Optimization of the high-pressure, near-critical liquid-based microsortation of recyclable post-consumer plastics

Abstract

Abstract High-pressure, near-critical liquids were used as float-sink separation media for the microsortation of polyolefin mixtures and PET/PVC mixtures. Near-critical carbon dioxide was used for the refinement of the polyolefins, and sulfur hexafluoride was used to separate post-consumer PVC from PET. Preliminary experiments indicated that there was no overlap in the density ranges of post-consumer HDPE, LDPE and PP containers. There was no overlap in the PET and PVC densities, with the exception of a single PVC packaging material with a density in the PET range. These initial results indicated that a float-sink separation was a viable means of microsortation. Separations of 91% LDPE (1/8′ beads)/9% PP (1/8′ chopped strands) resin mixtures and mixed post-consumer polyolefin flakes were then conducted in a laboratory-scale, 1-I batch apparatus. This apparatus not only permitted the observation of the separation, but also enabled the separated fractions to be removed from the high-pressure environment. The results indicated that LDPE purity of greater than 98.9% was obtained in 3 min or less if (a) the fluid density was 0.018 g/cm 3 greater than the PP density and only 0.002 g/cm 3 less than the LDPE density, thereby providing the greatest buoyancy force for the removal of the PP, (b) the fluid was recirculated upward through the bed of mixed plastics, facilitating the upward movement of the PP, and (c) the loading was kept at levels below 40% by volume. HDPE purity of 99% was also attained with clean, dry, post-consumer mixed plastic flakes. The loadings for these separations were very low, however, due to the difficulty in agitating the mixed bed of plastics using fluid recirculation. An economic analysis of these microsortation processes indicated that the value of the sorted plastics relative to the mixed feed must increase by approx. $0.08/lb for the CO 2 -based separation and approx. $0.27/lb for the SF 6 -based separation to justify the implementation of these high-pressure processes.