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Recycling & Recovery

Low-Cost, High-Value Aromatics from Upcycling of Polyolefins Through Microwave Catalytic Processing

Low-Cost, High-Value Aromatics from Upcycling of Polyolefins Through Microwave Catalytic Processing

In this project, a simple one-step microwave catalytic process is proposed for upcycling single-use plastics into high-value BTX (benzene, toluene, xylene). This project will deliver optimized catalyst and processes to allow lower operating temperatures and higher BTX yield, the goal is to further increase the BTX yield up to 80% and reduce the reaction temperature from 300 ◦C to 200 ◦C and develop designs for quartz fluidized reactor and H-field microwave cavity for continuous large-scale single-use plastics microwave upcycling treatment. The TPMs of this project are estimated at 2MMT of secondary materials use, 73PJ of energy savings and 1.923MMT of CO2 reduction. Assumptions based on utilization of 10% of 20MMT of polyolefins that are recoverable.

Project Team:
West Virginia University (WVU), Braskem America, Inc.

21-01-RR-5007

Recycling Technologies for Silicon Solar Modules

Recycling Technologies for Silicon Solar Modules

The objective of this project is to develop a ready-to-commercialize recycling process to recover materials from silicon modules: solar-grade silicon, lead, silver, tin, solar-quality glass cullet, aluminum, and copper. The focus is on a new chemical recycling process to recover solar-grade silicon, lead, silver, tin, and copper from silicon cells.

Upon completion, this project will deliver an optimized chemical recycling process for silicon solar cells extracted from modules. The optimized process will be the basis for designing and constructing a pilot plant for silicon module recycling at 100,000 modules/year in the U.S. which recovers solar-grade silicon, lead, silver, solar-quality glass cullet, aluminum, copper, and tin from silicon modules. This project will increase secondary materials recovery by about 0.2MMT, embodied energy savings of 22PJ, and GHG emissions reduction of 1.106MMT. Assumptions based on recycling 20% of the expected EOL solar panels in the U.S. in 2030.

Project Team:
Arizona State University (ASU), First Solar Inc., TG Companies LLC

21-01-RR-5014

Recovery of Plastics and Natural Fibers from Non-Recyclable Municipal Solid Waste for Composites Production

Recovery of Plastics and Natural Fibers from Non-Recyclable Municipal Solid Waste for Composites Production

This project aims to recover secondary feedstocks of plastics and fibers from mixed flexible plastics (MFP) stream of nonrecyclable waste and develop advanced compounding and manufacturing processes to convert these recyclates to fiber-reinforced polymer composites.

Upon completion, this project will develop an integrated fractionation method that combines novel wet separation and fractionation approaches with air classification and NIR-based separation to decontaminate and obtain four plastic fractions and one natural fiber fraction from waste streams, processable material formulations out of these recyclates, and an advanced compounding procedure based on Ring Extrusion technology that produces high quality feedstocks. This project will reduce primary feedstock by 1.12 million metric tons (MMT) of flexible plastics, 96.7 PJ energy reduction, 1.52MMCO2e. Assumptions based on utilization of 20% of 5.62MMT of flex plastics available for recovery. 

Project Team:
University of Massachusetts-Lowell (UM-L), Idaho National Laboratory (INL), Auburn University, Washington State University, Remacol Inc., CPM Extrusion Group, DTG Recycle Group

21-01-RR-5052

Recycling and Refining of Aluminum Foils and other Difficult Scraps

Recycling and Refining of Aluminum Foils and other Difficult Scraps

The goal of this project is to produce a cost-competitive secondary feedstock for the aluminum industry using under-utilized foil materials as a source of material. Upon completion, this project will deliver a new processing technology that can continuously process thin gauge materials with a high level of organic contamination with high recovery yields, and design and demonstration of a novel prototype multi-chamber kiln for processing aluminum foils for recycling. This project will reduce primary feedstock by 0.326 million metric tons (MMT) of scrap aluminum, 55.6 PJ energy reduction, 2.71 MMTCO2e. Assumptions based on recovery of 360,000 short tons of scrap aluminum foil. 

