Polyurethanes made with a new sustainable polyol, known as polycarbonate ether (PCE) polyols, offer an appealing prospect for paint and coatings companies: enhanced performance with a reduced carbon footprint. From specialty coatings for apparel and automotive interiors to beloved household paint brands, consumers no longer have to compromise between the planet and products that work.

By opting for polyols based on renewable carbon, brand owners can make progress on corporate climate targets and capture demand from discerning consumers who are willing to pay premiums for products with climate-related claims.

Sustainability Starting at the Source

Paint and coatings manufacturers rely on the chemical industry. Carbon-based molecules are essential to chemistry. Therefore, unlike other sectors, the chemical industry cannot be decarbonized. However, it can be defossilized. Manufacturers can opt for renewable carbon sources rather than fossil fuels.

There are three main types of renewable carbon:

• Captured carbon (i.e., waste CO2)
• Chemically recycled carbon
• Bio-based carbon

Formulators will need all three of these new technologies to maintain the “polyol toolbox” that delivers the range of functionality, molecular weight and composition they rely on today.

Testing and Commercializing Polyols from Captured Carbon 

Econic Technologies, a deep tech company focused on renewable carbon, has licensed its novel catalyst and process technology for synthesizing PCE polyols based on captured carbon to several manufacturers. These include Monument Chemical in the United States and Changhua Chemical in China. Since traditional polycarbonate polyols are known for their high performance, paint and coatings companies are eager to road-test these new PCE polyols with carbonate (CO3) linkages to see how the technology can enhance performance and support the shift to more sustainable products.

The company’s team has worked closely with customers in the market to tailor polyols for specific applications. "Tuning the performance of polyurethanes across the scope of applications requires a range of polyol types with respect to functionality, molecular weight and particularly CO2 content, which the Econic process can finely tune," explains Econic Senior Scientist Richard Stevenson.

To understand the performance of these polycarbonate ether (PCE) polyols in coatings, his team led a series of experiments comparing these sustainable polyols against conventional materials. The study evaluated two PCE polyols with different CO2 contents (9% and 21% by weight) alongside industry-standard polyols: polypropylene glycol (PPG), polytetramethylene ether glycol (PTMEG) and polycarbonate (PC). All polyols in the study were 2,000 molecular weight diols.

The polyols were used to create waterborne polyurethane dispersions (PUDs) via a standard pre-polymer method. Each coating was prepared using a consistent formulation to ensure that results were comparable across all polyol types. The performance of the resulting PUD coatings was then analyzed based on key parameters such as drying time, gloss, tensile strength, and resistance to hydrolysis and chemical agents.

Performance Insights

Econic's polycarbonate ether (PCE) polyols demonstrated promising results. By incorporating captured CO2 into the polyol structure, these materials maintain the required performance properties — such as tensile strength, gloss and chemical resistance — while offering additional benefits like improved hydrolytic stability compared to traditional polyether systems. This makes them well-suited for applications where long-term durability and environmental impact are critical considerations.

Testing results revealed that the PCE polyols, even at higher CO2 levels, delivered properties comparable to those of traditional polycarbonate polyols. The coatings prepared using PCE polyols demonstrated drying times, gloss values and elongation profiles similar to the control polyols, showcasing their versatility and potential to replace fossil-based alternatives.

One of the most notable findings was that increasing the CO2 content in PCE polyols not only enhanced the tensile strength of the coatings but also improved their resistance to hydrolysis.

This was particularly evident in the sample with 21% CO2 content, which showed a significantly lower loss in strength after prolonged water exposure compared to traditional polyether systems. This increased stability suggests that high-CO2 PCE polyols may be especially well-suited for outdoor and marine coatings. For more flexible applications, lower CO2 contents showed greater elongation properties.

The findings from these experiments highlight that increasing the CO2 content within PCE polyols can lead to enhanced performance characteristics, particularly in terms of hydrolysis and chemical resistance. This suggests that the tunability of CO2 levels in PCE polyols could be a key factor in optimizing properties for specific coatings applications.

Testing the Tech for Synthetic Leather Coatings

One industry that may benefit from the tunable characteristics of the PCE polyols based on the company’s technology is the synthetic leather industry. Consumers have embraced synthetic PU leather (i.e., vegan leather), a category that continues to grow. The quality of such products is often determined in part by the properties of the coatings applied.

Deers Seda, one of the company’s partners in the Korean coatings industry, has assessed PCE polyols for this application. “When testing synthetic leather coatings, we observed significant benefits using Econic’s PCE polyols, including improved elongation, good hydrolysis resistance and superior adherence to substrates,” commented Deers Seda Senior Managing Director, Hyosup Koh. “These properties are crucial for achieving the flexibility and durability needed in synthetic leather applications, where maintaining both visual appeal and long-term performance under environmental stress is essential.”

Ensuring the Commercial Viability of Carbon-Based Coatings

While developing the technology for carbon-dioxide-based polyols, Econic's team knew that economics would play a role in the widespread adoption of its technology. The company recognized that consumers want to make sustainable choices but still care about price. This has hindered the adoption of some new technologies, which cannot yet be cost-competitive with existing oil-based solutions due to feedstock prices and scale.

As an alternative, the company developed a process that makes it possible for companies to use captured CO₂ at temperatures and pressures in line with standard production, so existing manufacturing plants can be used, reducing the cost of market entry. The process is also less energy-intensive than traditional processes, so it can be cost-competitive with existing polyols.

Expanding into Surfactants

Econic is also developing its technology for other applications relevant to the paint and coatings industry, demonstrating the flexibility of its catalyst and process technology. The company has been investing in surfactants based on captured carbon. CO2 surfactants have the potential for use in many industries, particularly as wetting agents and dispersants in paints and coatings.

“By changing the structure of the molecule, it brings a whole range of benefits that you can’t get otherwise,” explained Anthea Blackburn, Econic’s Surfactants lead. Examples include enhanced durability and chemical resistance.

By enabling formulators to achieve the same (or better) performance with lower environmental impact, this technology is not just an incremental improvement — it represents a fundamental shift toward sustainable chemistry.

Implications for the Future

The versatility of polycarbonate ether (PCE) polyols, combined with the ability to incorporate high levels of captured CO2 and fine-tuned characteristics, means that paint and coatings manufacturers are no longer limited to fossil-based chemistries. Instead, they can access a new generation of carbon-based materials that maintain or exceed the quality of conventional polyols while offering an immediate reduction in the environmental footprint.

The future of coatings is one where sustainability and performance are no longer opposing forces. With continued development and adoption of these next-generation polyols, coatings companies have the opportunity to offer consumers a choice that is better for the planet without compromising on quality.

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