recycling of multilayer packaging foils - …€¦ · and chemical engineering ... define recycled...
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RECYCLING
OF MULTILAYER PACKAGING FOILS Prof. Dr. Kim Ragaert
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CPMT GROUP
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SOLID PLASTIC WASTE
CO2
H2O
MATCH DEPARTMENT OF MATERIALS, TEXTILES AND CHEMICAL ENGINEERING
CENTRE FOR POLYMER AND MATERIAL TECHNOLOGIES
Our mission is to contribute to the circular economy by demonstrating the sustainable potential of plastics.
This is achieved by transferring fundamental materials science to improved industrial processing of recycled plastics.
TEAM RECYCLING
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RECENT AND CURRENT PROJECTS
Improved methods for
plastics recycling
Design from Recycling
Routes for mixed plastic waste
Resource efficiency
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REPROCESSING MPO
ReFOIL
DESIGN FROM RECYCLING
MICRO FIBRILLAR COMPOSITES
DEFINE RECYCLED CONTENT
RE2CYCLING OF COMPATIBILIZERS
PROFIT: PLASTICS FROM HOUSEHOLD WASTE H2020 POLYCE
WEEE PLASTICS
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OUTLINE OF THE TALK RECYCLING OF MULTILAYER PACKAGING FOILS (MPF)
MPF: Why? Where? How much?
Challenges for the recycling of MPF
Science for the effective recycling of MPF
The ReFOIL project
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MPF: WHY?
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Source: Sekisui
Multiple materials are combined into one foil for technical functionality
PET/PE PA/PE
PET/PE/EVOH/PE …
+ tie layers
polymer typical purpose
PE Sealing, H2O barrier, freezable
PP Sealing, H2O barrier, heatable
EVOH Gas barrier
PA Strength, gas barrier, puncture resistance
PET H2O and gas barrier, strength
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MPF: WHERE AND HOW MUCH?
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Post industrial
B2B
clean
Composition (mostly) known
Post consumer
Mixed household
waste
Separate mixed plastic waste
Contaminated (organic and
other plastics)
Composition unknown
Production waste from: • Foil producer (cutting edges, changeover
rolls, bad products) • Packager (unfilled trays, leftovers,
cutting edges) • retailer (unsold food à depackaging)
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MPF: WHERE AND HOW MUCH?
Post industrial
B2B
Numbers hard to come by
Example of foil producing company: 600 tonnes/yr waste
of a single multilayer application
To incineration (or storage)
Post consumer
BE: Currently in mixed household waste
BE: 6% (13.000 tonnes/yr) of total packaging waste
NL, DE: currently in selective plastic waste
NL: 18.000 tonnes/yr PET multilayer
Quite often considered ‘residue’ within this sorting
To incineration
Source tonnage: Fostplus
Source tonnage: KIDV
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OUTLINE OF THE TALK RECYCLING OF MULTILAYER PACKAGING FOILS (MPF)
MPF: Why? Where? How much?
Challenges for the recycling of MPF
Science for the effective recycling of MPF
The ReFOIL project
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basic principle of mechanical recycling
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CHALLENGES FOR THE RECYCLING OF MPF
grinding
reprocessing
PP boxes 66,5 kg/m³
Flakes 395 kg/m³
For post consumer waste + washing + sorting/separation
parts 890 kg/m³
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Sorting challenges MPF ‘contaminate’ mono-materials like PET à quality reduction
Pitfall: NIR recognition of only one ‘side’
à wrongful sorting However…newer sorting equipment will recognize
‘multilayer’
…so let’s assume we can (or will be able) to sort them out…
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CHALLENGES FOR THE RECYCLING OF MPF
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CHALLENGES FOR THE RECYCLING OF MPF
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shredding+ compounding
multilayer to multilayer (closed loop) is not self-evident
On top of ‘standard’ challenges related to recycling polymers: Layers cannot be separated into mono-materials
Mechanical recycling turns multilayer into complex blend
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‘POLYMERS DO NOT MIX’
• Multilayer plastic waste à blend • Plastics will not mix spontaneously in the melt, not even the ones
that are ‘alike’ like PP-PE
Yeganeh et al, Anomalous phase separation behavior in dynamically asymmetric LCST polymer blends RSC Adv., 2014,4, 2809-12825
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CHALLENGES FOR THE RECYCLING OF MPF
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Multilayers will become complex immiscible blends • Hard to predict exact composition
• Dominant polymer ( in v%) will most likely form the matrix • Barrier properties and sealability will be dependent on matrix polymer,
previously thin layers (like EVOH for barrier or PE for sealability) are now dispersed
• Optical clarity expected to be reduced • Divergent flow behaviour in processing
• Mechanical properties will depend on miscibility of the system
‘POLYMERS DO NOT MIX’
CHALLENGES FOR THE RECYCLING OF MPF
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THE EFFECT OF IMMISCIBILITY The mechanical properties of the blend are largely dependent on the miscibility of the system
A. Synergy in miscible blends (rare!)
B. (nearly) additive response for immiscible blends (good adhesion)
C. Grossly immiscible blend: failure due to poor interfacial adhesion
Source: Paul, Polymer Blends: Phase behaviour and property relationships, 1985
Boundaries for B: Eb = ϕ1E1 + ϕ2E2
Eb = E1E2 /(ϕ1E2+ ϕ2E1)
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If you do nothing, they will not mix
Typically (negatively) affected properties: Strength, stiffness, toughness (à impact)
CHALLENGES FOR THE RECYCLING OF MPF
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OUTLINE OF THE TALK RECYCLING OF MULTILAYER PACKAGING FOILS (MPF)
MPF: Why? Where? How much?
