mm 2◦ cone, and the gap between the truncated tip of the cone and the bottom Peltier plate was maintained at 56 µm. The particle size of the polyurethane dispersions was measured by a Zetasizer Nano-S (Malvern Instruments, Herrenberg, Germany). Approximately 0.1 mL of the polyurethane dispersion was diluted with 3 mL distilled water and measured at 25 ◦ C. 4. Conclusions Jatropha oil-based polyols were successfully synthesised by epoxidation and an oxirane ring opening method, and the physicochemical properties of the products were reported. The epoxidation reaction parameters such as temperature, the oil double bond to formic acid molar ratio, and time showed a significant effect on the conversion of the double bond to an oxirane group. About 75% conversion was obtained at a temperature of 60 ◦ C, a molar ratio of 1:0.6, and a 4 h reaction time, Molecules 2017, 22, 551 16 of 17 which is equivalent to 4.30% OOC of epoxidised jatropha oil (EJO). Furthermore, a series of JOLs with a hydroxyl number of 138–217 mgKOH/g was successfully prepared after the oxirane ring opening of the EJO produced at a reaction time of 2.25 to 4.5 h. The resulting JOLs exhibited Newtonian behaviour, with a low viscosity of 430–970 mPas, and molecular weight of 1349–2129 g/mol. Polyurethane was successfully synthesised from JOL, as monitored by FTIR. 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