WO2018118580A1 - Method for separating and purifying polymers from reclaimed product - Google Patents
Method for separating and purifying polymers from reclaimed product Download PDFInfo
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- WO2018118580A1 WO2018118580A1 PCT/US2017/066090 US2017066090W WO2018118580A1 WO 2018118580 A1 WO2018118580 A1 WO 2018118580A1 US 2017066090 W US2017066090 W US 2017066090W WO 2018118580 A1 WO2018118580 A1 WO 2018118580A1
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- particulate additives
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J11/00—Recovery or working-up of waste materials
- C08J11/04—Recovery or working-up of waste materials of polymers
- C08J11/06—Recovery or working-up of waste materials of polymers without chemical reactions
- C08J11/08—Recovery or working-up of waste materials of polymers without chemical reactions using selective solvents for polymer components
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
- Y02W30/00—Technologies for solid waste management
- Y02W30/50—Reuse, recycling or recovery technologies
- Y02W30/62—Plastics recycling; Rubber recycling
Definitions
- the present invention generally relates to a method for separating and purifying polymers from a reclaimed product (rP) with the use of heated and pressurized solvent, and solid medium. More specifically, the separated and purified polymers are colorless or clear, odor-free, and virginlike polymers.
- Reclaimed film (rF) and reclaimed absorbent hygiene product (rAHP) are examples of rP which contain at least two polymers and can be post-consumer and/or post-industrial use products.
- the method is particularly useful for the separation and purification of adhesives (ADH), thermoplastic elastomers (TPE), polypropylene (PP), polyethylene (PE), polyester, cellulose, and poly(acrylic acid) (PAA) from rAHP.
- Synthetic plastics are ubiquitous in daily life due to their relatively low production costs and good balance of material properties. Synthetic plastics are used in a wide variety of applications, such as packaging, automotive components, medical devices, and consumer goods. To meet the high demand of these applications, tens of billions of pounds of synthetic plastics are produced globally on an annual basis. The overwhelming majority of synthetic plastics are produced from increasingly scarce fossil sources, such as petroleum and natural gas. Additionally, the manufacturing of synthetic plastics from fossil sources produces CO2 as a by-product, which is a potent greenhouse gas.
- Plastics recycling has emerged as one solution to mitigate the issues associated with the wide-spread usage of plastics. Recovering and re-using plastics diverts waste from landfills and reduces the demand for virgin plastics made from fossil-based resources, which consequently reduces greenhouse gas emissions. In developed regions, such as the United States and the European Union, rates of plastics recycling are increasing due to greater awareness by consumers, businesses, and industrial manufacturing operations. The majority of recycled materials, including plastics, are mixed into a single stream which is collected and processed by a material recovery facility (MRF). At the MRF, materials are sorted, washed, and packaged for resale.
- MRF material recovery facility
- Plastics can be sorted into individual materials, such as high-density polyethylene (HDPE) or poly(ethylene terephthalate) (PET), or mixed streams of other common plastics, such as PP, low-density polyethylene (LDPE), poly(vinyl chloride) (PVC), polystyrene (PS), polycarbonate (PC), and polyamides (PA).
- HDPE high-density polyethylene
- PET poly(ethylene terephthalate)
- mixed streams of other common plastics such as PP, low-density polyethylene (LDPE), poly(vinyl chloride) (PVC), polystyrene (PS), polycarbonate (PC), and polyamides (PA).
- LDPE low-density polyethylene
- PVC poly(vinyl chloride)
- PS polystyrene
- PC polycarbonate
- PA polyamides
- recycled plastics are sorted into predominately uniform streams and are washed with aqueous and/or caustic solutions, the final reprocessed pellets often remain highly contaminated with unwanted waste impurities, such as spoiled food residue and residual perfume components.
- recycled plastic pellets except for those from recycled beverage containers, are darkly colored due to the mixture of dyes and pigments commonly used to color plastic articles. While there are some applications that are insensitive to color and contamination (for example black plastic paint containers and concealed automotive components), the majority of applications require non-colored pellets.
- the need for high quality, "virgin-like" recycled resin is especially important for food and drug contact applications, such as food packaging.
- many recycled resin products are often heterogeneous in chemical composition and may contain a significant amount of polymeric contamination, such as PE contamination in recycled PP and vice versa.
- U.S. Patent No. 7,935,736 describes a method for recycling polyester from polyester-containing waste using a solvent to dissolve the polyester prior to cleaning.
- the '736 patent also describes the need to use a precipitant to recover the polyester from the solvent.
- U.S. Patent No. 6,555,588 describes a method to produce a polypropylene blend from a plastic mixture that comprises other polymers.
- the '588 patent describes the extraction of contaminants from a polymer at a temperature below the dissolution temperature of the polymer in the selected solvent, such as hexane, for a specified residence time period.
- the '588 patent further describes increasing the temperature of the solvent (or a second solvent) to dissolve the polymer prior to filtration.
- the '588 patent yet further describes the use of shearing or flow to precipitate PP from solution.
- the PP blend described in the '588 patent contained PE contamination up to 5.6 wt%.
- European Patent Application No. 849,312 (translated from German to English) describes a process to obtain purified polyolefins from a polyolefin-containing plastic mixture or a polyolefin-containing waste.
- the '312 patent application describes the extraction of polyolefin mixtures or wastes with a hydrocarbon fraction of gasoline or diesel fuel with a boiling point above 90°C at temperatures between 90°C and the boiling point of the hydrocarbon solvent.
- the '312 patent application further describes contacting a hot polyolefin solution with bleaching clay and/or activated carbon to remove foreign components from the solution.
- the '312 patent yet further describes cooling the solution to temperatures below 70°C to crystallize the polyolefin and then removing adhering solvent by heating the polyolefin above the melting point of the polyolefin, or evaporating the adhering solvent in a vacuum or passing a gas stream through the polyolefin precipitate, and/or extraction of the solvent with an alcohol or ketone that boils below the melting point of the polyolefin.
- U.S. Patent No. 5,198,471 describes a method for separating polymers from a physically commingled solid mixture (for example, waste plastics) containing a plurality of polymers using a solvent at a first lower temperature to form a first single phase solution and a remaining solid component.
- the '471 patent further describes heating the solvent to higher temperatures to dissolve additional polymers that were not solubilized at the first lower temperature.
- the '471 patent describes filtration of insoluble polymer components.
- U.S. Patent No. 5,233,021 describes a method of extracting pure polymeric components from a multi-component structure (for example, waste carpeting) by dissolving each component at an appropriate temperature and pressure in a supercritical fluid and then varying the temperature and/or pressure to extract particular components in sequence.
- a multi-component structure for example, waste carpeting
- the '021 patent only describes filtration of undissolved components.
- U.S. Patent No. 5,739,270 describes a method and apparatus for continuously separating a polymer component of a plastic from contaminants and other components of the plastic using a co-solvent and a working fluid.
- the co-solvent at least partially dissolves the polymer and the second fluid (that is in a liquid, critical, or supercritical state) solubilizes components from the polymer and precipitates some of the dissolved polymer from the co-solvent.
- the '270 patent further describes the step of filtering the thermoplastic-co-solvent (with or without the working fluid) to remove particulate contaminants, such as glass particles.
- absorbent hygiene products such as baby diapers, feminine protection pads, and adult incontinence pads
- product and packaging films F
- these products contain various polymers, such as in the case of AHP, ADH, TPE, PP, PE, PET, cellulose, and PAA, that can be recycled as individual streams.
- a method for separating and purifying polymers from a reclaimed product comprising said polymers and contaminants; wherein said polymer comprises a base polymer, particulate additives associated with said polymer, and extractable materials associated with said polymer; wherein said particulate additives associated with each polymer are dispersed in said base polymer at a concentration; wherein said polymer is selected from the group consisting of a dissolvable polymer, a non- dissolvable polymer, and mixtures thereof; wherein said contaminants comprise particulate matter associated with said contaminants and extractable materials associated with said contaminants; wherein said extractable materials in said rP comprise said extractable materials associated with said polymers and said extractable materials associated with said contaminants; and wherein said extractable materials in said rP are at a concentration in said rP.
- Said method comprises: (a) obtaining said rP; wherein said rP is selected from the group consisting of post-consumer use products, post-industrial use products, and combinations thereof; (b) extracting said rP with an extraction solvent at a temperature greater than about 100°C and at a pressure greater than about 150 psig (1 MPa); wherein said extraction solvent has a standard boiling point less than about 70°C; whereby an extracted rP (erP) is produced; and wherein said extractable materials have a concentration in said erP which is lower than said concentration of said extractable materials in said rP; (c) dissolving a first dissolvable base polymer of said rP by contacting said erP with a dissolving step solvent at a temperature range and a pressure range sufficient to cause said first dissolvable base polymer to solubilize in said dissolving step solvent; whereby producing an initial suspension; wherein said initial suspension comprises a suspension of said particulate additives associated with said first dissolvable polymer, and
- a method for separating and purifying ADH, TPE, PP, PE, PET, cellulose, and PAA polymers from a reclaimed absorbent hygiene product wherein said rAHP comprises said polymers and contaminants; wherein each said polymer comprises a base polymer, particulate additives associated with each said polymer, and extractable materials associated with each said polymer; wherein said particulate additives associated with each said polymer are dispersed in each said base polymer at a concentration; wherein each said polymer is selected from the group consisting of a dissolvable polymer, a non-dissolvable polymer, and mixtures thereof; wherein said contaminants comprise particulate matter associated with said contaminants and extractable materials associated with said contaminants; wherein said extractable materials in said rAHP comprise said extractable materials associated with said polymers and said extractable materials associated with said contaminants; and wherein said extractable materials in said rAHP are at a concentration in said rAHP.
- Said method comprises: (a) obtaining said rAHP; wherein said rAHP is selected from the group consisting of post-consumer use products, post-industrial use products, and combinations thereof; (b) extracting said rAHP with an extraction solvent at a temperature greater than about 100°C and at a pressure greater than about 150 psig (1 MPa); wherein said extraction solvent has a standard boiling point less than about 70°C; whereby an extracted rAHP (erAHP) is produced; and wherein said extractable materials have a concentration in said erAHP which is lower than the concentration of said extractable materials in said rAHP; (c) dissolving said ADH base polymer of said rAHP by contacting said erAHP with a dissolving step solvent at a temperature range and a pressure range sufficient to cause said ADH base polymer to solubilize in said dissolving step solvent; whereby producing an initial suspension; wherein said initial suspension comprises a suspension of said particulate additives associated with said ADH polymer
- a method for separating and purifying PP, cellulose, and PAA polymers from a reclaimed absorbent hygiene product comprises said polymers and contaminants; wherein said PP polymer comprises a PP base polymer, particulate additives associated with said PP polymer, and extractable materials associated with said PP polymer; wherein said particulate additives associated with said PP polymer are dispersed in said PP base polymer at a concentration; wherein said PP polymer is a dissolvable polymer; wherein said cellulose and said PAA polymers are non- dissolvable polymers; wherein said contaminants comprise particulate matter associated with said contaminants and extractable materials associated with said contaminants; wherein said extractable materials in said rAHP comprise said extractable materials associated with said polymers and said extractable materials associated with said contaminants; and wherein said extractable materials in said rAHP are at a concentration in said rAHP.