Project Team:
Oculatus Consulting, Phinix LLC, Eck Industries, GPRL R&E LLLC

21-01-RR-5059

Enhanced Processing of Aluminum Scrap at End-of-life via Artificial Intelligence & Smart Sensing

Enhanced Processing of Aluminum Scrap at End-of-life via Artificial Intelligence & Smart Sensing

This project aims to deliver value-based intelligent melt control (VALI-MELT), a process control software tool with advanced sensing and processing capabilities, which enables closed loop quality control and optimal blending of scrap material.  VALI-MELT incorporates a scrap quality assessment tool (SQA), control software and in melt LIBS analyzer to enable close loop control for the utilization of post-consumer scrap.

Upon completion, this project will deliver a commercially viable software and sensing control tool that will enable optimal blending of scrap and real time processing adjustments based on feedstock composition and quality. This project will reduce primary feedstock by 0.462 million metric tons (MMT) of aluminum, 85 PJ energy reduction, 4.57 MMCO2e. Assumptions are based on demand projection for aluminum in 2030.

Project Team:
Solvus Global, Energy Research Company (ERCo), Eck Industries, Mercury Marine, Novelis, Schnitzer Steel Industries

21-01-RR-5102

Development of an Automated Method for Disassembly and Separation of Apparel for Recycling

Development of an Automated Method for Disassembly and Separation of Apparel for Recycling

The overarching goal of this project is to develop a system that can rapidly and accurately characterize, then dismantle (detach), disposed garment materials by composition, thereby allowing for final separation into high purity, and therefore higher value, secondary material streams. 

The technology solution to be delivered at the end of the project will be a proof-of-concept system that implements; multi-spectral imaging, garment structural characterization, cutting pattern and path planning, and high-speed cutting, all of these elements will be integrated into a garment conveyance system having appropriate controls and safety features. This project will increase secondary feedstock by 0.66MMT, 27.7 PJ energy reduction, 1.07 MMCO2e. Assumptions based on increasing the recycle if apparel from 13% to 19.5%. 

Project Team:
Rochester Institute of Technology (RIT), Nike, Inc.

21-01-RR-5107

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Education and Workforce Development on Chemical Recycling of Plastics

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Education and Workforce Development on Chemical Recycling of Plastics

This project seeks to develop practitioner & expert level training in chemical recycling of plastics to educate, train, & develop the incumbent workforce for careers in Re-X, content will be prepared for both in-person and online delivery. The learning objectives include; to understand the state-of-the-art of various chemical recycling technologies, understand the product output for each type of chemical recycling process, understand the post-processing requirements needed to recover and separate products from a product state and to purify, modify and/or upgrade products to meet market requirements, understand the primary mechanisms for integrating the chemical recycling technologies into the supply chain for the products and co-products generated by the process, and understand the critical factors that affect the technical performance and costs of alternative chemical recycling process technologies.

The target audience for practitioner level training is intended for incumbent workers that currently work with Re-X technologies or in adjacent technology domains who wish to broaden their knowledge. Expert level training is intended to provide in-depth coverage of advanced Re-X concepts or technology and is targeted toward engineers or scientists trying to deepen their expertise.

Project Team:
University at Buffalo (UB), Resource Recycling Systems (RRS)

21-01-EWD-5074

Efficient Purification and Reuse of Carbon Black Recovered from End-of-Life Tires

Efficient Purification and Reuse of Carbon Black Recovered from End-of-Life Tires

This project seeks to develop process technology to recover a low-ash content high-quality carbon black from end-of-life tire rubber.

Project Team:
University of Utah, Idaho National Laboratory (INL), OTR Wheel Engineering/Green Carbon

20-01-RR-4087

Reprocessing and Upcycling of Mixed Polyurethane Waste Streams

Reprocessing and Upcycling of Mixed Polyurethane Waste Streams

This project seeks to increase post-consumer polyurethane foam recycling and circularity through an innovative reprocessing strategy which incorporates a catalyst into the post-consumer materials to enable these materials to be reprocessed by extrusion or injection molding at elevated temperatures to useful products.

