Mechanical Recycling Research Articles

Gasification for material recycling—A solution to the plastic flood?

AbstractSince 1950, only 9% of all plastic produced has undergone recycling, and a mere 10% of that has been recycled multiple times. Most discarded plastic (around 73%) ends up in landfills or is improperly managed, resulting in widespread littering. The main reason for low recycling rates is the lack of recycling technology for multi‐polymer and multi‐layer materials and unsortable mixed plastic waste. This plastic waste is one of the most accumulating types, including for example single‐use food packaging with an average lifetime of less than 6 months. These multi‐layer films, consisting of various polymer types, are not feasible for traditional mechanical recycling, which requires well‐sorted, clean, and homogeneous materials. Several methods for plastic recycling have been proposed to address this issue and tackle the overwhelming influx of plastic waste, among which steam gasification stands out as one of the most promising approaches for recycling mixed, contaminated, and unsortable plastics. This method utilizes high temperatures (800°C) to atomize the plastics, resulting in a gas mixture of , CO, and and small hydrocarbons. The resulting gas can be reformed through hydrocarbon syntheses, for example, via methanol to propylene and ethylene, and successive into new mono‐ and polymers of equal quality to fossil‐based plastics. Moreover, since the high temperatures atomize any organic structure, biomass can be used as a substitute for an extension of the carbon feed, ultimately reducing reliance on fossil feedstock. With these advantages, steam gasification can significantly increase recycling rates and contribute to a bio‐integrated circular carbon economy.

Fine Regeneration of ABS and PS Plastics from Waste Refrigerators through Mechanical Physical Recycling

Fine Regeneration of ABS and PS Plastics from Waste Refrigerators through Mechanical Physical Recycling

Evaluation of Thermoplastic Starch Contamination in the Mechanical Recycling of High-Density Polyethylene

This research highlights the importance of addressing bioplastic contamination in recycling processes to ensure the quality of recycled material and move towards a more sustainable circular economy. Polyethylene (PE) is a conventional plastic commonly used in packaging for which large amounts of waste are produced; therefore, PE is generally recycled and has an established recycling process. However, the contamination of biodegradable polymers in the PE waste stream could impact recycling. This study, therefore, focuses on polyethylene (PE) that has been polluted with a commercial thermoplastic starch polymer (TPS), as both materials are used to produce plastic films and bags, so cross-contamination is very likely to occur in waste separation. To achieve this, recycled PE was blended with small quantities of the commercial TPS and processed through melt extrusion and injection molding, and it was further characterized. The results indicate that the PE-TPS blend lacks miscibility, evidenced by deteriorated microstructure and mechanical properties. In addition, the presence of the commercial TPS affects the thermal stability, oxidation, and color of the recycled PE.

High-quality acrylic fibers from waste textiles

The objective of this work is to develop a closed-loop recycling method specifically tailored for acrylic fibers. Recycling waste acrylic is essential, given the vast volumes of acrylic-containing textiles produced yearly and the strong capability of acrylics to generate toxic microplastics. However, none of the available closed-loop recycling, mechanical recycling, chemical recycling, and direct extrusion technologies work for acrylics. Acrylic fibers are always blended with other textile fibers, making fiber separation via mechanical recycling almost impossible. Polyacrylonitrile, an addition-polymerized thermoplastic material, cannot be depolymerized into its original monomer. Direct extrusion of waste acrylics faces issues of uncontrollable colors on fibers and pollution of spinning lines due to the influence of existing colorants. In our method, acrylic fibers were extracted from waste textiles using a novel approach involving maximized acrylic swelling and dissolution with dimethyl sulfoxide and butanediol. Cationic dyes were effectively removed through cost-effective recycling technology. This work demonstrates that cationic dyes seriously affect the acrylic dissolution, color consistency, and dyeability of regenerated fibers via direct wet extrusion. Such negative impacts of dyes have been eliminated by our cost-effective and closed-loop acrylic recycling technology, which enables the efficient separation of non-acrylic fibers and dyes from acrylic fibers. Our recycling system achieved zero discharges through recycling solvents, dyes, and acrylics. The regenerated acrylic fibers exhibited mechanical properties and dyeability comparable to virgin acrylic fibers. The material and energy costs to produce pure acrylic from waste textiles were only 40 % of those from fossils. This study successfully introduces a closed-loop recycling method for acrylic fibers from waste textiles, addressing key challenges in acrylic fiber recycling. Further research and implementation of this technology are recommended to advance its commercial viability and widespread adoption.