- Said method comprises: (a) obtaining said rAHP; wherein said rAHP is selected from the group consisting of post-consumer use products, post- industrial use products, and combinations thereof; (b) extracting said rAHP with an extraction solvent at a temperature greater than about 100°C and at a pressure greater than about 150 psig (1 MPa); wherein said extraction solvent has a standard boiling point less than about 70°C; whereby an extracted rAHP (erAHP) is produced; and wherein said extractable materials have a concentration in said erAHP which is lower than the concentration of said extractable materials in said rAHP; (c) dissolving said PP base polymer of said rAHP by contacting said erAHP with a dissolving step solvent at a temperature range and a pressure range sufficient to cause said PP base polymer to solubilize in said dissolving step solvent; whereby producing an initial suspension; and wherein said initial suspension comprises a suspension of said particulate additives associated with said PP poly
- a method for separating and purifying polymers from a reclaimed product comprising said polymers and contaminants; wherein said polymer comprises a base polymer, particulate additives associated with said polymer, and extractable materials associated with said polymer; wherein said particulate additives associated with each polymer are dispersed in said base polymer at a concentration; wherein said polymer is selected from the group consisting of a dissolvable polymer, a non-dissolvable polymer, and mixtures thereof; wherein said contaminants comprise particulate matter associated with said contaminants and extractable materials associated with said contaminants; wherein said extractable materials in said rP comprise said extractable materials associated with said polymers and said extractable materials associated with said contaminants; and wherein said extractable materials in said rP are at a concentration in said rP.
- Said method comprises: (a) obtaining said rP; wherein said rP is selected from the group consisting of post- consumer use products, post-industrial use products, and combinations thereof; (b) reducing the size of said rP to particles with a largest dimension of less than about 10 mm; (c) solids separating each polymer of said rP in a polymer stream, and processing each polymer stream comprising a dissolvable polymer separately in a process comprising: (1) extracting said polymer stream comprising said dissolvable polymer with an extraction solvent at a temperature greater than about 100°C and at a pressure greater than about 150 psig (1 MPa); wherein said extraction solvent has a standard boiling point less than about 70°C; whereby an extracted polymer is produced; and wherein said extractable materials have a concentration in said extracted polymer which is lower than said concentration of said extractable materials in said rP; (2) dissolving said dissolvable polymer by contacting said extracted polymer with a dissolving step solvent at a temperature range and
- FIG. 1 is a block flow diagram showing the major steps of one embodiment of the present invention.
- FIG. 2 is a block flow diagram showing the major steps of another embodiment of the present invention.
- reclaimed product refers to a product used for a previous purpose and then recovered for further processing.
- reclaimed film refers to a film used for a previous purpose and then recovered for further processing.
- rAHP reclaimed absorbent hygiene product
- AHP absorbent hygiene product
- post-consumer use product refers to a product that has been used by the end consumer and disposed of in a waste stream.
- post-industrial use product refers to a product that has been manufactured but not used by the consumer yet, and it is typically a waste product from the manufacturing process.
- PCR post-consumer recycle material
- polymer refers to a material that comprises a base polymer, particulate additives associated with the polymer, and extractable materials associated with the polymer.
- base polymer refers to a polymer before any additive packages (either particulate or extractable) are added to it (i.e., the base polymer is unmodified).
- particulate additives refers to particles which are added to the base polymer before the polymer or article are sold in the trade.
- Non limiting examples of such particulate additives that can be used in both cases of dissolvable and non-dissolvable base polymers are clarifiers, flame retardants, fillers, reinforcement, antacids, stabilizers, antioxidants, slid agents, antiblocking agents, lubricants, mold release agents, nucleating agents, and pigments.
- extractable materials refers to materials which can be extracted with an extracting solvent.
- dissolvable polymer refers to a polymer which is capable of being dissolved in a solvent at the molecular level. Further, the thermodynamic stability of the polymer / solvent solution can be described by the following Equation 1:
- G mix is the Gibbs free energy change of mixing of the dissolvable polymer with a solvent
- H mix is the enthalpy change of mixing
- T is the absolute temperature
- S mix is the entropy of mixing.
- the Gibbs free energy must be negative and at a minimum.
- any combination of dissolvable polymer and solvent that minimize a negative Gibbs free energy at appropriate temperature and pressure can be used for the present invention.
- non-dissolvable polymer refers to a polymer which cannot be dissolved in a solvent at the molecular level.
- contaminants refers to unwanted or undesired materials which are present in an rP and were not part of the polymers used to make the product (e.g. contaminants are materials deposited to the product during its use, disposal process, or reclaiming process of the rP). These contaminants comprise particulate matter associated with the contaminants and extractable materials associated with the contaminants.
- extraction solvent and “dissolving step solvent” refer to substances that may exist in the liquid state under specified conditions of temperature and pressure.
- the extraction solvent and the dissolving step solvent may have a predominantly homogenous chemical composition of one molecule or isomer, while in other embodiments, the extraction solvent and the dissolving step solvent may be a mixture of several different molecular compositions or isomers.
- the terms “extraction solvent” and “dissolving step solvent” may also apply to substances that are at, near, or above the critical temperature and critical pressure (critical point) of that substance. It is well known to those having ordinary skill in the art that substances above the critical point of that substance are known as “supercritical fluids" which do not have the typical physical properties (i.e. density) of a liquid.
- standard boiling point refers to the boiling temperature at an absolute pressure of exactly 100 kPa (1 bar, 14.5 psia, 0.9869 atm) as established by the International Union of Pure and Applied Chemistry (IUPAC).
- standard enthalpy change of vaporization refers to the enthalpy change required to transform a specified quantity of a substance from a liquid into a vapor at the standard boiling point of the substance.
- polymer solution refers to a solution of a base polymer dissolved in a solvent.
- settling refers to the process of precipitating suspended particles in response to a force (typically a gravitational force) acting upon the particles.
- a force typically a gravitational force
- settling and “sedimentation” are used interchangeably.
- solid medium refers to a substance that exists in the solid state under the conditions of use.
- the solid medium may be crystalline, semi-crystalline, or amorphous.
- the solid medium may be granular and may be supplied in different shapes (i.e. spheres, cylinders, pellets, etc.). If the solid medium is granular, its particle size and particle size distribution may be defined by the mesh size used to classify the granular media.
- An example of standard mesh size designations can be found in the American Society for Testing and Material (ASTM) standard ASTM El 1 "Standard Specification for Woven Wire Test Sieve Cloth and Test Sieves.”
- the solid medium may also be a non-woven fibrous mat or a woven textile.
- purified polymer refers to a polymer in which the particulate additives and extractable materials have lower concentration than their concentration is in the same polymer prior to the extracting, dissolving, settling, and purifying steps.
- purified polymer and “purer polymer” have the same meaning and are used interchangeably.
- the term "separated and purified polymer” refers to a purified polymer that is separated from the other polymers.
- extracting refers to the process of transferring a solute species from a liquid phase (or solid matrix) across a phase boundary to a separate immiscible liquid phase.
- the driving force(s) for extraction are described by partition theory.
- extract refers to a material having fewer solute species (i.e., extractable materials) relative to the same material prior to an extraction step.
- extracted rAHP refers to an rAHP having fewer solute species (i.e., extractable materials) relative to the same rAHP prior to an extraction step.
- the term "virgin-like polymer” refers to a polymer which is essentially free of particulate additives, extractable materials, and contaminants; homogenous; and with similar properties to its base polymer.
- the terms “virgin-like polymer” and “base-polymer” are used interchangeably.
- oligomeric acrylic acid refers to a molecular complex with less than 1,000 AA units, as opposed to AA polymer (PAA) which refers to a molecular complex with more than 1,000 AA units.
- poly(acrylic acid) and PAA refer polymers of acrylic acid used in various applications, such as superabsorbent polymers (SAP), adhesives, coatings, flocculating agents, etc.
- any reference to international units of pressure refers to gauge pressure.
- step c in FIG. 1 1), followed by dissolving the base polymer in a dissolving step solvent at a dissolution temperature (TD) and at a dissolution pressure (PD) (step c in FIG. 1) and forming a suspension of the particulate additives in the base polymer solution, followed by settling the polymer suspension at a dissolution temperature (TD) and at a dissolution pressure (PD) (step d in FIG. 1) and forming a suspension of the particulate additives that have not settled in the previous step in a base polymer solution, followed by purifying the suspension by contacting it with a solid medium at a dissolution temperature (TD) and at a dissolution pressure (PD) (step e in FIG.
- TD dissolution temperature
- PD dissolution pressure
- step f in FIG. 1 the process steps of dissolving, settling, purifying, and separating are repeating for each one of the dissolvable polymers in the reclaimed product.
- the separated and purified polymers which may be sourced from post-consumer waste streams, are essentially particulate-additive-free (e.g. pigment- free), contaminant-free, extractable-materials-free (e.g. odor-free), homogenous, and similar in properties to virgin polymers.
- the physical properties of the dissolving step solvent of the present invention may enable more energy efficient methods for separating that solvent from the purified polymers.
- reclaimed product refers to either product or packaging.
- post-consumer use products or packaging are products or packaging derived from curbside recycle streams where end-consumers place used products or packaging into a designated bin for collection by a waste hauler or recycler, and products or packaging derived from in-store "take-back" programs where the consumer brings waste products or packaging into a store and places the waste products or packaging in a designated collection bin.
- a non-limiting example of post-industrial waste products are waste polymers produced during the manufacture or shipment of a good or product that are collected as unusable material by the manufacturer (i.e. trim scraps, out of specification material, start up scrap).
- waste products from special waste streams are waste products derived from the recycling of electronic waste, also known as e-waste, automobiles, and used carpeting and textiles.
- said rP is selected from form the group consisting of post-consumer use products, post-industrial use products, post-commercial use products, special waste streams, and combinations thereof. In another embodiment of the present invention, said rP is selected from the group consisting of post-consumer use products, post- industrial use products, and combinations thereof. In yet another embodiment of the present invention, a method for separating and purifying polymers from a reclaimed product (rP) comprises obtaining said rP.
- said rP is a reclaimed film.
- said rF comprises at least 2 polymers.
- said rF comprises at least 4 polymers.
- said rF comprises a multilayer film.