Project Team:
Northwestern University, BASF

20-01-RR-4071

Identification of Mixed Plastics and Valuable Electronics at the Source

Identification of Mixed Plastics and Valuable Electronics at the Source

This project seeks to develop vision sensing software that will enable consumers to determine how materials should be sorted for recycling, based on local recycling requirements.

Project Team:
University of Miami, Lid Vizion, LLC

20-01-RR-4042

Smart Additive Manufacturing Towards Use of Recycled Paper Fibers for Producing High-quality Fiber-Reinforced Plastic (FRP) Composites

Smart Additive Manufacturing Towards Use of Recycled Paper Fibers for Producing High-quality Fiber-Reinforced Plastic (FRP) Composites

This project seeks to enable a reliable and high-throughput conversion of recycled paper and paperboard products with contaminants into lightweight, high-strength FRP composites for reuse in industries such as transportation vehicles, furniture, construction, production tooling, etc. The objective of this project is to establish a smart additive manufacturing technology that can reliably produce recycled paper fibers for use in composites with uncompromised performance.

Project Team:
University of Iowa, Impossible Objects, Inc.

20-01-RR-4038

Chemical Recycling of Mixed PET/Polyolefin Streams Through Sequential Pyrolysis and Catalytic Upgrading

Chemical Recycling of Mixed PET/Polyolefin Streams Through Sequential Pyrolysis and Catalytic Upgrading

This project seeks to convert mixed plastics waste to re-usable products through the development of catalysts to convert polymer pyrolysis products to BTX and olefins. The feedstock for the proposed two-stage process (pyrolysis followed by catalytic upgrading of the pyrolysis products to BTX and olefins) is a mix of PET and PP waste plastics.

Project Team:
The Pennsylvania State University (PSU), Northwestern University, Shaw Group Industries, Inc., Process Systems Enterprise, Inc. - A Siemens Business

20-01-RR-4034

Diverting Mixed Polyolefins from Municipal Solid Waste to Feedstocks for Automotive and Building Applications

Diverting Mixed Polyolefins from Municipal Solid Waste to Feedstocks for Automotive and Building Applications

This project seeks to develop effective processing strategies to control the melt flow properties of mixed polyolefins to enable the reuse of mixed polyolefin waste plastics for new upcycling applications.

Project Team:
Michigan State University (MSU), National Renewable Energy Laboratory (NREL), PADNOS

20-01-RR-4032

Selective Recovery of Elements from Molten Aluminum Alloys

Selective Recovery of Elements from Molten Aluminum Alloys

This project seeks to develop, validate, and commercialize several processes to selectively remove iron, copper, silicon, manganese, and zinc from molten-scrap–based secondary aluminum melts to improve the recyclability of scrap aluminum.

Project Team:
Phinix, LLC, Worcester Polytechnic Institute (WPI), Kingston Process Metallurgy, Smelter Service Corporation, Certified Flux Solutions, LLC

20-01-RR-4010

Recycling of PET in Sustainable Food Packaging Systems

Recycling of PET in Sustainable Food Packaging Systems

The primary objective of this project is to replace conventionally produced milk cartons, aseptic bricks, and food trays with 100% recycled PET.

Project Team:
MuCell Extrusion LLC, Plastilene SAS a Plastilene Group Company, Wingate Packaging, Sugar Creek Packaging Co., Center for Innovative Food Technology (CIFT), The Ohio State University (OSU)

20-01-RR-4065

Dynamic Crosslinking to Enable EVA Recycling

Dynamic Crosslinking to Enable EVA Recycling

This project seeks to convert cross-linked EVA footwear industrial scrap that can then be re-incorporated into the manufacturing process.

Project Team:
Braskem America, Case Western Reserve University (CWRU), Allbirds, Inc.

