The effect of PP contamination in recycled high-density polyethylene (rPE-HD) from post-consumer bottle waste and their compatibilization with olefin block copolymer (OBC)

Parameters optimization for decontamination and fine physical regeneration pathways of polypropylene plastics from waste lunchboxes

Due to the development of the food delivery industry, a large amount of waste lunchboxes made of homo polypropylene (PP) plastic have been generated. This study developed a new technological strategy to effectively regenerate PP from waste lunchboxes. Through response surface curve analysis, it was found that under the optimal process conditions of hot alkali washing at 80 ℃, 30 min, and pH 13, the optimal contact angle was 65.55°, indicating a good oil stain removal effect. By identifying and analyzing the characteristics of impurities in waste lunchboxes, a physical sorting and granulation regeneration process was constructed. And through large-scale statistical analysis and data collection, it was further verified that recycled PP plastics maintained their physical stability and excellent processing performance. The quality stability of recycled PP plastics in terms of impurities content was also verified. By designing different formulations specifically, recycled PP was mixed with different virgin PP and antioxidants in appropriate proportions, and extruded into particles under 150-300 mesh filtration conditions to obtain modified recycled PP. Modified recycled PP was applied in textiles, clothing, and injection molded products. In conclusion, we achieve the up-cylcing of waste PP lunchboxes instead of down-cylcing.

Analysis of different polypropylene waste bales: Evaluation of the source material for PP recycling

The use of the polypropylene (PP) recyclates in certain processing methods and applications is still limited by their quality. The high melt flow rate (MFR) and the inconsistent properties of recyclates are common obstacles to their use. Therefore, this work aims to identify possible reasons for the low and inconsistent quality of PP recyclates depending on the source material in PP waste bales. The levels of polymeric and non-polymeric contaminants were assessed. As mixing of different PP grades is an issue for the MFR, the proportions of the different processing grades were also investigated and the potential of sorting by processing method to produce lower MFR recyclates was assessed. The analysis showed that the waste bales, although pre-sorted, still contained high amounts of contaminants. Injection moulding was found to be the predominant processing method in the bales, explaining the high MFR of PP recyclates. However, a sufficiently high amount of low MFR products was found in the bales, which seems promising for the production of low MFR recyclates. Seasonal variations in the composition of the waste bales were identified as one of the reasons for the inconsistent qualities of recyclates. These results highlight the importance of proper sorting and treatment of PP waste bales prior to reprocessing in order to obtain high-quality recycled products.

Towards designer polyolefins: highly tuneable olefin copolymerisation using a single permethylindenyl post-metallocene catalyst

Using a highly active permethylindenyl-phenoxy (PHENI*) titanium catalyst, high to ultra-high molecular weight ethylene-linear-α-olefin (E/LAO) copolymers are prepared in high yields under mild conditions (2 bar, 30-90 °C). Controllable, efficient, and predictable comonomer enchainment provides access to a continuum of copolymer compositions and a vast range of material properties using a single monomer-agnostic catalyst. Multivariate statistical tools are employed that combine the tuneability of this system with the analytical and predictive power of data-derived models, this enables the targeting of polyolefins with designer properties directly through predictive alteration of reaction conditions.

Investigation of Crystallization, Morphology, and Mechanical Properties of Polypropylene/Polypropylene-Polyethylene Block Copolymer Blends