- said rF comprises a film with at least two layers. These layers in the rF can include tie layers, as known to those skilled in the art.
- Non-limiting examples of the polymers used in the layers of a multilayer film are PE, PP, PET, polystyrene (PS), poly(lactic acid) (PLA), ionomer, polyamides (PA), and polybutylene succinate (PBS).
- said rP is a reclaimed adsorbent hygiene product (rAHP).
- said rAHP is selected from the group consisting of baby diaper, feminine protection product, and adult incontinence product.
- said rP comprises said polymers and contaminants.
- the polymers in the reclaimed product are homogenous polymers or mixtures of several different polymer compositions.
- Non-limiting examples of polymers are PE, PP, PET, ADH, TPE, cellulose, hemicellulose, lignin, PAA, PLA, ionomer, PA, and PBS.
- Non-limiting examples of PP compositions are homopolymers of propylene, copolymers of propylene and ethylene (including “impact” and “random-clarified” copolymers), copolymers of propylene and alpha-olefins, polypropylene rubbers, and other dissolvable polypropylene compositions that may be apparent to those having ordinary skill in the art.
- said polymers are dissolvable.
- said polymers are non-dissolvable.
- said polymer is selected from the group consisting of a dissolvable polymer, a non-dissolvable polymer, and mixtures thereof.
- said dissolvable polymers are selected from the group consisting of PP, PE, PET, ADH, TPE, and mixtures thereof.
- said first dissolvable polymer is ADH
- said second dissolvable polymer is TPE
- said third dissolvable polymer is PP
- said fourth dissolvable polymer is PE
- said fifth dissolvable polymer is PET.
- said non-dissolvable polymers are selected from the group consisting of cellulose, hemicellulose, lignin, and PAA, and mixtures thereof.
- said non-dissolvable polymers are cellulose and PAA.
- Non- limiting examples of contaminants are dust particles, soils from the use, disposal, and reclaiming processes of the product, odors, and pieces from other products.
- said contaminants comprise particulate matter associated with said contaminants and extractable materials associated with said contaminants.
- the polymers in the reclaimed product comprise base polymer, particulate additives associated with the polymer, and extractable materials associated with the polymer.
- the particulate additives are added to the base polymers during polymerization or conversion of the base polymer to the product.
- Non-limiting examples of the particulate additives are clarifiers, flame retardants, fillers, reinforcements, antacids, stabilizers, antioxidants, slip agents, antiblocking agents, lubricants, mold release agents, nucleating agents, pigments, and plasticizers.
- Non-limiting examples of pigments are organic pigments, such as copper phthalocyanine, inorganic pigments, such as titanium dioxide, and other pigments that may be apparent to those having ordinary skill in the art.
- a non-limiting example of an organic dye is Basic Yellow 51.
- Non-limiting examples of antistatic agents is glycerol monostearate, and slip agents is erucamide.
- a non-limiting example of a stabilizer is octadecyl-3-(3,5-di-tert.butyl-4-hydroxyphenyl)-propionate.
- Non-limiting examples of fillers are calcium carbonate, talc, and glass fibers.
- said particulate additives are selected from the group consisting of clarifiers, flame retardants, fillers, reinforcements, antacids, stabilizers, antioxidants, slip agents, antiblocking agents, lubricants, mold release agents, nucleating agents, pigments, and mixtures thereof.
- the particulate additives associated with the polymer are dispersed in said base polymer at a concentration.
- said concentration of said particulate additives associated with each dissolvable polymer dispersed in said each dissolvable base polymer in said rP is less than about 5%.
- said concentration of said particulate additives associated with each dissolvable polymer dispersed in said each dissolvable base polymer in said rP is about 3%. In yet another embodiment of the present invention, said concentration of said particulate additives associated with each dissolvable polymer dispersed in said each dissolvable base polymer in said rP is less than about 3%. In even yet another embodiment of the present invention, said concentration of said particulate additives associated with each dissolvable polymer dispersed in said each dissolvable base polymer in said rP is less than about 1%. In one embodiment of the present invention, said concentration of said particulate additives associated with each dissolvable polymer dispersed in said each dissolvable base polymer in said rP is less than about 0.1%.
- said concentration of said particulate additives associated with each dissolvable polymer dispersed in said each dissolvable base polymer in said rAHP is less than about 5%. In another embodiment of the present invention, said concentration of said particulate additives associated with each dissolvable polymer dispersed in said each dissolvable base polymer in said rAHP is about 3%. In yet another embodiment of the present invention, said concentration of said particulate additives associated with each dissolvable polymer dispersed in said each dissolvable base polymer in said rAHP is less than about 3%.
- said concentration of said particulate additives associated with each dissolvable polymer dispersed in said each dissolvable base polymer in said rAHP is less than about 1%. In one embodiment of the present invention, said concentration of said particulate additives associated with each dissolvable polymer dispersed in said each dissolvable base polymer in said rAHP is less than about 0.1%.
- said concentration of said particulate additives associated with PP polymer dispersed in said PP base polymer in said rP is less than about 5%. In another embodiment of the present invention, said concentration of said particulate additives associated with PP polymer dispersed in said PP base polymer in said rP is about 3%. In yet another embodiment of the present invention, said concentration of said particulate additives associated with PP polymer dispersed in said PP base polymer in said rP is less than about 3%. In even yet another embodiment of the present invention, said concentration of said particulate additives associated with PP polymer dispersed in said PP base polymer in said rP is less than about 1%. In one embodiment of the present invention, said concentration of said particulate additives associated with PP polymer dispersed in said PP base polymer in said rP is less than about 0.1%.
- said concentration of said particulate additives associated with PP polymer dispersed in said PP base polymer in said rAHP is less than about 5%. In another embodiment of the present invention, said concentration of said particulate additives associated with PP polymer dispersed in said PP base polymer in said rAHP is about 3%. In yet another embodiment of the present invention, said concentration of said particulate additives associated with PP polymer dispersed in said PP base polymer in said rAHP is less than about 3%. In even yet another embodiment of the present invention, said concentration of said particulate additives associated with PP polymer dispersed in said PP base polymer in said rAHP is less than about 1%. In one embodiment of the present invention, said concentration of said particulate additives associated with PP polymer dispersed in said PP base polymer in said rAHP is less than about 0.1%.
- said extractable materials in said rP comprise said extractable materials associated with said polymers and said extractable materials associated with said contaminants.
- said extractable materials in said rP are at a concentration in said rP.
- Non-limiting examples of extractable materials associated with either the polymers or the contamination are dyes, perfumes, flavors, and mixtures thereof.
- the extractable materials associated with either the polymers or the contamination may be residual processing aides added to the polymer, residual product formulations which contacted the polymer during the use of the product, and any other extractable materials that may have been intentionally added or unintentionally incorporated into the polymer, for example, during waste collection and subsequent accumulation with other waste products.
- said method further comprises sterilizing said rP after said obtaining step. In another embodiment of the present invention, said method further comprises sterilizing said rAHP after said obtaining step.
- the sterilization is required to eliminate the microbial load on the rP, and more specifically, the rAHP, since the AHP are considered biohazardous products after use. Sterilization processes and conditions are well known to those skilled in the art, and can be done in autoclaves, Parr reactors, and similar equipment.
- said method further comprises reducing the size of said rAHP after said obtaining step and before said extracting step.
- said reducing step comprises milling, cutting, shearing, or mixtures thereof.
- said method comprises obtaining said rP, extracting said rP with an extraction solvent, dissolving said first dissolvable base polymer with a dissolving step solvent to produce an initial suspension, settling said initial suspension to produce an intermediate suspension, purifying said intermediate suspension with a solid medium to produce a final suspension, separating said dissolving step solvent from said final suspension to produce a separated and purified first dissolvable polymer; and repeating said dissolving step, said settling step, said purifying step, and said separating step with all remaining dissolvable polymers.
- a method for separating and purifying polymers from a reclaimed product includes extracting said rP with an extraction solvent at a temperature greater than about 100°C and at a pressure greater than about 150 psig (1 MPa); wherein said extraction solvent has a standard boiling point less than about 70 °C; whereby an extracted rP (erP) is produced; and wherein said extractable materials have a concentration in said erP which is lower than said concentration of said extractable materials in said rP.
- said extracting step comprises extracting said rAHP with an extraction solvent at a temperature greater than about 100°C and at a pressure greater than about 150 psig (1 MPa); wherein said extraction solvent has a standard boiling point less than about 70°C; whereby an extracted rAHP (erAHP) is produced; and wherein said extractable materials have a concentration in said erAHP which is lower than said concentration of said extractable materials in said rAHP.
- said extracting step comprises extracting said rF with an extraction solvent at a temperature greater than about 100°C and at a pressure greater than about 150 psig (1 MPa); wherein said extraction solvent has a standard boiling point less than about 70°C; whereby an extracted rF (erF) is produced; and wherein said extractable materials have a concentration in said erF which is lower than said concentration of said extractable materials in said rF.
- the extraction solvent of the present invention has a standard boiling point less than about 70°C. Pressurization maintains extraction solvents, which have standard boiling points below the operating temperature range of the present invention, in a state in which there is little or no solvent vapor.
- the extraction solvent with a standard boiling point less than about 70°C is selected from the group consisting of carbon dioxide, ketones, alcohols, ethers, esters, alkenes, alkanes, and mixtures thereof.
- said extraction solvent is selected from the group consisting of olefinic hydrocarbons, aliphatic hydrocarbons, and mixtures thereof.
- Non-limiting examples of extraction solvents with standard boiling points less than about 70°C are carbon dioxide, acetone, methanol, dimethyl ether, diethyl ether, ethyl methyl ether, tetrahydrofuran, methyl acetate, ethylene, propylene, 1-butene, 2-butene, isobutylene, 1-pentene, 2-pentene, branched isomers of pentene, 1- hexene, 2-hexene, methane, ethane, propane, n-butane, isobutane, n-pentane, isopentane, neopentane, n-hexane, isomers of isohexane, and other substances that may be apparent to those having ordinary skill in the art.
- said extraction solvent in n-butane. In another embodiment of the present invention, said extraction solvent in propane. In yet another embodiment of the present invention, said extraction solvent in pentane. In even yet another embodiment of the present invention, said extraction solvent in hexane.
- a method for separating and purifying a polymer from a reclaimed product (rP) includes contacting said rP with an extraction solvent at a temperature and at a pressure wherein said polymer is essentially insoluble in the extraction solvent.
- the extraction may be accomplished by fixing the temperature of the polymer / extraction solvent system and then controlling the pressure below a pressure, or pressure range, where the polymer dissolves in the extraction solvent.
- the extraction may be accomplished by fixing the pressure of the polymer / extraction solvent system and then controlling the temperature below a temperature, or temperature range, where the polymer dissolves in the extraction solvent.