20-01-RR-4029

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Advanced Education and Workforce Training in Fibers Recycling

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Advanced Education and Workforce Training in Fibers Recycling

This Education and Workforce Development project focused on developing training in advanced fibers recycling for the Awareness, Practitioner, and Expert levels. Courses developed included:

New Technology Developments in Paper Recycling (Awareness)

Recycled Paper Lab Research and Testing with TAPPI Standards (Awareness)

Paper Recycling Pilot Plant and Industry Tours (Awareness)

The Recycling System: Value Chains, Collection, MRFs, & Markets (Awareness, Practitioner)

Manufacturing of Paper from Recycled Fibers-Process, Products, and Technologies (Awareness, Practitioner)

Fiber Properties and Paper Physics (Awareness, Practitioner)

Printing Inks and Deinking in the Paper Recycling Process (Awareness, Practitioner, Expert)

Chemical Agents Used in Paper Recycling to Improve Process Operation and Process Quality (Awareness, Practitioner, Expert)

Stickies and Organic Materials Characterization and Removal in the Paper Recycling Process (Awareness, Practitioner, Expert)

Project Team:
Western Michigan University, Graphic Packaging International, Recourse Recovery Systems (RRS)

19-01-EWD-01

The goal of this project is to develop curriculum and coursework for training modules in advanced fibers recycling for the REMADE Education and Workforce Development Tiered Certificate Pathway program. The specific objectives of the project are to develop course content that fills the knowledge gap including (1) developing course materials to cover all the major recycled fibers and all major paper grades; (2) developing course materials to cover the entire fiber recycling process; (3) develop course materials to address specific challenges in the paper recycling process; (4) develop course materials to cover fiber identification, testing, and quality control, and sensor technologies in sorting; (5) develop a coursework structure that is in line with REMADE Tiered Certificate Pathway framework and that can be delivered through traditional teaching methods, online and distance learning, and hands-on experience in-person short course format.

Chemical Recycling of Mixed Plastics and Valuable Metals in the Electronic Waste Using Solvent-Based Processing

Chemical Recycling of Mixed Plastics and Valuable Metals in the Electronic Waste Using Solvent-Based Processing

This project seeks to demonstrate the potential of solvent-based extraction process to recover plastics mixed metals and plastics electronic waste (e‐waste) for cross-industry reuse. Following extraction of the plastics, the mixed-stream would be primarily metals. The plastics would be recovered from the process solvent using an anti-solvent. If successful, this project will significantly increase the recycling rates of e-waste, and the recovery of plastics and metals from this source material. The potential energy savings and emission reduction from this project are estimated at 16PJ per year and 334,000 MT of CO2eq. per year.

Project Team:
University of Massachusetts-Lowell, Sunnking, Inc., Institute of Scrap Recycling

18-02-RR-17

New Approaches to Improve Deinking Flotation to Increase the Availability of High-Quality, Low-Cost Recycle Paper Fibers

New Approaches to Improve Deinking Flotation to Increase the Availability of High-Quality, Low-Cost Recycle Paper Fibers

This project addresses paper fiber recycling needs. The paper industry in the U.S. replaces more than half of its fiber needs with secondary resources recovered from post-consumer paper and paper products. This project will help the industry to further increase their economically competitive recycling rates to those achieved in Europe by developing more efficient separation technologies that can produce higher brightness fibers by removing impurities more efficiently from spent wood fibers. The project could enable the use of an additional 1.3 million metric tons per year of secondary fiber.

Project Team:
Virginia Tech and Thiele Kaolin Company

18-02-RR-15

Development and Validation of Metal Separation Technology for Complex Metal Systems

Development and Validation of Metal Separation Technology for Complex Metal Systems

The goal of the proposed work is to develop, design, and demonstrate novel bench scale processes for efficient, low-cost, and environmentally benign elemental separation from low concentration solutions obtained from leaching of electronic waste (e-waste) processing streams. These are key processes for the recovery of valuable materials from e-waste and will provide a pathway to profitable recycling processes for high-value metals. Separation of multiple elements from complex metal-bearing waste streams (with low concentration) through traditional metal separation processes, such as solvent extraction (SX), ion exchange (IX), and precipitation, is economically and environmentally challenging. The objective of this proposal is to evaluate two innovative processes/technology, viz., electrosterically stabilized nanocrystalline cellulose (ENCC), and Continuous Ion Exchange and Ion Chromatography (CIX-CIC) with modified zeolite and polymers, for the separation of Al, Cu, Au, Ag, and Pd from e-waste streams (i.e., printed wiring boards).

Project Team:
The Pennsylvania State University, CHZ Technologies LLC

19-01-RR-12

 

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