Design of sustainable supply chains for managing plastic waste: The case of low density polyethylene

Plastic waste management presents a significant challenge that requires the integration of supply chain and sustainability principles. This study proposes a comprehensive supply chain model for plastic waste and management, specifically low-density polyethylene (LDPE), focusing on economic and environmental considerations. A model based on Mixed Integer Linear Programming (MILP) is developed to address the type of plastic waste management technology, their location through the United States East Coast and the effect of transitioning to an electrified transportation. The model determines plastic waste pyrolysis as the preferred technology to maximize profitability, and mechanical recycling combined with hydrogenolysis and hydrocracking to minimize the global warming potential (GWP). The mix of technologies for minimizing the GWP is highly correlated with the type of transportation, being desired to remove hydrogenolysis when electric trucks are introduced. This electrification of the transportation reduces the emissions by 23 %, but with an increase in the costs by 4 %.

Mechanical recycling of printed flexible plastic packaging: The role of binders and pigments

Low-density polyethylene (LDPE), extensively employed in flexible plastic packaging, often undergoes printing with inks. However, during the mechanical recycling of post-consumer waste, these inks act as contaminants, subsequently compromising the quality and usability of recycled material. To understand better exactly which ink components cause which effects, this study comprehensively assesses the thermal behavior of three organic pigments and two commonly utilised binders, correlated with the impact on the mechanical recycling of LDPE-based flexible plastic packaging. In this regard, the study focuses on four pivotal factors: processability, mechanical properties, aesthetic attributes, and volatile organic compound profiles. The results indicate that nitrocellulose, used as a binder, degrades during reprocessing, resulting in film discoloration and the emission of potentially odorous compounds. Conversely, pigments are found to be dispersed within droplets of polyurethane binder in LDPE recyclates, whilst reprocessing printed samples detrimentally affects film properties, notably dart drop impact resistance, strain at break, and the number of inclusions. Additionally, it is shown that both inks comprise components that emit volatile compounds during reprocessing: non-thermally stable components, nitrocellulose and pigment yellow PY13, as well as low-molecular weight molecules from polyurethane and by-products from wax, plasticisers, and additives.

Exposure to Microplastics Made of Plasmix-Based Materials at Low Amounts Did Not Induce Adverse Effects on the Earthworm Eisenia foetida.

The implementation of recycling techniques represents a potential solution to the plastic pollution issue. To date, only a limited number of plastic polymers can be efficiently recycled. In the Italian plastic waste stream, the residual, non-homogeneous fraction is called 'Plasmix' and is intended for low-value uses. However, Plasmix can be used to create new materials through mechanical recycling, which need to be tested for their eco-safety. This study aimed to investigate the potential toxicity of two amounts (0.1% and 1% MPs in soil weight) of microplastics (MPs) made of naïve and additivated Plasmix-based materials (Px and APx, respectively) on the earthworm Eisenia foetida. Changes in oxidative status and oxidative damage, survival, gross growth rate and reproductive output were considered as endpoints. Although earthworms ingested both MP types, earthworms did not suffer an oxidative stress condition or growth and reproductive impairments. The results suggested that exposure to low amounts of both MPs can be considered as safe for earthworms. However, further studies testing a higher amount or longer exposure time on different model species are necessary to complete the environmental risk assessment of these new materials.

Effect of Carbon Nanofiber Distribution on Mechanical Properties of Injection-Molded Aramid-Fiber-Reinforced Polypropylene.

The mechanical recycling of discarded plastic products as resources for environmental preservation has recently gained research attention. In this context, it is necessary to use waste materials for fiber-reinforced thermoplastics (FRTP). Glass and carbon fibers are often damaged by shear and compression during melt-forming processes. To achieve a sustainable society, it is necessary for thermal recycling to produce minimal to no residue and for mechanical recycling to maintain the length of fibers used in FRTP to preserve their performance as a reinforcing agent. Aramid fibers (AFs) do not shorten during the melt-molding process, and their composites have excellent impact strength. On the other hand, plastics reinforced with glass or carbon fibers are reported to have a superior strength and modulus of elasticity compared to aramid fibers. This study investigates the dispersion of a carbon nanofiber (CNF), a whisker, as the third component in aramid-fiber-reinforced polypropylene (PP/AF). The results and discussion sections demonstrate how the dispersion of CNF in PP/AF can enhance the mechanical properties of injection-molded products without compromising their impact resistance. The proposed composition will have excellent material recyclability and initial mechanical properties compared to glass-fiber-reinforced thermoplastics.