- the temperature and pressure-controlled extraction of the polymer with an extraction solvent uses a suitable pressure vessel and may be configured in a way that allows for continuous extraction of the polymer with the extraction solvent.
- the pressure vessel may be a continuous liquid- liquid extraction column where molten polymer is pumped into one end of the extraction column and the extraction solvent is pumped into the same or the opposite end of the extraction column.
- the fluid containing extracted contamination is removed from the process.
- the fluid containing the extracted materials is purified, recovered, and recycled for use in the extracting step or a different step in the process.
- the extracting step may be performed as a batch method, wherein the reclaimed product is fixed in a pressure vessel and the extraction solvent is continuously pumped through the fixed product phase.
- the extraction time or the amount of the extraction solvent used will depend on the desired purity of the separated and purified polymers and the amount of extractable materials in the starting reclaimed product.
- said extracting step is in batch mode. In another embodiment of the present invention, said extracting step is in continuous mode.
- the erP is contacted with a solid medium in a separate step as described in the "purifying step” section below.
- said extracting step comprises the use of adsorbent materials to extract a fraction of said extractable materials.
- Non- limiting examples of adsorbent materials are silicon oxide (silica), silica gel, aluminum oxide (alumina), iron oxide, aluminum silicate, magnesium silicate, amorphous volcanic glass, reclaimed glass, sand, quartz, diatomaceous earth, zeolite, perlite, clay, fuller's earth, bentonite clay, metal organic framework (MOF), covalent organic framework (COF), zeolitic imidazolate framework (ZIF), anthracite coal, carbon black, coke, and activated carbon.
- said adsorbent materials are selected from the group consisting of activated carbon, zeolite, MOF, COF, (ZIF), and mixtures thereof.
- said method includes contacting said rP with an extraction solvent at a temperature and at a pressure wherein said polymers are molten and in the liquid state.
- said rP is contacted with said extraction solvent at a temperature and at a pressure wherein said polymers are in the solid state.
- a method for separating and purifying PP from an rP includes contacting PP with an extraction solvent at a temperature and a pressure wherein PP remains essentially undissolved.
- a method for separating and purifying PP from an rP includes contacting said PP with n-butane at a temperature from about 80°C to about 220°C.
- a method for separating and purifying PP from an rP includes contacting said PP with n-butane at a temperature from about 100°C to about 200°C.
- a method for separating and purifying PP from an rP includes contacting said PP with n-butane at a temperature from about 130°C to about 180°C. In one embodiment of the present invention, a method for separating and purifying PP from an rP includes contacting said PP with n-butane at a temperature from about 110°C to about 170°C.
- a method for separating and purifying PP from an rP includes contacting said PP with n-butane at a pressure from about 150 psig (1 MPa) to about 3,000 psig (20.7 MPa). In another embodiment of the present invention, a method for separating and purifying PP from an rP includes contacting said PP with n-butane at a pressure from about 1,000 psig (6.9 MPa) to about 2,750 psig (19 MPa).
- a method for separating and purifying PP from an rP includes contacting said PP with n-butane at a pressure from about 1,500 psig (10.3 MPa) to about 2,500 psig (17.2 MPa). In one embodiment of the present invention, a method for separating and purifying PP from an rP includes contacting said PP with n-butane at a pressure from about 1,100 psig (7.6 MPa) to about 2,100 psig (14.5 MPa).
- a method for separating and purifying PP from an rP includes contacting said PP with propane at a temperature from about 80°C to about 220°C. In another embodiment of the present invention, a method for separating and purifying PP from an rP includes contacting said PP with propane at a temperature from about 100°C to about 200 °C. In yet another embodiment of the present invention, a method for separating and purifying PP from an rP includes contacting said PP with propane at a temperature from about 130°C to about 180°C.
- a method for separating and purifying PP from an rP includes contacting said PP with propane at a pressure from about 200 psig (1.4 MPa) to about 8,000 psig (55.2 MPa). In another embodiment of the present invention, a method for separating and purifying PP from an rP includes contacting said PP with propane at a pressure from about 1,000 psig (6.9 MPa) to about 6,000 psig (41.4 MPa). In yet another embodiment of the present invention, a method for separating and purifying PP from an rP includes contacting said PP with propane at a pressure from about 2,000 psig (13.8 MPa) to about 4,000 psig (27.6 MPa).
- said concentration of said extractable materials in said erP is less than about 90% of said concentration of said extractable materials in said rP. In another embodiment of the present invention, said concentration of said extractable materials in said erP is less than about 75% of said concentration of said extractable materials in said rP. In yet another embodiment of the present invention, said concentration of said extractable materials in said erP is less than about 50% of said concentration of said extractable materials in said rP. In even yet another embodiment of the present invention, said concentration of said extractable materials in said erP is about half said concentration of said extractable materials in said rP.
- said concentration of said extractable materials in said erAHP is less than about 90% of said concentration of said extractable materials in said rAHP. In another embodiment of the present invention, said concentration of said extractable materials in said erAHP is less than about 75% of said concentration of said extractable materials in said rAHP. In yet another embodiment of the present invention, said concentration of said extractable materials in said erAHP is less than about 50% of said concentration of said extractable materials in said rAHP. In even yet another embodiment of the present invention, said concentration of said extractable materials in said erAHP is about half said concentration of said extractable materials in said rAHP.
- said erP is essentially free of said extractable materials.
- said erAHP is essentially free of said extractable materials.
- said concentration of said extractable materials in said erP is further reduced during said purifying step.
- said concentration of said extractable materials in said erAHP is further reduced during said purifying step.
- a method for separating and purifying a PP polymer from an rAHP wherein said temperature range in said extracting step is from about 110°C to about 170°C, and wherein said pressure range in said extracting step is from about 1,100 psig (7.6 MPa) to about 2,100 psig (14.5 MPa).
- a method for separating and purifying polymers from an rP wherein said extraction solvent is propane, wherein said temperature in said extracting step is greater than about 100°C, and wherein said pressure in said extracting step is greater than about 150 psig (1 MPa) and lower than about 1,500 psig (10.3 MPa).
- a method for separating and purifying polymers from an rP wherein said extraction solvent is n-butane, wherein said temperature in said extracting step is greater than about 100°C, and wherein said pressure in said extracting step is greater than about 150 psig (1 MPa) and lower than about 900 psig (6.2 MPa).
- a method for separating and purifying polymers from an rP wherein said extraction solvent is pentane, wherein said temperature in said extracting step is greater than about 100°C, and wherein said pressure in said extracting step is greater than about 150 psig (1 MPa) and lower than about 500 psig (3.4 MPa).
- a method for separating and purifying polymers from an rP wherein said extraction solvent is hexane, wherein said temperature in said extracting step is greater than about 100°C, and wherein said pressure in said extracting step is about 150 psig (1 MPa).
- a method for separating and purifying polymers from a reclaimed product includes dissolving a first dissolvable base polymer of said rP by contacting said erP with a dissolving step solvent at a temperature range and a pressure range sufficient to cause said first dissolvable base polymer to solubilize in said dissolving step solvent; whereby producing an initial suspension; wherein said initial suspension comprises a suspension of said particulate additives associated with said first dissolvable polymer and domains of all remaining polymers in a first dissolvable base polymer solution; and wherein said first dissolvable base polymer has a solubilization range below the solubilization range of the remaining dissolvable base polymers.
- a method for separating and purifying polymers from a reclaimed absorbent hygiene product includes dissolving a first dissolvable base polymer of said rAHP by contacting said erAHP with a dissolving step solvent at a temperature range and a pressure range sufficient to cause said first dissolvable base polymer to solubilize in said dissolving step solvent; whereby producing an initial suspension; wherein said initial suspension comprises a suspension of said particulate additives associated with said first dissolvable polymer and domains of all remaining polymers in a first dissolvable base polymer solution; and wherein said first dissolvable base polymer has a solubilization range below the solubilization range of the remaining dissolvable base polymers.
- a method for separating and purifying polymers from a reclaimed film (rF) includes dissolving a first dissolvable base polymer of said rF by contacting said erF with a dissolving step solvent at a temperature range and a pressure range sufficient to cause said first dissolvable base polymer to solubilize in said dissolving step solvent; whereby producing an initial suspension; wherein said initial suspension comprises a suspension of said particulate additives associated with said first dissolvable polymer and domains of all remaining polymers in a first dissolvable base polymer solution; and wherein said first dissolvable base polymer has a solubilization range below the solubilization range of the remaining dissolvable base polymers.
- a method for separating and purifying an ADH polymer from a reclaimed absorbent hygiene product includes dissolving said ADH base polymer of said rAHP by contacting said erAHP with a dissolving step solvent at a temperature range and a pressure range sufficient to cause said ADH base polymer to solubilize in said dissolving step solvent; whereby producing an initial suspension; wherein said initial suspension comprises a suspension of said particulate additives associated with said ADH polymer and domains of TPE, PP, PE, PET, cellulose, and PAA polymers in an ADH base polymer solution; and wherein said ADH base polymer has a solubilization range below the solubilization range of said TPE, PP, PE, and PET base polymers; and wherein said dissolving step domains comprise said TPE, PP, PE, PET, cellulose, and PAA polymers.
- a method for separating and purifying a PP polymer from a reclaimed absorbent hygiene product includes dissolving said PP base polymer of said rAHP by contacting said erAHP with a dissolving step solvent at a temperature range and a pressure range sufficient to cause said PP base polymer to solubilize in said dissolving step solvent; whereby producing an initial suspension; wherein said initial suspension comprises a suspension of said particulate additives associated with said PP polymer and domains of cellulose and PAA polymers in a PP base polymer solution.
- the temperature and pressure can be controlled in such a way to enable thermodynamic ally favorable dissolution of the polymers in a dissolving step solvent. Furthermore, the temperature and pressure can be controlled in such a way to enable dissolution of a particular polymer or polymer mixture while not dissolving other polymers or polymer mixtures. This controllable dissolution enables the separation of polymers from polymer mixtures or reclaimed products.
- a method for separating and purifying polymers includes dissolving a reclaimed product containing these polymers in a dissolving step solvent that dissolves one of the polymers and does not dissolve the other polymers under the same conditions of temperature and pressure, which remain as domains in the suspension. The above process is then repeated for the other polymers.
- a method for separating and purifying a PP polymer from a reclaimed absorbent hygiene product (rAHP), wherein said PP polymer comprises a PP base polymer, particulate additives associated with said PP polymer, and extractable materials associated with said PP polymer includes dissolving said PP base polymer of said rAHP by contacting said rAHP with a dissolving step solvent at a temperature and a pressure wherein said PP base polymer is dissolved in said dissolving step solvent.
- a method for separating and purifying a PP polymer from an rAHP includes dissolving said PP base polymer in n-butane at a temperature from about 90 °C to about 220 °C.