Polyethylene (PE)-based elastomers are the ideal choice for enhancing the compatibility of polypropylene/polyethylene (PP/PE) blends and improving the mechanical properties of PP-based materials. However, the issue of blend systems lies in the interplay between the crystallization processes. Therefore, we investigated the crystallization behavior during the cooling process of a new generation of PP/PE block copolymers (PP-b-PE) and random polypropylene (PPR, a copolymer of propylene and a small amount of ethylene or an alpha-olefin) blends using in-situ X-ray diffraction/scattering and differential scanning calorimetry (DSC) techniques. We also conducted mechanical performance tests on PPR/PP-b-PE blends at room temperature and low temperature (-5 °C). The results indicate that during the cooling process, the PP phase of PP-b-PE will follow the PPR to crystallize in advance and form a eutectic mixture, thereby enhancing the compatibility of PP/PE. Moreover, the PPR/PP-b-PE blend will form stable β-(300) crystals with excellent mechanical properties. Due to the improved compatibility of PP/PE with PP-b-PE, PE crystals are dispersed within PP crystals, providing bonding that improves the toughness of PPR under the low stiffness failure conditions of PPR/PP-b-PE blends, thereby enhancing their impact performance at low and room temperatures. This research has great significance for both recycling waste plastics and enhancing the low-temperature toughness of PPR.

Thermomechanical Properties of Virgin and Recycled Polypropylene-High-Density Polyethylene Blends

This paper provides evidence and discusses the variability in the thermomechanical behaviour of virgin and recycled polypropylene/high-density polyethylene blends without the addition of other components, which is sparse in the literature. Understanding the performance variability in recycled polymer blends is of critical importance in order to facilitate the re-entering of recycled materials to the consumer market and, thus, contribute towards a circular economy. This is an area that requires further research due to the inhomogeneity of recycled materials. Therefore, the thermal and mechanical properties of virgin and recycled polypropylene/high-density polyethylene blends were investigated systematically. Differential scanning calorimetry concludes that both the recycled and virgin blends are immiscible. Generally, recycled blends have lower overall crystallinity and melting temperatures compared with virgin blends while, remarkably, their crystallisation temperatures are compared favourably. Dynamical mechanical analysis showed little variation in the storage modulus of recycled and virgin blends. However, the alpha and beta relaxation temperatures are lower in recycled blends due to structural deterioration. Deterioration in the thermal and mechanical properties of recycled blends is thought to be caused by the presence of contaminants and structural degradation during reprocessing, resulting in shorter polymeric chains and the formation of imperfect crystallites. The tensile properties of recycled blends are also affected by the recycling process. The Young's modulus and yield strength of the recycled blends are inferior to those of virgin blends due to the deterioration during the recycling process. However, the elongation at break of the recycled blends is higher compared with the virgin blends, possibly due to the plasticity effect of the low-molecular-weight chain fragments.

Effects of Recycled Polymer on Melt Viscosity and Crystallization Temperature of Polyester Elastomer Blends

As the world is paying attention to the seriousness of environmental pollution, the need for a resource circulation economy is emerging due to the development of eco-friendly industrial groups. In particular, the recycling of thermoplastic elastomers without cross-link has been highlighted in the plastics field, which has rapidly developed the industry. Growing interests have been directed towards the advancement of thermoplastic polyether-ester elastomer (TPEE) as a material suitable for the circular economy owing to its remarkable recyclability, both in terms of mechanical and chemical processes. Due to its excellent processability, simple mechanical recycling is easy, which is a driving force towards achieving price competitiveness in the process. In molding TPEE resin, it is essential to check the thermal properties of the resin itself because the thermal properties, including the melting and crystallization temperatures of the resin, depend on the design of the polymer. In this study, the thermal and mechanical performances of TPEE blends were evaluated by manufacturing compounds by changing the amount of recycled resin and additives. When the recycled resin was added, the melt flow index (MFI) changed rapidly as the temperature of the melt flow index measurement increased. Rapid changes in MFI make the fiber spinning process uncontrollable and must be controlled by optimizing the addition of compatibilizers. Based on the thermal property results, compatibilizers such as Lotader and Elvaloy series exhibited minimal change in glass transition temperature, even with greater amounts added. This makes them well-suited as compatibilizers for fiber spinning.

