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Fibers

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

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

Modeling reverse flows of selected recycled materials, their associated energy use and their GHG emissions

Modeling reverse flows of selected recycled materials, their associated energy use and their GHG emissions: An application to California and a blueprint for the US

The objective of this project is to create a unique systems analysis tool for REMADE, the recycling industry, and U.S. consumers of recycled materials (using the California State Freight Forecasting Model (CSFFM) in the California Statewide Freight Forecasting and Travel Demand Model (CSF2TDM) as a framework) that will enable REMADE, recycling agencies, and industry to analyze and project the generation, flow, recycling, reuse, and disposal of scrap metal, e-waste, selected plastics, and fibers from packaging, and their associated net energy consumption and net greenhouse gas (GHG) emissions, under different scenarios.  The tool will be developed using California as a case study; detailed step-by-step instructions to enable the extension of this tool to other states and the U.S. will be developed.​​ 

Project Team:
University of California-Irvine (UCI), TruckPay.com

21-01-SA-5104

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

Building Re-X (BREX): Data, Methodology, and Design Integration

Building Re-X (BREX): Data, Methodology, and Design Integration

This project seeks to bring the concept of Design for Building Re-X (BREX) to the building construction materials. The project will develop a set of open access EOL databases for construction materials and create open-access BREX process models to enable EOL constraints to be incorporated into building design and materials selection.

Project Team:
National Renewable Energy Laboratory (NREL), Building Transparency, Skidmore Owings & Merrill

20-01-DE-4108

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

Assessment of the Impact of Single Stream Recycling on Paper Contamination in Recovery Facilities and Paper Mills

Assessment of the Impact of Single Stream Recycling on Paper Contamination in Recovery Facilities and Paper Mills

This project aims to evaluate the impact of single stream recycling (SSR) on paper contamination in recovery operations and explore emerging recovery processes for minimizing fiber contamination.

Project Team:
University fo Miami

17-FP-RR-03

Biological & Bio-Mechanical Technologies for Recycled Fibers to Regain Fiber Quality and Increase Secondary Feedstock in High Value-Added Paper Grades

Biological & Bio-Mechanical Technologies for Recycled Fibers to Regain Fiber Quality and Increase Secondary Feedstock in High Value-Added Paper Grades

The goal of this project is to develop new technologies for removing contaminants from recycled paper to less than 0.5% and to develop technologies for regaining or fiber quality without using only mechanical refining. The new technologies developed will help paper recycling industry to produce much cleaner pulp and higher quality fibers so more recycled fibers can be used in place of virgin fibers in high grade paper. The new technologies developed based on new enzyme applications will also reduce the energy consumptions in both contamination removal and fiber refining process and increase the yield of the fiber recycling.

Project Team:
Western Michigan University, Idaho National Laboratory, Graphic Packaging International, WestRock Company

19-01-MM-03

Mapping the Material Base for REMADE

Mapping the Material Base for REMADE

This project will develop a materials flow baseline for REMADE materials (metals, fibers, polymers, and e-waste) to support measurement of the impact of future technology improvements through REMADE projects. A harmonized and validated set of data for metals, fibers, polymers and e-waste will be developed within a consistent framework that allows comparisons of material efficiencies across REMADE materials at all life-cycle stages.

Project Team:
Yale University, Unilever, International Zinc Association, Massachusetts Institute of Technology

18-01-SA-05

A Dynamic Techno-economic Systems Modeling Framework for U.S. Fiber Recycling

A Dynamic Techno-economic Systems Modeling Framework for U.S. Fiber Recycling

This project will model and test the U.S. fiber recycling industry – specifically for paper and paperboard – to improve its long-term profitability and increase its environmental benefits. 

The project will provide a virtual testbed that will explore resilience to volatility in scrap quantities, quality, markets, and prices, and consider changes to current and future recycling capacities and technologies in order to increase domestic fiber recycling by 15% or more.

Project Team:
Northwestern University, Yale University, Institute of Scrap Recycling Industries

18-02-SA-02

Identifying strategies to maximize benefit of fiber recovery through systems quantification

Identifying strategies to maximize benefit of fiber recovery through systems quantification

This project will analyze the system‐wide economic and environmental implications of changes in the recovery of fibers. The project will use a dynamic modeling framework that integrates material flow analysis, life cycle inventories, and technical cost modeling to inform potential ideas for cost‐effective fiber recovery approaches.

A goal of this project is for REMADE members to more accurately determine the energy and emissions benefits associated with paper and paperboard recovery.  

Project Team:
Massachusetts Institute of Technology, The American Forest & Paper Association, WestRock, Graphic Packaging

18-02-SA-05

 

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