- a method for separating and purifying a PP polymer from an rAHP includes dissolving said PP base polymer in n-butane at a temperature from about 100°C to about 200°C.
- a method for separating and purifying a PP polymer from an rAHP includes dissolving said PP base polymer in n-butane at a temperature from about 130°C to about 180°C.
- a method for separating and purifying a PP polymer from an rAHP includes dissolving said PP base polymer in n-butane at a pressure from about 350 psig (2.4 MPa) to about 20,000 psig (137.9 MPa).
- a method for separating and purifying a PP polymer from an rAHP includes dissolving said PP base polymer in n-butane at a pressure from about 350 psig (2.4 MPa) to about 4,000 psig (27.6 MPa).
- a method for separating and purifying a PP polymer from an rAHP includes dissolving said PP base polymer in n-butane at a pressure from about 1,000 psig (6.9 MPa) to about 3,500 psig (24.1 MPa).
- a method for separating and purifying a PP polymer from an rAHP includes dissolving said PP base polymer in n-butane at a pressure from about 2,000 psig (13.8 MPa) to about 3,000 psig (20.7 MPa).
- a method for separating and purifying a PP polymer from an rAHP wherein said temperature range in said dissolving step is from about 90°C to about 220°C, and wherein said pressure range in said dissolving step is from about 350 psig (2.4 MPa) to about 20,000 psig (137.9 MPa).
- a method for separating and purifying a PP polymer from a reclaimed absorbent hygiene product (rAHP), wherein said PP polymer comprises a PP base polymer, particulate additives associated with said PP polymer, and extractable materials associated with said PP polymer includes dissolving said PP base polymer of said rAHP by contacting said rAHP with n-butane at a weight concentration of at least about 0.5%.
- said method for separating and purifying a PP polymer from an rAHP includes dissolving said PP base polymer in n-butane at a weight concentration of at least about 1%.
- a method for separating and purifying a PP polymer from an rAHP includes dissolving said PP base polymer in n-butane at a weight concentration of at least about 2%.
- a method for separating and purifying a PP polymer from an rAHP includes dissolving said PP base polymer in n-butane at a weight concentration of at least about 3%.
- a method for separating and purifying a PP polymer from a reclaimed absorbent hygiene product (rAHP), wherein said PP polymer comprises a PP base polymer, particulate additives associated with said PP polymer, and extractable materials associated with said PP polymer includes dissolving said PP base polymer of said rAHP by contacting said rAHP with n-butane at a weight concentration of at least about 4%.
- said method for separating and purifying a PP polymer from an rAHP includes dissolving said PP base polymer in n-butane at a weight concentration of at least about 5%.
- a method for separating and purifying a PP polymer from a reclaimed absorbent hygiene product (rAHP), wherein said PP polymer comprises a PP base polymer, particulate additives associated with said PP polymer, and extractable materials associated with said PP polymer includes dissolving said PP base polymer of said rAHP by contacting said rAHP with a dissolving step solvent at a weight concentration up to about 20%.
- said method for separating and purifying a PP polymer from an rAHP includes dissolving said PP base polymer in n-butane at a weight concentration up to about 18%.
- a method for separating and purifying a PP polymer from an rAHP includes dissolving said PP base polymer in n-butane at a weight concentration up to about 16%.
- a method for separating and purifying a PP polymer from an rAHP includes dissolving said PP base polymer in n-butane at a weight concentration up to about 14%.
- a method for separating and purifying a PP polymer from a reclaimed absorbent hygiene product (rAHP), wherein said PP polymer comprises a PP base polymer, particulate additives associated with said PP polymer, and extractable materials associated with said PP polymer includes dissolving said PP base polymer of said rAHP by contacting said rAHP with a dissolving step solvent at a weight concentration up to about 12%.
- a method for separating and purifying a PP polymer from a reclaimed absorbent hygiene product (rAHP), wherein said PP polymer comprises a PP base polymer, particulate additives associated with said PP polymer, and extractable materials associated with said PP polymer includes dissolving said PP base polymer of said rAHP by contacting said rAHP with propane at a temperature and a pressure wherein said PP base polymer is dissolved in said dissolving step solvent.
- a method for separating and purifying a PP polymer from an rAHP includes dissolving said PP base polymer in propane at a temperature from about 90°C to about 220°C.
- a method for separating and purifying a PP polymer from an rAHP includes dissolving said PP base polymer in propane at a temperature from about 100°C to about 200°C.
- a method for separating and purifying a PP polymer from an rAHP includes dissolving said PP base polymer in propane at a temperature from about 130°C to about 180°C.
- a method for separating and purifying a PP polymer from an rAHP includes dissolving said PP base polymer in propane at a pressure from about 2,000 psig (13.8 MPa) to about 8,000 psig (55.2 MPa).
- a method for separating and purifying a PP polymer from an rAHP includes dissolving said PP base polymer in propane at a pressure from about 3,000 psig (20.7 MPa) to about 6,000 psig (41.4 MPa).
- a method for separating and purifying a PP polymer from an rAHP includes dissolving said PP base polymer in propane at a pressure from about 3,500 psig (24.1 MPa) to about 5,000 psig (34.5 MPa).
- a method for separating and purifying a PP polymer from a reclaimed absorbent hygiene product (rAHP), wherein said PP polymer comprises a PP base polymer, particulate additives associated with said PP polymer, and extractable materials associated with said PP polymer includes dissolving said PP base polymer of said rAHP by contacting said rAHP with propane at a weight concentration of at least about 0.5%.
- said method for separating and purifying a PP polymer from an rAHP includes dissolving said PP base polymer in propane at a weight concentration of at least about 1%.
- a method for separating and purifying a PP polymer from an rAHP includes dissolving said PP base polymer in propane at a weight concentration of at least about 2%.
- a method for separating and purifying a PP polymer from an rAHP includes dissolving said PP base polymer in propane at a weight concentration of at least about 3%.
- a method for separating and purifying a PP polymer from a reclaimed absorbent hygiene product (rAHP), wherein said PP polymer comprises a PP base polymer, particulate additives associated with said PP polymer, and extractable materials associated with said PP polymer includes dissolving said PP base polymer of said rAHP by contacting said rAHP with propane at a weight concentration of at least about 4%.
- said method for separating and purifying a PP polymer from an rAHP includes dissolving said PP base polymer in propane at a weight concentration of at least about 5%.
- a method for separating and purifying a PP polymer from a reclaimed absorbent hygiene product (rAHP), wherein said PP polymer comprises a PP base polymer, particulate additives associated with said PP polymer, and extractable materials associated with said PP polymer includes dissolving said PP base polymer of said rAHP by contacting said rAHP with propane at a weight concentration up to about 20%.
- said method for separating and purifying a PP polymer from an rAHP includes dissolving said PP base polymer in propane at a weight concentration up to about 18%.
- a method for separating and purifying a PP polymer from an rAHP includes dissolving said PP base polymer in propane at a weight concentration up to about 16%.
- a method for separating and purifying a PP polymer from an rAHP includes dissolving said PP base polymer in propane at a weight concentration up to about 14%.
- a method for separating and purifying a PP polymer from a reclaimed absorbent hygiene product (rAHP), wherein said PP polymer comprises a PP base polymer, particulate additives associated with said PP polymer, and extractable materials associated with said PP polymer includes dissolving said PP base polymer of said rAHP by contacting said rAHP with propane at a weight concentration up to about 12%.
- said dissolving step solvent is selected from the group consisting of olefinic hydrocarbons, aliphatic hydrocarbons, and mixtures thereof.
- said extraction solvent is the same as said dissolving step solvent.
- said dissolving step is in batch mode. In another embodiment of the present invention, said dissolving step is in continuous mode.
- the dissolving step produces an initial suspension.
- the initial suspension comprises a suspension of particulate additives associated with a dissolvable polymer in a dissolvable base polymer solution and domains of all remaining polymers.
- said domains of all remaining polymers comprise cellulose and PAA polymers. In another embodiment of the present invention, said domains of all remaining polymers are separated into said PAA polymer and said cellulose polymer.
- One of the purposes for separating the PAA polymer and the cellulose polymer is to reuse them in future AHP.
- said PAA polymer separated from said dissolving step domains comprises water at a level exceeding 30 g water / g PAA polymer. In another embodiment of the present invention, said PAA polymer is further dehydrated to less than 1 g water / g PAA polymer via a dehydration process.
- Non-limiting examples of dehydration processes are contacting the PAA polymer with a salt solution, an acidic solution, a basic solution, and a solvent that forms an azeotrope with water; pressurization; and centrifugation.
- said dehydration process is selected from the group consisting of contacting said PAA polymer with a salt solution, an acidic solution, a basic solution, and a solvent that forms an azeotrope with water; pressurization; centrifugation; and mixtures thereof.
- Non-limiting examples of solvents that form an azeotrope with water are methanol, ethanol, n-propanol, isopropyl alcohol, n-butanol, isobutanol, and 2-butanol.
- said solvent is an alcohol selected from the group consisting of methanol, ethanol, n-propanol, isopropyl alcohol, n-butanol, isobutanol, 2-butanol, and mixtures thereof.
- said dehydrated PAA polymer is used to produce a new AHP.
- said PAA polymer is subjected to de-polymerization to produce monomeric acrylic acid (AA) or oligomeric acrylic acid (OAA).
- said AA or OAA is further polymerized to virgin PAA polymer and used to produce a new AHP.
- de-polymerization of PAA polymers are de-polymerization in the presence of dissolved CO2, de- polymerization using ultrasonics and solar irradiation, thermal degradation, and mechano- chemistry (e.g. applying mechanical forces to achieve de-polymerization).
- a method for separating and purifying an ADH polymer from an rP wherein said dissolving step solvent is propane, wherein said temperature range in said dissolving step starts at about 100°C, and wherein said pressure range in said dissolving step starts at about 1,500 psig (10.3 MPa).
- a method for separating and purifying an ADH polymer from an rP wherein said dissolving step solvent is n-butane, wherein said temperature range in said dissolving step starts at about 100°C, and wherein said pressure range in said dissolving step starts at about 900 psig (6.2 MPa).
- a method for separating and purifying an ADH polymer from an rP wherein said dissolving step solvent is pentane, wherein said temperature range in said dissolving step starts at about 100°C, and wherein said pressure range in said dissolving step starts at about 500 psig (3.4 MPa).
- a method for separating and purifying an ADH polymer from an rP wherein said dissolving step solvent is hexane, wherein said temperature range in said dissolving step starts at about 100°C, and wherein said pressure range in said dissolving step starts at about 150 psig (1 MPa).
- a method for separating and purifying a TPE polymer from an rP wherein said dissolving step solvent is propane, wherein said temperature range in said dissolving step starts at about 100°C, and wherein said pressure range in said dissolving step starts at about 3,000 psig (20.7 MPa).