Selection of recycled waste plastic for incorporation in sustainable asphalt pavements: A novel multi-criteria screening tool based on 31 sources of plastic

This study investigated the suitability of 31 recycled waste plastic samples obtained from 15 major recycling companies across Australia and New Zealand to be used as bitumen/asphalt modifiers. The plastics have been selected to be representative of recycled waste plastic around Australia and New Zealand. The recycled waste plastics belonged to either the post-industrial or post-consumer collection scheme. A new classification scheme was developed to rank each recycled waste plastic based on their chemical and physical properties against those of bitumen/asphalt. Specifically, density, polarity, melting point, solubility and melt flow index of the samples as well as the presence of contaminants, fillers and additives were analyzed for each recycled waste plastic material and their virgin counterpart. These 8 properties were used to rank various sources of recycled low-density poly(ethylene), linear low-density poly(ethylene), high density poly(ethylene) and poly(propylene) in addition to commingled plastics based on their suitability for bitumen modification (wet method). The modification of asphalt via replacement of virgin quarry aggregate with plastic aggregate (dry method) by recycled acrylonitrile butadiene styrene and poly(ethylene terephthalate) was also assessed by considering four criteria of purity, polarity, recycling contamination and hazardous additives. This new multi-criterion ranking approach revealed that low-density and linear low-density poly(ethylene) and acrylonitrile butadiene styrene and poly(ethylene terephthalate) should be preferentially used as bitumen/asphalt modifiers. This tool has been developed for recycling companies and bitumen/asphalt contractors to determine the suitability of recycled waste plastics within asphalt roads by a series of experimental techniques.

Raman technology application for plastic waste management aligned with FAIR principle to support the forthcoming plastic and environment initiatives

Plastic production and worldwide use of plastic materials have continued to rise due to their convenience and excellent marketing advantages. This is generating an environmental crisis and global scale pollution which is one of the greatest threats to our planet. One of the best responses could be accomplished by improving recycling and waste management strategies. In this paper we conducted Raman analyses of representative stock of plastics aged in terrestrial or aquatic environments spanning in age up to 15 years. We aimed to establish any potential influence of the aging conditions on the Raman signature of specific plastics. This information is further used to build up a Raman logic gate for automatic sorting of plastic waste recovered from environment. Pigments and aging introduced indeed small changes in the Raman signature of the respective plastics. However, we were able to identify unique spectral ranges characteristic for the main plastic types and intensity threshold of fingerprint bands sufficiently strong for building robust Raman barcodes for sorting. Waste plastics Raman data handling and the proposed methodology for sorting complies with the FAIR (Findability, Accessibility, Interoperability and Reusability) principles of scientific data, being useful for researchers, policymakers and stakeholders. Our spectral characterization of solid plastic waste comes in support of improved waste plastic management and could have economic and environmental positive impact.

Sugar-Based Polymers with Stereochemistry-Dependent Degradability and Mechanical Properties

Stereochemistry in polymers can be used as an effective tool to control the mechanical and physical properties of the resulting materials. Typically, though, in synthetic polymers, differences among polymer stereoisomers leads to incremental property variation, i.e., no changes to the baseline plastic or elastic behavior. Here we show that stereochemical differences in sugar-based monomers yield a family of nonsegmented, alternating polyurethanes that can be either strong amorphous thermoplastic elastomers with properties that exceed most cross-linked rubbers or robust, semicrystalline thermoplastics with properties comparable to commercial plastics. The stereochemical differences in the monomers direct distinct intra- and interchain supramolecular hydrogen-bonding interactions in the bulk materials to define their behavior. The chemical similarity among these isohexide-based polymers enables both statistical copolymerization and blending, which each afford independent control over degradability and mechanical properties. The modular molecular design of the polymers provides an opportunity to create a family of materials with divergent properties that possess inherently built degradability and outstanding mechanical performance.

