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Plastics

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

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

A Technical Evaluation Framework for Recycling Technologies

A Technical Evaluation Framework for Recycling Technologies

his project seeks to develop a framework for determining a temporal hierarchy of technical recycling constraints and corresponding recycling parameters (recycling rates, recycled contents, and environmental benefits), develop a consistent quantitative methodology for defining the performance of recycling technologies, and collect sufficient material flow, composition, and recycling technology data to demonstrate the framework by evaluating the merits of emerging metal and polymer recycling technologies for select scrap streams.

Upon completion, this project aims to validate the Python‐based Recycling Constraint Evaluation Framework (RCEF) model containing the metal and polymer case study results that can be easily adapted to any material stream, an excel‐based Recycling Technology Performance (RTP) model (input to the RCEF model) containing a quantitative description of >11 emerging recycling technology processes and that can be easily adapted to add new technology definitions, and a published report on A New Framework for Evaluating Recycling Constraints and the Efficacy of Emerging Recycling technologies. Systems Analysis and Integration projects do not directly impact TPMs. 

Project Team:
University of Michigan, National Renewable Energy Laboratory (NREL), Institute of Scrap Recycling Industries (ISRI), The Plastics Industry Association, The Aluminum Association, Steel Manufacturers Association

21-01-SA-5034

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

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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

Catalytic Upcycling of Polyolefins

Catalytic Upcycling of Polyolefins

This project's overall objective is to integrate catalysis, reaction engineering with process design, and technoeconomic analysis to allow waste polyolefins to be a viable feedstock to produce chemicals and monomers. Upon completion, this project will deliver a low-temperature catalytic process for upgrading pyrolysis oils from waste polyolefins to chemical intermediates. This project will reduce primary feedstock by 2.0 million metric tons (MMT) of polyolefins, 20 PJ energy reduction, 1.005 MMCO2e. Assumptions based on utilization of 10% of PP and LPDE in MSW.

Project Team:
University California Santa Barbara, BASF

21-01-MM-5056

Enabling Cross-industry Reuse of Comingled Waste Plastics as Quality Asphalt Modifier for Sustainable Pavement

Enabling Cross-industry Reuse of Comingled Waste Plastics as Quality Asphalt Modifier for Sustainable Pavement

This project seeks to evaluate reactive feedstock pre-treatment and to develop real-time process measurements to increase post-consumer and post-industrial polyolefin film waste utilization.

Project Team:
University of Tennessee - Knoxville, Oak Ridge National Laboratory (ORNL), Paragon Technical Services Inc. (a subsidiary of Ergon Asphalt and Emulsions, Inc.)

20-01-MM-4044

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

Chemical Conversion and Process Control for Increased used of Polyethylene and Polypropylene Secondary Feedstocks

Chemical Conversion and Process Control for Increased use of Polyethylene and Polypropylene Secondary Feedstocks

This project seeks to evaluate reactive feedstock pre-treatment and to develop real-time process measurements to increase post-consumer and post-industrial polyolefin film waste utilization.

Project Team:
University of Massachusetts Lowell (UM-L), Massachusetts Institute of Technology (MIT), SER North America LLC, iMFLUX Inc.

20-01-MM-4130

Supramolecular Interfacial Reinforcement for Manufacture Utilizing Mixed Secondary Plastic Feedstock

Supramolecular Interfacial Reinforcement for Manufacture Utilizing Mixed Secondary Plastic Feedstock

This project seeks to develop a compatibilizer for MPO (mixed polymeric olefins, i.e., PE and PP) which are difficult to separate from each other and are incompatible. The compatibilized MPO will compete with virgin PE and virgin PP.

Project Team:
The University of Akron, Braskem

20-01-MM-4026

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

Analysis and Design for Sustainable Circularity of Barrier Film in Sheet Molding Composites

Analysis and Design for Sustainable Circularity of Barrier Film in Sheet Molding Composites

This project seeks to develop 1) data and models about alternatives for recycling, reusing, or replacing the current nylon-based SMC barrier film, and 2) an approach, database, and software for the design of sustainable and circular networks of this barrier film.

Project Team:
The Ohio State University (OSU), Kohler Co., National Renewable Energy Laboratory (NREL), Arizona State University (ASU)

20-01-DE-4103

Dynamic Systems Analysis of PET and Olefin Polymers in a Circular Economy

Dynamic Systems Analysis of PET and Olefin Polymers in a Circular Economy

This project seeks to continue the development of a Systems Analysis model including materials flow analysis, techno-economic assessment, and life-cycle assessment for PET and Olefins materials flow in the U.S. economy.

Project Team:
Michigan Technological University (MTU), Idaho National Laboratory (INL), Resource Recycling Systems (RRS), Yale University, Chemstations

20-01-SA-4014

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

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

Scalable High Shear Catalyzed Depolymerization of Multilayer Plastic Packaging

Scalable High Shear Catalyzed Depolymerization of Multilayer Plastic Packaging

Industry is increasingly combining layers of different polymer materials to construct highly functional, lightweight packaging (e.g. to extend food life). These multilayer films are unfortunately less recyclable than single layer films. This project will investigate catalytic depolymerization as a cost-effective approach to process these films into higher value products suitable for use in a variety of applications.

Project Team:
University of Massachusetts-Lowell, Michigan State University, Unilever, American Chemistry Council, National Renewable Energy Laboratory

18-01-RR-20

 

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