Mechanical recycling of biobased polyethylene-agave fiber composites

Biobased polymers have emerged as a promising alternative to petroleum-based polymers in terms of lower environmental impact. However, to improve their carbon footprint, it is important to study strategies, such as recycling, extending the useful life of these biopolymers, and mitigate their higher costs compared to petroleum-based polymers. Adding agro-industrial wastes as fillers or reinforcements is another option to reduce the cost and increase the biobased content to produce composites. This study aimed to evaluate the addition of agave fibers to biobased linear low-density polyethylene (bio-LLDPE) and their effect on its reprocessing by extrusion, i.e., close-loop mechanical recycling. The results revealed that it was possible to reprocess the bio-LLDPE alone as limited changes in their physical properties were observed up to 34 cycles. However, for the composites, the viscosity changed in the first eight cycles mainly due to fiber break-up (lower aspect ratio). The dimensions of the agave fibers are modified by reprocessing. In the initial 8 cycles, there is a notable decrease in fiber dimensions, affecting the tensile, flexural, and impact properties of the composites. The water uptake was found to decrease with each cycle due to better fiber dispersion and the reduction of interfacial voids/defects. Nevertheless, the color of the bio-LLDPE and its composites showed significant changes by reprocessing, which is associated with thermal and oxidation degradation. Despite minor property losses, the study reveals that bio-LLDPE/agave fiber composites exhibit a commendable level of sustainability. This characteristic enables their extended reuse and reprocessing over a prolonged duration.

Recycling of a commercial biodegradable polymer blend: Influence of reprocessing cycles on rheological and thermo-mechanical properties

Mechanical recycling is a viable option for reducing plastic waste, especially for post-consumer waste and scraps from production processes. Biodegradable polymers have gained attention as alternatives to conventional ones, and their potential for reprocessing using standard techniques before composting needs to be explored. This study focused on a commercial biodegradable polymer blend which underwent ten extrusion cycles to assess the effects of mechanical recycling on mechanical properties, rheological behavior, and thermal stability. The results indicated that the blend's mechanical properties were largely maintained across the extrusion cycles, with only a 53 % decrease in ductility. The thermal stability slightly declined by 2.3 % in T5% onset temperature. This can be attributed to a balance between molecular chain scission (resulting in an average molecular weight reduction of approximately 8.4 %) and crosslinking phenomenon (evidenced by an increase in complex viscosity throughout the extrusion cycles). Overall, the results suggest a suitable recycling attitude of this material.

Material recycling of acrylonitrile butadiene styrene (ABS) from wiring devices using mechanical recycling

Plastics play a significant role in various sectors by offering advantages such as durability, cost-effectiveness, and lightweight properties. However, the extensive production and consumption of plastics create significant environmental threats, leading to high carbon footprints, global warming, and the accumulation of hard-to-recycle waste. This study explores innovative recycling technologies, focusing on the circular economy and zero waste strategies. In line with this scope, the study aims to conduct research on the reuse of coated plastic materials in production, specifically selecting ABS materials that are difficult to recycle. In the study, wiring devices were prepared using 70% raw ABS (Acrylonitrile Butadiene Styrene) material and 30% recycled ABS (rABS) material, with this cycle being repeated three times. Experiments have been conducted to evaluate the suitability and performance of recycled ABS material for mass production. The results have revealed a slight decrease in tensile strength and impact strength compared to raw ABS material, yet significant mechanical performance has been maintained, thus demonstrating the viability of rABS in preserving product quality throughout successive recycling processes.

Recycling Polyethylene/Polyamide Multilayer Films with Poly(isoprene-g-Maleic Anhydride) Compatibilizer.

Polymers generally form incompatible mixtures that make the process of recycling difficult, especially the mechanical recycling of mixed plastic waste. One of the most commonly used films in the packaging industry is multilayer films, mainly composed of polyethylene (PE) and polyamide (PA). Recycling these materials with such different molecular structures requires the use of compatibilizers to minimize phase separation and obtain more useful recycled materials. In this work, commercial polyisoprene-graft-maleic anhydride (PI-g-MA) was tested as a compatibilizer for a blend of PE and PA derived from the mechanical recycling of PE/PA multilayer films. Different amounts of PI-g-MA were tested, and the films made with 1.5% PI-g-MA showed the best results in terms of mechanical properties and dart impact. The films were also characterized thermally via thermogravimetric analysis (TG) and differential scanning calorimetry (DSC), using Fourier-transform infrared spectroscopy (FTIR), and morphologically using a scanning electron microscope (SEM). Other parameters, such as tearing and perforation, were analyzed.

