Techno-economic assessment of polyurethane flexible foam waste-to- energy via incineration: a Kenyan case study

Abstract

In response to escalating waste management challenges and growing energy demands, this study evaluates the technical and economic feasibility of recovering energy from post-consumer flexible polyurethane (PU) foam waste in Kenya via advanced incineration technologies. Employing empirical data analysis, thermochemical modelling, and economic assessment, the research first estimates Kenya’s annual PU foam waste generation—projected at 18,909.20 tonnes in 2025, with 9,545.60 tonnes deemed collectable—and determines a net calorific value of 23.131 MJ/kg, corresponding to an energy potential of 218.7 million MJ for collectable waste. Comparative analysis demonstrates that a fluidized bed incinerator yields 167.3 million MJ of thermal energy and 13,825.58 MWh of electricity, outperforming a mass burn incinerator’s 13.94 million MJ and 9,294.51 MWh, while Levelized Cost of Electricity (LCOE) calculations indicate marginal cost differences of USD 0.22 /kWh versus USD 0.23 /kWh, respectively. The findings offer critical insights into waste generation patterns, energy recovery efficiencies, and financial viability and support recommendations for refining waste estimation models, conducting experimental energy-content analyses, and establishing pilot-scale facilities to advance sustainable waste-to-energy solutions.

Keywords: Post-consumer polyurethane foam waste; Fluidized bed incineration; Mass burn incineration; Energy recovery potential; Levelized Cost of Electricity; Techno-economic assessment