Choosing an Effective Compatibilizer for a Virgin HDPE Rich-HDPE/PP Model Blend

The most widely used commodity polymers in the rigid packaging industry are polypropylene (PP) and high-density polyethylene (HDPE). For example, blow molding grade of HDPE as a bottle and injection molding grade of PP as a cap are often used to produce detergent bottles. Therefore, the recycled HDPE bottles from post-consumer waste include PP as a contaminant originated from PP bottle caps. To simulate mechanical recycling of bottle waste, the mechanical properties of HDPE-rich-HDPE/PP virgin model blend were studied. For compatibilization, ethylene-based olefin block copolymer, propylene-based olefin block copolymer, ethylene propylene random copolymer, and styrene-butadiene-styrene triblock copolymer were chosen as potential compatibilizer candidates. Contact angle measurements, morphological analysis, adhesion tests of compatibilizer candidates to polymer blend components and the tensile as well as tensile impact properties of the ternary blends were studied. It was found that the ethylene-based olefin block copolymer was the most effective compatibilizer resulting in a return of mechanical properties to those of neat vHDPE due to its ability to encapsulate dispersed vPP particles in a vHDPE matrix (core-shell morphology) and the best adhesion to polymer blend components.

Polypropylene Contamination in Post-Consumer Polyolefin Waste: Characterisation, Consequences and Compatibilisation

Plastic recycling strikes a balance between functional, mass producible products and environmental sustainability and is pegged by governments for rapid expansion. However, ambitious targets on recycled material adoption across new markets are at odds with the often heterogenous properties of contaminated regranulates. This study investigated polypropylene (PP) contamination in post-consumer low-density polyethylene (PE-LD) and mixed polyolefin (PO) regranulates. Calibration curves were constructed and PP content, its effect on mechanical properties and property recovery in compatibilised material assessed. FT-IR band ratios provided more reliable estimations of PP content than DSC melt enthalpy, which suffered considerable error for PP copolymers. PE-LD regranulates contained up to 7 wt.% PP contamination and were considerably more brittle than virgin PE-LD. Most mixed PO regranulates contained 45-95 wt.% PP and grew more brittle with increasing PP content. Compatibilisation with 5 wt.% ethylene-based olefin block copolymer resulted in PE-LD blends resembling virgin PE-LD and considerable improvements in the properties of mixed PO blends. These results illustrate the prevalence of PP in recycled PE, challenges associated with its quantification, effect on mechanical properties, and compatibilisation viability, thereby representing an important step towards higher quality regranulates to meet the recycling demands of tomorrow.

Extruded-Calendered Sheets of Fully Recycled PP/Opaque PET Blends: Mechanical and Fracture Behaviour

This work presents the experimental results of the mechanical and fracture behaviour of three polymeric blends prepared from two recycled plastics, namely polypropylene and opaque poly (ethylene terephthalate), where the second one acted as a reinforcement phase. The raw materials were two commercial degrees of recycled post-consumer waste, i.e., rPP and rPET-O. Sheets were manufactured by a semi-industrial extrusion-calendering process. The mechanical and fracture behaviours of manufactured sheets were analyzed via tensile tests and the essential work of fracture approach. SEM micrographics of cryofractured sheets revelated the development of in situ rPP/rPET-O microfibrillar composites when 30 wt.% of rPET-O was added. It was observed that the yield stress was not affected with the addition of rPET-O. However, the microfibrillar structure increased the Young’s modulus by more than a third compared with rPP, fulfilling the longitudinal value predicted by the additive rule of mixtures. Regarding the EWF analysis, the resistance to crack initiation was highly influenced by the resistance to its propagation owing to morphology-related instabilities during tearing. To analyze the initiation stage, a partition energy method was successfully applied by splitting the total work of fracture into two specific energetic contributions, namely initiation and propagation. The results revelated that the specific essential initiation-related work of fracture was mainly affected by rPET-O phase. Remarkably, its value was significantly improved by a factor of three with the microfibrillar structure of rPET-O phase. The results allowed the exploration of the potential ability of manufacturing in situ MFCs without a “precursor” morphology, providing an economical way to promote the recycling rate of PET-O, as this material is being discarded from current recycling processes.