- a method for separating and purifying a TPE polymer from an rP wherein said dissolving step solvent is n-butane, wherein said temperature range in said dissolving step starts at about 100°C, and wherein said pressure range in said dissolving step starts at about 1,200 psig (8.3 MPa).
- a method for separating and purifying a TPE polymer from an rP wherein said dissolving step solvent is pentane, wherein said temperature range in said dissolving step starts at about 100°C, and wherein said pressure range in said dissolving step starts at about 700 psig (4.8 MPa).
- a method for separating and purifying a TPE polymer from an rP wherein said dissolving step solvent is hexane, wherein said temperature range in said dissolving step starts at about 100°C, and wherein said pressure range in said dissolving step starts at about 200 psig (1.4 MPa).
- a method for separating and purifying a PP polymer from an rP wherein said dissolving step solvent is propane, wherein said temperature range in said dissolving step starts at about 100°C, and wherein said pressure range in said dissolving step starts at about 7,000 psig (48.3 MPa).
- a method for separating and purifying a PP polymer from an rP wherein said dissolving step solvent is n-butane, wherein said temperature range in said dissolving step starts at about 100°C, and wherein said pressure range in said dissolving step starts at about 1,800 psig (12.4 MPa).
- a method for separating and purifying a PP polymer from an rP wherein said dissolving step solvent is pentane, wherein said temperature range in said dissolving step starts at about 100°C, and wherein said pressure range in said dissolving step starts at about 1,400 psig (9.7 MPa).
- a method for separating and purifying a PP polymer from an rP wherein said dissolving step solvent is hexane, wherein said temperature range in said dissolving step starts at about 100°C, and wherein said pressure range in said dissolving step starts at about 350 psig (2.4 MPa).
- a method for separating and purifying a PE polymer from an rP wherein said dissolving step solvent is propane, wherein said temperature range in said dissolving step starts at about 100°C, and wherein said pressure range in said dissolving step starts at about 10,000 psig (68.9 MPa).
- a method for separating and purifying a PE polymer from an rP wherein said dissolving step solvent is n-butane, wherein said temperature range in said dissolving step starts at about 100°C, and wherein said pressure range in said dissolving step starts at about 4,500 psig (31 MPa).
- a method for separating and purifying a PE polymer from an rP wherein said dissolving step solvent is pentane, wherein said temperature range in said dissolving step starts at about 100°C, and wherein said pressure range in said dissolving step starts at about 2,900 psig (20 MPa).
- a method for separating and purifying a TPE polymer from an rP wherein said dissolving step solvent is hexane, wherein said temperature range in said dissolving step starts at about 100°C, and wherein said pressure range in said dissolving step starts at about 1,000 psig (6.9 MPa).
- a method for separating and purifying a PET polymer from an rP wherein said dissolving step solvent is propane, wherein said temperature range in said dissolving step starts at about 100°C, and wherein said pressure range in said dissolving step starts at about 34,000 psig (234.4 MPa).
- a method for separating and purifying a PET polymer from an rP wherein said dissolving step solvent is n-butane, wherein said temperature range in said dissolving step starts at about 100°C, and wherein said pressure range in said dissolving step starts at about 15,000 psig (103.4 MPa).
- a method for separating and purifying a PET polymer from an rP wherein said dissolving step solvent is pentane, wherein said temperature range in said dissolving step starts at about 100°C, and wherein said pressure range in said dissolving step starts at about 10,000 psig (68.9 MPa).
- a method for separating and purifying a PET polymer from an rP wherein said dissolving step solvent is hexane, wherein said temperature range in said dissolving step starts at about 100°C, and wherein said pressure range in said dissolving step starts at about 3,500 psig (24.1 MPa).
- a method for separating and purifying polymers from a reclaimed product includes settling said initial suspension at a temperature range and a pressure range sufficient to produce a collection of settled particulate additives and said domains of all remaining polymers, and an intermediate suspension; wherein said collection of settled particulate additives comprises particulate additives associated with said first dissolvable polymer; and wherein said intermediate suspension comprises a suspension of non-settled particulate additives associated with said first dissolvable polymer in said first dissolvable base polymer solution.
- a method for separating and purifying polymers from a reclaimed absorbent hygiene product includes settling said initial suspension at a temperature range and a pressure range sufficient to produce a collection of settled particulate additives and said domains of all remaining polymers, and an intermediate suspension; wherein said collection of settled particulate additives comprises particulate additives associated with said first dissolvable polymer; and wherein said intermediate suspension comprises a suspension of non-settled particulate additives associated with said first dissolvable polymer in said first dissolvable base polymer solution.
- a method for separating and purifying polymers from a reclaimed film (rF) includes settling said initial suspension at a temperature range and a pressure range sufficient to produce a collection of settled particulate additives and said domains of all remaining polymers, and an intermediate suspension; wherein said collection of settled particulate additives comprises particulate additives associated with said first dissolvable polymer; and wherein said intermediate suspension comprises a suspension of non-settled particulate additives associated with said first dissolvable polymer in said first dissolvable base polymer solution.
- a method for separating and purifying an ADH polymer from a reclaimed absorbent hygiene product includes settling said initial suspension at a temperature range and a pressure range sufficient to produce a collection of settled particulate additives and said domains of TPE, PP, PE, PET, cellulose, and PAA polymers, and an intermediate suspension; wherein said collection of settled particulate additives comprises particulate additives associated with said ADH polymer; and wherein said intermediate suspension comprises a suspension of non-settled particulate additives associated with said ADH polymer in said ADH base polymer solution.
- a method for separating and purifying a PP polymer from a reclaimed absorbent hygiene product includes settling said initial suspension at a temperature range and a pressure range sufficient to produce a collection of settled particulate additives and said domains of cellulose and PAA polymers, and an intermediate suspension; wherein said collection of settled particulate additives comprises particulate additives associated with said PP polymer; and wherein said intermediate suspension comprises a suspension of non- settled particulate additives associated with said PP polymer in said PP base polymer solution.
- the settling step causes the undissolved particulate additives associated with the polymers, and the particulate matter associated with the contaminants to experience a force that uniformly moves the particulate additives and matter in the direction of the force.
- the applied settling force is gravity, but can also be a centrifugal, centripetal, or some other force.
- the amount of applied force and duration of settling time will depend upon several parameters, including, but not limited to: particle size and particle density of the particulate additives and particulate matter, and density and viscosity of the base polymer solution (i.e., solution of the base polymer dissolved in the dissolving step solvent).
- v is the settling velocity
- p p is the density of the particulate additives and matter
- p j is the density of the base polymer solution
- g is the acceleration due to the applied force (typically gravity)
- d is the diameter of the particles in the particulate additives and matter
- ⁇ is the dynamic viscosity of the base polymer solution.
- a method for separating and purifying a PP polymer from an rAHP includes n-butane as the dissolving step solvent, and the temperature range in the settling step is from about 90°C to about 220°C.
- a method for separating and purifying a PP polymer from an rAHP includes n-butane as the dissolving step solvent, and the temperature range in the settling step is from about 100°C to about 200°C.
- a method for separating and purifying a PP polymer from an rAHP includes n-butane as the dissolving step solvent, and the temperature range in the settling step is from about 130°C to about 180°C.
- a method for separating and purifying a PP polymer from an rAHP includes n-butane as the dissolving step solvent, and the pressure range in the settling step is from about 350 psig (2.4 MPa) to about 4,000 psig (27.6 MPa).
- a method for separating and purifying a PP polymer from an rAHP includes n-butane as the dissolving step solvent, and the pressure range in the settling step is from about 1,000 psig (6.9 MPa) to about 3,500 psig (24.1 MPa).
- a method for separating and purifying a PP polymer from an rAHP includes n-butane as the dissolving step solvent, and the pressure range in the settling step is from about 2,000 psig (13.8 MPa) to about 3,000 psig (20.7 MPa).
- a method for separating and purifying a PP polymer from an rAHP wherein said temperature range in said settling step is from about 90°C to about 220°C, and wherein said pressure range in said settling step is from about 350 psig (2.4 MPa) to about 20,000 psig (137.9 MPa).
- a method for separating and purifying a PP polymer from an rAHP includes n-butane as the dissolving step solvent, and a weight concentration of said PP base polymer in said PP base polymer solution in said settling step of at least about 0.5%.
- a method for separating and purifying a PP polymer from an rAHP includes n-butane as the dissolving step solvent, and a weight concentration of said PP base polymer in said PP base polymer solution in said settling step of at least about 1%.
- a method for separating and purifying a PP polymer from an rAHP includes n-butane as the dissolving step solvent, and a weight concentration of said PP base polymer in said PP base polymer solution in said settling step of at least about 2%.
- a method for separating and purifying a PP polymer from an rAHP includes n-butane as the dissolving step solvent, and a weight concentration of said PP base polymer in said PP base polymer solution in said settling step of at least about 3%.
- a method for separating and purifying a PP polymer from an rAHP includes n-butane as the dissolving step solvent, and a weight concentration of said PP base polymer in said PP base polymer solution in said settling step of at least about 4%.
- a method for separating and purifying a PP polymer from an rAHP includes n-butane as the dissolving step solvent, and a weight concentration of said PP base polymer in said PP base polymer solution in said settling step of at least about 5%.
- a method for separating and purifying a PP polymer from an rAHP includes n-butane as the dissolving step solvent, and a weight concentration of said PP base polymer in said PP base polymer solution in said settling step up to about 20%.
- a method for separating and purifying a PP polymer from an rAHP includes n-butane as the dissolving step solvent, and a weight concentration of said PP base polymer in said PP base polymer solution in said settling step up to about 18%.
- a method for separating and purifying a PP polymer from an rAHP includes n-butane as the dissolving step solvent, and a weight concentration of said PP base polymer in said PP base polymer solution in said settling step up to about 16%.
- a method for separating and purifying a PP polymer from an rAHP includes n-butane as the dissolving step solvent, and a weight concentration of said PP base polymer in said PP base polymer solution in said settling step up to about 14%.
- a method for separating and purifying a PP polymer from an rAHP includes n-butane as the dissolving step solvent, and a weight concentration of said PP base polymer in said PP base polymer solution in said settling step up to about 12%.
- a method for separating and purifying a PP polymer from an rAHP includes propane as the dissolving step solvent, and the temperature range in the settling step is from about 90°C to about 220°C.
- a method for separating and purifying a PP polymer from an rAHP includes propane as the dissolving step solvent, and the temperature range in the settling step is from about 100°C to about 200°C.
- a method for separating and purifying a PP polymer from an rAHP includes propane as the dissolving step solvent, and the temperature range in the settling step is from about 130°C to about 180°C.