Chemically Recyclable and Biodegradable Vulcanized Rubber.

The cross-linked nature of vulcanized rubbers as used in tire and many other applications prohibits an effective closed-loop mechanical or chemical recycling. Moreover, vulcanization significantly retards the material's biodegradation. Here, we report a recyclable and biodegradable rubber that is generated by the vulcanization of amorphous, unsaturated polyesters. The elastic material can be broken down via solvolysis into the underlying monomers. After removal of the vulcanized repeat units, the saturated monomers, constituting the major share of the material, can be recovered in overall recycling rates exceeding 90%. Respirometric biodegradation experiments by 13CO2 tracking under environmental conditions via the polyesters' diol monomer indicated depolymerization and partial mineralization of the vulcanized polyester rubbers.

The impact of mechanical recycling on the degradation of polyamide

There is currently no agreement on the degradation mechanisms for PA6 as a result of mechanical recycling. In this study, PA6 was extruded five times to simulate mechanical melt recycling process. Both virgin PA6 and the extruded PA6 were characterised to determine the predominant degradation mechanism. Melt flow rate (MFR) increases with increasing number of extrusion passes suggesting a reduction in melt viscosity due to mechanical processing. Gel permeation chromatography (GPC) results confirmed a reduction in molecular weight from 18,600 g/mol to 13,100 g/mol. Chain ends titration showed a decrease in the concentration of both the amine and carboxyl chain ends after the fifth extrusion. There were no changes to the chemical structure of the virgin PA6 and extruded PA6 observed from the Fourier transform infra-red (FTIR) and Nuclear magnetic resonance (NMR) spectra. X-ray photoelectron spectroscopy (XPS) showed a reduction in the C–N peak area supporting the scission of the N-alkylamide bond. The increase in the O=C–N peak area suggests that chain recombination via branching is possible. The shorter chains have higher mobility, and this gives rise to an increase in the crystallisation rate as seen from the differential scanning calorimeter (DSC) thermograms. The appearance of the γ phase after the fifth extrusion was identified in the DSC melting endotherms. The understanding of the degradation process of recycled PA6 will enable targeted modifications involving the incorporation of additives in the recycling process to ensure good mechanical properties in the recycled polymer.

Analysis of Mechanical and Thermal Properties of Polymer Materials Derived from Recycled Overprinted Metallized PP Films.

Polymer materials and their composites are one of the most frequently used materials in the packaging and food industries. This applies to both disposable and reusable packaging, layered films with barrier properties, as well as densely overprinted polymer films and metallized food wrap films. According to statistical data from Plastics Europe, approximately 40% of processed thermoplastics are used to produce packaging, including single- and multi-layer film packaging. Growing requirements and new EU directives require the use of recycled materials in new products, which is not easy because the properties of recyclates may differ significantly from those of the primary materials with which the former are mixed. This work attempts to analyze the properties of the primary material used to produce a film using the casting method in comparison with the industrial recyclate obtained by the processing of film made of the primary material and then overprinted and metallized. The process of obtaining re-granulates and preparing test samples was presented, and the mechanical, structural, and thermal properties of the tested materials were compared. The conducted research and the obtained results demonstrated the advisability of conducting advanced mechanical recycling, which leads to obtaining re-granulates with repeatable processing properties and thermal and mechanical properties comparable to the original material despite the impurities they contain.

Assessing the circularity of post-consumer HDPE milk bottles through open-loop recycling and their environmental impact

Plastics are key in the packaging sector, but their widespread use contributes significantly to environmental challenges, such as the short life and high daily production of HDPE milk bottles. This study therefore aims to find a solution to this plastic waste, focusing on mechanical recycling. A comprehensive characterization of this post-consumer recycled HDPE reveals significant PP contamination, which poses a significant barrier due to polyolefin incompatibility, a common challenge in mixed plastics recycling. To mitigate this, blending with virgin HDPE and the use of various compatibilizers were investigated to improve the recyclability of the material. Several extrusion cycles were performed to analyse the thermo-mechanical degradation and to measure the performance and stability of the blends. The environmental impact of incorporating recycled HDPE into new bottles was also evaluated. Comparative evaluations with virgin bottles show that incorporating 25% or 50% recycled HDPE in the bottle yields carbon footprint reductions of 3% and 14%, respectively. These benefits could amplify with a wind-powered supply chain and a 100% recycled content. The findings lay the foundation for future plastic recycling scenarios, including dedicated sorting for this waste stream, providing a pathway to address the environmental impact of HDPE milk bottle disposal through recycling practices.