Challenges for the recycling of MPF
Science for the effective recycling of MPF
The ReFOIL project
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SCIENCE FOR THE EFFECTIVE RECYCLING OF MPF
• Polymer Science vs. the problem of immiscibility • Mitigate it à use of compatibilizers • Use it à micro fibrillar composites
• Product design: Design from Recycling
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MITIGATING THE IMMISCIBILITY
• Often these blends are composed of an apolar (PP, PE) + polar (PET, PA, EVOH) fractionà immiscibility ñ
• Improved distributive and dispersive mixing is achieved by reducing interfacial tension between the components
• A compatibilizer will do this by combining structural elements to achieve interaction with both components
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Example: SEBS-g-GMA as compatibilizer for PET + PP
Source: Re2cycling of compatibilizing agents for recycling, Karen Van Kets
SEBS SEBS
polyester polyester
GMA
polypropyleen
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EXAMPLES OF TYPICAL COMPATIBILIZERS
Backbones • Rubberlike
• SEBS • POE
• Polyolefin • PP
• PE
Functional groups • Maleic anhydride
• Glycidyl methacrylate
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SEBS
MITIGATING THE IMMISCIBILITY
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MITIGATING THE IMMISCIBILITY
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Compatibilizers reduce interfacial tension and improve dispersive and distributive mixing, thus improving properties greatly
19 Example : addition of 2,5 wt%
SEBS-g-GMA tot 80/20 PP-PET
Van Bruggen, Picken, Koster & Ragaert. Influence of Processing Parameters and Chemical Functionality on the Effective Compat ib i l izat ion of Polypropylene - Poly(ethylene terephthalate) blends. International Polymer Processing, 2016.
Charpy-impact (kJ/m²)
0 10 20 30 40 50
Flex
ural
mod
ulus (
MPa
)
800
900
1000
1100
1200
1300
1400
1500
1600
BASE
SEBS2
SEBS2+CA
Ragaert et. al, Design from Recycling: principles and case study. submitted to Polymer Engineering & Science, 2017.
Effect of addition of SEBS and SEBS-g-MA to r(PP-PET) mix
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Micro Fibrillar Composites (MFC)à taking advantage of immiscibility and strengthen matrix (e.g. PP) with second phase (e.g. PET) à Increased strength, toughness and barrier properties
Kuzmanovic, Delva, Cardon and Ragaert. The Effect of I n j e c t i o n M o u l d i n g T e m p e r a t u r e o n t h e Morphology and Properties of P P / P E T B l e n d s a n d Microf ibri l lar Composites. Polymers, 2016
USING THE IMMISCIBILITY à MFC
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making it easier to recycle the individual materials making up the product at its end-of life
PRODUCT DESIGN - DESIGN FOR RECYCLING
Source: EU Parliament, 2015, Circular economy: the importance of re-using products and materials
DESIGN FOR RECYCLING
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Making it easier to recycle the individual materials making up the product at its end-of life.
DESIGN FROM RECYCLING
DESIGN FOR RECYCLING
DESIGN FROM RECYCLING
Developing new products, based on available recycled materials, at start-of life.
1. Knowing the possibilities and properties of the available r-polymers
2. Matchmaking between products and available r-polymers
3. ‘tweaking’ r-polymers if you have to (remain cost-effective)
4. Adapted product design for r-polymers • This includes mould design
Material-driven design approach
VLAIO-TETRA 150151: Design from Recycling
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OUTLINE OF THE TALK RECYCLING OF MULTILAYER PACKAGING FOILS (MPF)
MPF: Why? Where? How much?
Challenges for the recycling of MPF
Science for the effective recycling of MPF
The ReFOIL project
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REFOIL
RECYCLING OF MULTILAYER PACKAGING FOILS
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VLAIO – TETRA HBC.2017.0056 NOV 17 – OKT 19
SAMEN MAKEN WEMORGEN MOOIER
OVAM
Conhomat bvba
Intersolution bvba
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GOAL The development of effective and efficient pathways for the
mechanical recycling of multi-layer packaging waste.
Packaging waste of interest dominant post-industrial and post-consumer
Research approach includes § Identification and characterization § Simulation § Upcycling § Design from Recycling strategy § Realization of demonstrators
Problem statement no current options for mechanical recycling
Mechanical recycling
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PET-PO post-industrial
PA-PO post-industrial
PET-PO post-consumer
MIX post-consumer
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START EVENT - INVITATION 26/10, 11u15-14u00
Centre for Polymer and Material Technologies, UGent Technologiepark 915, Gent-Zwijnaarde
If you are interested in joining the user committee, contact:
prof. Kim RAGAERT, [email protected] dr. Laurens DELVA, [email protected]
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Prof. Dr. Kim Ragaert Sustainable Use and Recycling of Polymers [email protected] +32 9 331 03 91 Ghent University Faculty of Engineering and Architecture MATCH – CPMT Tech Lane A Technologiepark 915 9052 Zwijnaarde, BE
match.ugent.be
www.resourcerecovery.be
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START EVENT - INVITATION 26/10, 11u15-14u00
Centre for Polymer and Material Technologies, UGent Technologiepark 915, Gent-Zwijnaarde
If you are interested in joining the user committee, contact:
prof. Kim RAGAERT, [email protected] dr. Laurens DELVA, [email protected]