- a method for separating and purifying a PP polymer from an rAHP includes propane as the dissolving step solvent, and the pressure range in the settling step is from about 2,000 psig (13.8 MPa) to about 8,000 psig (55.2 MPa).
- a method for separating and purifying a PP polymer from an rAHP includes propane as the dissolving step solvent, and the pressure range in the settling step is from about 3,000 psig (20.7 MPa) to about 6,000 psig (41.4 MPa).
- a method for separating and purifying a PP polymer from an rAHP includes propane as the dissolving step solvent, and the pressure range in the settling step is from about 3,500 psig (24.1 MPa) to about 5,000 psig (34.5 MPa).
- a method for separating and purifying a PP polymer from an rAHP includes propane as the dissolving step solvent, and a weight concentration of said PP base polymer in said PP base polymer solution in said settling step of at least about 0.5%.
- a method for separating and purifying a PP polymer from an rAHP includes propane as the dissolving step solvent, and a weight concentration of said PP base polymer in said PP base polymer solution in said settling step of at least about 1%.
- a method for separating and purifying a PP polymer from an rAHP includes propane as the dissolving step solvent, and a weight concentration of said PP base polymer in said PP base polymer solution in said settling step of at least about 2%.
- a method for separating and purifying a PP polymer from an rAHP includes propane as the dissolving step solvent, and a weight concentration of said PP base polymer in said PP base polymer solution in said settling step of at least about 3%.
- a method for separating and purifying a PP polymer from an rAHP includes propane as the dissolving step solvent, and a weight concentration of said PP base polymer in said PP base polymer solution in said settling step of at least about 4%.
- a method for separating and purifying a PP polymer from an rAHP includes propane as the dissolving step solvent, and a weight concentration of said PP base polymer in said PP base polymer solution in said settling step of at least about 5%.
- a method for separating and purifying a PP polymer from an rAHP includes propane as the dissolving step solvent, and a weight concentration of said PP base polymer in said PP base polymer solution in said settling step up to about 20%.
- a method for separating and purifying a PP polymer from an rAHP includes propane as the dissolving step solvent, and a weight concentration of said PP base polymer in said PP base polymer solution in said settling step up to about 18%.
- a method for separating and purifying a PP polymer from an rAHP includes propane as the dissolving step solvent, and a weight concentration of said PP base polymer in said PP base polymer solution in said settling step up to about 16%.
- a method for separating and purifying a PP polymer from an rAHP includes propane as the dissolving step solvent, and a weight concentration of said PP base polymer in said PP base polymer solution in said settling step up to about 14%.
- a method for separating and purifying a PP polymer from an rAHP includes propane as the dissolving step solvent, and a weight concentration of said PP base polymer in said PP base polymer solution in said settling step up to about 12%.
- said settling step is in batch mode.
- the settling step produces a collection of settled particulate additives and the domains of all remaining polymers, and an intermediate suspension, and it lasts for a settling time.
- the collection of settled particulate additives comprises particulate additives associated with a dissolvable polymer
- the intermediate suspension comprises a suspension of non-settled particulate additives associated with a dissolvable polymer in the dissolvable base polymer solution.
- said collection of settled particulate additives comprises particulate additives associated with a dissolvable polymer and particulate matter associate with said contaminants.
- said intermediate suspension comprises a suspension of non-settled particulate additives associated with a dissolvable polymer in the dissolvable base polymer solution, and non-settled particulate matter associated with said contaminants.
- said collection of settled particulate additives comprises particles with diameter larger than about 1 mm. In another embodiment of the present invention, said collection of settled particulate additives comprises particles with diameter larger than about 0.75 mm. In yet another embodiment of the present invention, said collection of settled particulate additives comprises particles with diameter larger than about 0.5 mm. In even yet another embodiment of the present invention, said collection of settled particulate additives comprises particles with diameter larger than about 300 ⁇ . In one embodiment of the present invention, said collection of settled particulate additives comprises particles with diameter larger than about 100 ⁇ . In another embodiment of the present invention, said collection of settled particulate additives comprises particles with diameter larger than about 50 ⁇ . In yet another embodiment of the present invention, said collection of settled particulate additives comprises particles with diameter larger than about 20 ⁇ .
- said settling time is longer than about 24 h. In another embodiment of the present invention, said settling time is longer than about 12 h. In yet another embodiment of the present invention, said settling time is longer than about 6 h. In even yet another embodiment of the present invention, said settling time is longer than about 3 h. In one embodiment of the present invention, said settling time is longer than about 1 h. In yet another embodiment of the present invention, said settling time is longer than about 0.5 h.
- said settling time is between about 24 h and 0.1 h. In another embodiment of the present invention, said settling time is between about 18 h and about 0.25 h. In yet another embodiment of the present invention, said settling time is between about 12 h and about 0.5 h. In even yet another embodiment of the present invention, said settling time is between about 12 h and about 1 h. In one embodiment of the present invention, said settling time is between about 6 h and about 2 h. In yet another embodiment of the present invention, said settling time is about 4 h.
- said density of the particulate additives and particulate matter is higher than about 9 g/mL. In another embodiment of the present invention, said density of the particulate additives and particulate matter is from about 1 g/mL to about 9 g/mL. In yet another embodiment of the present invention, said density of the particulate additives and particulate matter is from about 1 g/mL to about 4 g/mL. In even yet another embodiment of the present invention, said density of the particulate additives and particulate matter is from about 2 g/mL to about 3.5 g/mL.
- said density of the base polymer solution is higher than about 0.8 g/mL. In another embodiment of the present invention, said density of the base polymer solution is from about 0.8 g/mL to about 3 g/mL. In yet another embodiment of the present invention, said density of the base polymer solution is from about 0.9 g/mL to about 2 g/mL. In even yet another embodiment of the present invention, said density of the base polymer solution is from about 1 g/mL to about 1.5 g/mL.
- said dynamic viscosity of the base polymer solution is higher than about 0.5 mPa-s. In another embodiment of the present invention, said dynamic viscosity of the base polymer solution is from about 0.6 mPa-s to about 100 mPa-s. In yet another embodiment of the present invention, said dynamic viscosity of the base polymer solution is from about 1 mPa-s to about 20 mPa-s. In even yet another embodiment of the present invention, said dynamic viscosity of the base polymer solution is from about 2 mPa-s to about 10 mPa-s.
- a method for separating and purifying polymers from a reclaimed product (rP) includes purifying said intermediate suspension with a solid medium at a temperature range and a pressure range sufficient to produce a final suspension; wherein a fraction of said particulate additives associated with said first dissolvable polymer is retained by said solid medium; and wherein said final suspension comprises a suspension of non- retained particulate additives associated with said first dissolvable polymer in said first dissolvable base polymer solution.
- a method for separating and purifying polymers from a reclaimed absorbent hygiene product includes purifying said intermediate suspension with a solid medium at a temperature range and a pressure range sufficient to produce a final suspension; wherein a fraction of said particulate additives associated with said first dissolvable polymer is retained by said solid medium; and wherein said final suspension comprises a suspension of non-retained particulate additives associated with said first dissolvable polymer in said first dissolvable base polymer solution.
- a method for separating and purifying polymers from a reclaimed film (rF) includes purifying said intermediate suspension with a solid medium at a temperature range and a pressure range sufficient to produce a final suspension; wherein a fraction of said particulate additives associated with said first dissolvable polymer is retained by said solid medium; and wherein said final suspension comprises a suspension of non-retained particulate additives associated with said first dissolvable polymer in said first dissolvable base polymer solution.
- a method for separating and purifying an ADH polymer from a reclaimed absorbent hygiene product includes purifying said intermediate suspension with a solid medium at a temperature range and a pressure range sufficient to produce a final suspension; wherein a fraction of said particulate additives associated with said ADH polymer is retained by said solid medium; and wherein said final suspension comprises a suspension of non-retained particulate additives associated with said ADH polymer in said ADH base polymer solution.
- a method for separating and purifying a PP polymer from a reclaimed absorbent hygiene product includes purifying said intermediate suspension with a solid medium at a temperature range and a pressure range sufficient to produce a final suspension; wherein a fraction of said particulate additives associated with said PP polymer is retained by said solid medium; and wherein said final suspension comprises a suspension of non-retained particulate additives associated with said PP polymer in said PP base polymer solution.
- the solid medium of the present invention is any solid material that retains a fraction of said particulate additives from the final suspension. Said solid medium can also retain a fraction of said particulate matter associated with said contaminants, and a fraction of said extractable materials in said rP that has not been removed in said extracting step.
- the solid medium removes said particulate additives and particulate matter by a variety of mechanisms.
- Non- limiting examples of possible mechanisms include adsorption, absorption, size exclusion, ion exclusion, ion exchange, and other mechanisms that may be apparent to those having ordinary skill in the art.
- the pigments and other materials commonly found in reclaimed products may be polar compounds and may preferentially interact with the solid medium, which may also be at least slightly polar. The polar-polar interactions are especially favorable when non-polar solvents, such as alkanes, are used as the dissolving step solvent.
- the solid medium is selected from the group consisting of inorganic substances, carbon-based substances, and mixtures thereof.
- inorganic substances are silicon oxide (silica), silica gel, aluminum oxide (alumina), iron oxide, aluminum silicate, magnesium silicate, amorphous volcanic glass, reclaimed glass, sand, quartz, diatomaceous earth, zeolite, perlite, clay, fuller's earth, bentonite clay, metal organic framework (MOF), covalent organic framework (COF), and zeolitic imidazolate framework (ZIF).
- Non-limiting examples of carbon-based substances are anthracite coal, carbon black, coke, and activated carbon.
- said inorganic substances are selected from the group consisting of silicon oxide (silica), silica gel, aluminum oxide (alumina), iron oxide, aluminum silicate, magnesium silicate, amorphous volcanic glass, reclaimed glass, sand, quartz, diatomaceous earth, zeolite, perlite, clay, fuller's earth, bentonite clay, metal organic framework (MOF), covalent organic framework (COF), zeolitic imidazolate framework (ZIF), and mixtures thereof.
- silicon oxide sica
- silica gel aluminum oxide
- alumina aluminum oxide
- iron oxide aluminum silicate
- magnesium silicate amorphous volcanic glass
- reclaimed glass reclaimed glass
- sand quartz
- diatomaceous earth zeolite
- perlite perlite
- clay fuller's earth
- bentonite clay bentonite clay
- MOF metal organic framework
- COF covalent organic framework
- ZIF zeolitic imidazolate framework
- said inorganic substances are selected from the group consisting of silicon oxide (silica), silica gel, aluminum oxide (alumina), amorphous volcanic glass, reclaimed glass, sand, quartz, diatomaceous earth, zeolite, clay, fuller's earth, bentonite clay, and mixtures thereof.