An Overview of the Current Trends in Marine Plastic Litter Management for a Sustainable Development

This review summarizes recent data related to the management of marine plastic litter to promote sustainable development. It discusses the distribution and identification of marine plastic litter, assesses the potential socio-economic and environmental impacts of these pollutants, and explores their recovery strategies, from a circular economy perspective. The main findings indicate that the majority of marine plastic litter originates from land-based sources. Current technologies and approaches for valorizing marine plastic litter include mechanical and chemical recycling, blockchain technologies by providing traceability, verification, efficiency and transparency throughout the recycling process, and public awareness programs and education. The developed policies to prevent marine plastic litter emphasize regulations and initiatives focused toward reducing plastic use and improving plastic waste management. By adopting a holistic and sustainable approach, it is possible to mitigate the environmental impact of marine plastic debris while simultaneously creating economic opportunities.

Understanding the Interfacial and Self-Assembly Behavior of Multiblock Copolymers for Developing Compatibilizers toward Mechanical Recycling of Polymer Blends

Understanding the Interfacial and Self-Assembly Behavior of Multiblock Copolymers for Developing Compatibilizers toward Mechanical Recycling of Polymer Blends

Environmental impacts of circularity strategies for social distancing plastic shields made of polymethyl methacrylate in the United States.

One application of plastics that grew during the COVID-19 pandemic is for social distancing plastic shields, or protective barriers, made from polymethyl methacrylate (PMMA) such as transparent face guards. Although available for other applications, end-of-life impacts for barriers are currently lacking in the literature, and there is a need to fill in this gap to guide decisions. This study evaluated the end-of-life environmental impacts of PMMA barriers in the United States by using life cycle assessment. We evaluated five strategies including landfilling, waste-to-energy, mechanical recycling, chemical recycling and reuse. Data were sourced from literature and various life cycle inventory databases. The Tool for Reduction and Assessment of Chemicals and Other Environmental Impacts (TRACI) was used as the life cycle impact assessment method. Landfilling exhibited the highest impact in all indicators and reuse demonstrated optimal results for global warming potential. A scenario analysis was conducted to explore a combination of strategies, revealing that the most promising approach involved a mix of 40% reuse, 20% mechanical recycling and 40% chemical recycling. Circular economy recommendations are proposed for managing these sources of plastic waste in the United States.

Morphological analysis of mechanically recycled blends of high density polyethylene and polypropylene with strong difference in melt flow index

Polyolefin (PO) blends are difficult to separate due to density and chemical structure similarities. The associated waste treatment in the context of mechanical recycling is therefore complicated by the establishment of multi-phase morphologies that are not yet fully understood. In the present work, a high density polyethylene (HDPE) with a very high melt flow index (MFI) and a polypropylene (PP) with a very low MFI are deliberately mingled to better understand the full spectrum of morphological variations for PO blending. The linkage with the control over injection mold-based mechanical properties such as tensile strength, elasticity modulus, elongation at break, and impact strength is made. This is done supported by the connecting of experimental analyses at different scales, including (i) the molecular scale via size exclusion chromatography and Fourier transform infrared spectroscopy (FTIR), and (ii) the meso-scale via scanning electron and polarized light microscopy as well as differential scanning calorimetry, including a differentiation between the bulk and surface region. Emphasis is both on blends processed once and re-processed either once, twice or three times. For the single processing, it is demonstrated that in most cases a droplet morphology is obtained, with smaller droplets in case HDPE is the minor component and with a dominance of HDPE at the surface even for 60% PP, due to a better HDPE flowability. It is further shown that the scission of PP chains and crosslinking of HDPE chains respectively facilitates and inhibits crystallization, at least if meso-scale -mixing as more evident during re-processing is not taking over. It is also highlighted that the properties of PP can be enhanced by adding up to 10 wt% HDPE, acting as a filler, and that the (ideally) reprocessed blends remain suitable for application.