CaRP
Cascade recycling of plastic film
Publieke samenvatting / Public summary
Aanleiding
In the area of circularity of plastic packaging film, we have identified a number of challenges. The main challenge is that there is a large variety of film structure and used materials in the different packaging applications. These different types need to be separated one way or the other to be able to use them for high-quality recyclate. To give the packaging film their required functional and esthetical properties (e.g. puncture resistance, moisture and oxygen barrier, stretch or shrink properties, sealability, and printability) complex structures are used (multilayer, multimaterial, printed, tie layers, pigments, metallisation, etc.). These complex structures pose huge challenges in the sorting and recycling processes. Additionally, plastic film materials are difficult to process in general as they often are large, have a low bulk density, and have high surface contamination. Lastly, even if all the structures can be sorted separately, the challenge remains to find out which film structure is suitable for which recycling route. Therefore, the most important goal is to reduce the amount of plastic film ending up in residue streams for incineration.
Doelstelling
In the paper “Plastic recycling stripped naked”, a cascade recycling approach for plastics in general is described. The main objective in this project is to take the theoretical framework of cascade recycling and turn it into realistic cascade recycling routes for plastic packaging film, being a large fraction of household packaging waste. By tailoring the recycling processes to the eventual application requirements, we optimize the quality and utility of the recyclate. And minimise the amount of plastic film waste that is incinerated. In addition, the techno-economic feasibility will be assessed. We will use experimental results to show the feasibility of such cascading routes. This project contributes to MMIP6 “Raw materials and products for circularity of carbon” and specifically to the subprogram of MMIP 6, the circular plastics part. With this project we enable the increase of recycling rate for plastic packaging film.
Korte omschrijving
We will show experimentally the benefits of cascade recycling of plastic packaging film waste, applying the following approach: Material selection: In sorting this means selecting plastic packaging film waste from existing output streams, or from new streams that could be created using existing equipment in current sorting centres. Process design: Using existing technologies and knowledge built-up by the consortium partners, we design the process such that it can handle the selected materials while minimizing losses and reducing energy consumption. It is likely to include mechanical and optical sorting, shredding, dry and water-based washing, and mechanical & thermochemical recycling. Trials: The heart of the project is to experimentally showcase what is actually possible with the plastic packaging film waste when a cascading process is used. The trials are using setups at applicable (bench) scale in order to be able to use actual waste to quantify the effects of the choices that will be made. Analysis: For every process we monitor and analyse the process conditions, including energy and other resource use.
Resultaat
By the end of the project, based on hands-on research we will deliver: 1. Internal report on cascade recycling of plastic packaging film waste 2. Peer-reviewed paper(s) on cascade recycling of packaging film 3. Technical publications and presentations on cascade recycling of plastic packaging film 4. Selection tool for cascade recycling routes for packaging film waste 5. Recyclate (in a variety of appearances: clean flakes, pellets, pyrolysis oil, monomers, and cast or blown film) from a cascade recycling route for plastic packaging film
In the area of circularity of plastic packaging film, we have identified a number of challenges. The main challenge is that there is a large variety of film structure and used materials in the different packaging applications. These different types need to be separated one way or the other to be able to use them for high-quality recyclate. To give the packaging film their required functional and esthetical properties (e.g. puncture resistance, moisture and oxygen barrier, stretch or shrink properties, sealability, and printability) complex structures are used (multilayer, multimaterial, printed, tie layers, pigments, metallisation, etc.). These complex structures pose huge challenges in the sorting and recycling processes. Additionally, plastic film materials are difficult to process in general as they often are large, have a low bulk density, and have high surface contamination. Lastly, even if all the structures can be sorted separately, the challenge remains to find out which film structure is suitable for which recycling route. Therefore, the most important goal is to reduce the amount of plastic film ending up in residue streams for incineration.
Doelstelling
In the paper “Plastic recycling stripped naked”, a cascade recycling approach for plastics in general is described. The main objective in this project is to take the theoretical framework of cascade recycling and turn it into realistic cascade recycling routes for plastic packaging film, being a large fraction of household packaging waste. By tailoring the recycling processes to the eventual application requirements, we optimize the quality and utility of the recyclate. And minimise the amount of plastic film waste that is incinerated. In addition, the techno-economic feasibility will be assessed. We will use experimental results to show the feasibility of such cascading routes. This project contributes to MMIP6 “Raw materials and products for circularity of carbon” and specifically to the subprogram of MMIP 6, the circular plastics part. With this project we enable the increase of recycling rate for plastic packaging film.
Korte omschrijving
We will show experimentally the benefits of cascade recycling of plastic packaging film waste, applying the following approach: Material selection: In sorting this means selecting plastic packaging film waste from existing output streams, or from new streams that could be created using existing equipment in current sorting centres. Process design: Using existing technologies and knowledge built-up by the consortium partners, we design the process such that it can handle the selected materials while minimizing losses and reducing energy consumption. It is likely to include mechanical and optical sorting, shredding, dry and water-based washing, and mechanical & thermochemical recycling. Trials: The heart of the project is to experimentally showcase what is actually possible with the plastic packaging film waste when a cascading process is used. The trials are using setups at applicable (bench) scale in order to be able to use actual waste to quantify the effects of the choices that will be made. Analysis: For every process we monitor and analyse the process conditions, including energy and other resource use.
Resultaat
By the end of the project, based on hands-on research we will deliver: 1. Internal report on cascade recycling of plastic packaging film waste 2. Peer-reviewed paper(s) on cascade recycling of packaging film 3. Technical publications and presentations on cascade recycling of plastic packaging film 4. Selection tool for cascade recycling routes for packaging film waste 5. Recyclate (in a variety of appearances: clean flakes, pellets, pyrolysis oil, monomers, and cast or blown film) from a cascade recycling route for plastic packaging film
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