- said carbon-based substances are selected from the group consisting of anthracite coal, carbon black, coke, activated carbon, and mixtures thereof.
- the solid medium is recycled glass.
- the solid medium is contacted with said intermediate suspension in a vessel for a specified amount of time while the solid medium is agitated.
- the solid medium is removed from said final suspension via a solid-liquid separation step.
- solid-liquid separation steps include filtration, decantation, centrifugation, and settling.
- said intermediate suspension is passed through a stationary bed of solid medium.
- said solid medium is arranged in a fixed bed configuration. This fixed bed configuration includes an axial filter, a radial filter, or a combination of both.
- said fixed bed configuration comprises at least 2 fixed beds in series.
- the height or length of the fixed bed of said solid medium is greater than about 5 cm. In yet another embodiment of the present invention, the height or length of the fixed bed of said solid medium is greater than about 10 cm. In even yet another embodiment of the present invention, the height or length of the fixed bed of said solid medium is greater than about 20 cm. In one embodiment of the present invention, the diameter of the fixed bed of said solid medium is greater than about 1 cm. In another embodiment of the present invention, the diameter of the fixed bed of said solid medium is greater than about 2 cm. In yet another embodiment of the present invention, the diameter of the fixed bed of said solid medium is greater than about 5 cm. In one embodiment of the present invention, the length to diameter ratio of said fixed bed of said solid medium is greater than about 1.
- the length to diameter ratio of said fixed bed of said solid medium is greater than about 5. In yet another embodiment of the present invention, the length to diameter ratio of said fixed bed of said solid medium is greater than about 10. In even yet another embodiment of the present invention, the length to diameter ratio of said fixed bed of said solid medium is greater than about 20.
- the term “median solid medium particle size” refers to the diameter of a solid medium particle below or above which 50% of the total volume of particles lie, and is designated as D v 0 50 .
- the term “solid medium particle span” is a statistical representation of a given solid medium particle sample and can be calculated as follows. First, the median size is calculated as described above. Then, by a similar method, the solid medium particle size that separates the particle sample at the 10% by volume fraction, D v 0 10 , is determined, and then the solid medium particle size that separates the particle sample at the 90% by volume fraction, D v 0 90 , is determined.
- the solid medium particle span is then equal to: (D v 0 90 — D v 0 10 )/D v 0 50 .
- said solid medium particle span is less than about 2.
- said solid medium particle span is less than about 1.5.
- said solid medium particle span is less than about 1.5.
- said solid medium particle span is less than about 1.3.
- said solid medium particle span is between about 1.1 and about 2.
- said solid medium particle span is between about 1.3 and about 1.5.
- the solid medium is replaced, as needed, to maintain a desired composition of said final suspension.
- the solid medium is regenerated and re-used in the purifying step.
- the solid medium is regenerated by fluidizing the solid medium during a backwashing step.
- said purifying step is in continuous mode. In another embodiment of the present invention, said purifying step is in batch mode.
- a method for separating and purifying a PP polymer from an rAHP includes n-butane as the dissolving step solvent, and the temperature range in the purifying step is from about 90°C to about 220°C.
- a method for separating and purifying a PP polymer from an rAHP includes n-butane as the dissolving step solvent, and the temperature range in the purifying step is from about 100°C to about 200°C.
- a method for separating and purifying a PP polymer from an rAHP includes n-butane as the dissolving step solvent, and the temperature range in the purifying step is from about 130°C to about 180°C.
- a method for separating and purifying a PP polymer from an rAHP includes n-butane as the dissolving step solvent, and the pressure range in the purifying step is from about 350 psig (2.4 MPa) to about 4,000 (27.6 MPa).
- a method for separating and purifying a PP polymer from an rAHP includes n-butane as the dissolving step solvent, and the pressure range in the purifying step is from about 1,000 psig (6.9 MPa) to about 3,500 (24.1 MPa).
- a method for separating and purifying a PP polymer from an rAHP includes n- butane as the dissolving step solvent, and the pressure range in the purifying step is from about 2,000 psig (13.8 MPa) to about 3,000 (20.7 MPa).
- a method for separating and purifying a PP polymer from an rAHP is provided, wherein said temperature range in said purifying step is from about 90°C to about 220°C, and wherein said pressure range in said purifying step is from about 350 psig (2.4 MPa) to about 20,000 psig (137.9 MPa).
- a method for separating and purifying a PP polymer from an rAHP includes n-butane as the dissolving step solvent, and a weight concentration of said PP base polymer in said PP base polymer solution in said intermediate suspension of at least about 0.5%.
- a method for separating and purifying a PP polymer from an rAHP includes n-butane as the dissolving step solvent, and a weight concentration of said PP base polymer in said PP base polymer solution in said intermediate suspension of at least about 1%.
- a method for separating and purifying a PP polymer from an rAHP includes n-butane as the dissolving step solvent, and a weight concentration of said PP base polymer in said PP base polymer solution in said intermediate suspension of at least about 2%.
- a method for separating and purifying a PP polymer from an rAHP includes n-butane as the dissolving step solvent, and a weight concentration of said PP base polymer in said PP base polymer solution in said intermediate suspension of at least about 3%.
- a method for separating and purifying a PP polymer from an rAHP includes n- butane as the dissolving step solvent, and a weight concentration of said PP base polymer in said PP base polymer solution in said intermediate suspension of at least about 4%.
- a method for separating and purifying a PP polymer from an rAHP includes n-butane as the dissolving step solvent, and a weight concentration of said PP base polymer in said PP base polymer solution in said intermediate suspension of at least about 5%.
- a method for separating and purifying a PP polymer from an rAHP includes n-butane as the dissolving step solvent, and a weight concentration of said PP base polymer in said PP base polymer solution in said intermediate suspension up to about 20%.
- a method for separating and purifying a PP polymer from an rAHP includes n-butane as the dissolving step solvent, and a weight concentration of said PP base polymer in said PP base polymer solution in said intermediate suspension up to about 18%.
- a method for separating and purifying a PP polymer from an rAHP includes n-butane as the dissolving step solvent, and a weight concentration of said PP base polymer in said PP base polymer solution in said intermediate suspension up to about 16%.
- a method for separating and purifying a PP polymer from an rAHP includes n-butane as the dissolving step solvent, and a weight concentration of said PP base polymer in said PP base polymer solution in said intermediate suspension up to about 14%.
- a method for separating and purifying a PP polymer from an rAHP includes n- butane as the dissolving step solvent, and a weight concentration of said PP base polymer in said PP base polymer solution in said intermediate suspension up to about 12%.
- a method for separating and purifying a PP polymer from an rAHP includes propane as the dissolving step solvent, and the temperature range in the purifying step is from about 90°C to about 220°C.
- a method for separating and purifying a PP polymer from an rAHP includes propane as the dissolving step solvent, and the temperature range in the purifying step is from about 100°C to about 200°C.
- a method for separating and purifying a PP polymer from an rAHP includes propane as the dissolving step solvent, and the temperature range in the purifying step is from about 130°C to about 180°C.
- a method for separating and purifying a PP polymer from an rAHP includes propane as the dissolving step solvent, and the pressure range in the purifying step is from about 2,000 psig (13.8 MPa) to about 8,000 (55.2 MPa).
- a method for separating and purifying a PP polymer from an rAHP includes propane as the dissolving step solvent, and the pressure range in the purifying step is from about 3,000 psig (20.7 MPa) to about 6,000 (41.4 MPa).
- a method for separating and purifying a PP polymer from an rAHP includes propane as the dissolving step solvent, and the pressure range in the purifying step is from about 3,500 psig (24.1 MPa) to about 5,000 (34.5 MPa).
- a method for separating and purifying a PP polymer from an rAHP includes propane as the dissolving step solvent, and a weight concentration of said PP base polymer in said PP base polymer solution in said intermediate suspension of at least about 0.5%.
- a method for separating and purifying a PP polymer from an rAHP includes propane as the dissolving step solvent, and a weight concentration of said PP base polymer in said PP base polymer solution in said intermediate suspension of at least about 1%.
- a method for separating and purifying a PP polymer from an rAHP includes propane as the dissolving step solvent, and a weight concentration of said PP base polymer in said PP base polymer solution in said intermediate suspension of at least about 2%.
- a method for separating and purifying a PP polymer from an rAHP includes propane as the dissolving step solvent, and a weight concentration of said PP base polymer in said PP base polymer solution in said intermediate suspension of at least about 3%.
- a method for separating and purifying a PP polymer from an rAHP includes propane as the dissolving step solvent, and a weight concentration of said PP base polymer in said PP base polymer solution in said intermediate suspension of at least about 4%.
- a method for separating and purifying a PP polymer from an rAHP includes propane as the dissolving step solvent, and a weight concentration of said PP base polymer in said PP base polymer solution in said intermediate suspension of at least about 5%.
- a method for separating and purifying a PP polymer from an rAHP includes propane as the dissolving step solvent, and a weight concentration of said PP base polymer in said PP base polymer solution in said intermediate suspension up to about 20%.
- a method for separating and purifying a PP polymer from an rAHP includes propane as the dissolving step solvent, and a weight concentration of said PP base polymer in said PP base polymer solution in said intermediate suspension up to about 18%.
- a method for separating and purifying a PP polymer from an rAHP includes propane as the dissolving step solvent, and a weight concentration of said PP base polymer in said PP base polymer solution in said intermediate suspension up to about 16%.
- a method for separating and purifying a PP polymer from an rAHP includes propane as the dissolving step solvent, and a weight concentration of said PP base polymer in said PP base polymer solution in said intermediate suspension up to about 14%.
- a method for separating and purifying a PP polymer from an rAHP includes propane as the dissolving step solvent, and a weight concentration of said PP base polymer in said PP base polymer solution in said intermediate suspension up to about 12%.
- a method for separating and purifying polymers from a reclaimed product (rP) includes separating said dissolving step solvent from said final suspension at a temperature range and a pressure range sufficient to produce a separated and purified first dissolvable polymer; and wherein said separated and purified first dissolvable polymer comprises said first dissolvable base polymer and said particulate additives associated with said first dissolvable polymer dispersed in said separated and purified first dissolvable polymer at a concentration lower than said concentration of said particulate additives associated with said first dissolvable polymer in said first dissolvable polymer in said rP.
- a method for separating and purifying polymers from a reclaimed absorbent hygiene product includes separating said dissolving step solvent from said final suspension at a temperature range and a pressure range sufficient to produce a separated and purified first dissolvable polymer; and wherein said separated and purified first dissolvable polymer comprises said first dissolvable base polymer and said particulate additives associated with said first dissolvable polymer dispersed in said separated and purified first dissolvable polymer at a concentration lower than said concentration of said particulate additives associated with said first dissolvable polymer in said first dissolvable polymer in said rAHP.
- a method for separating and purifying polymers from a reclaimed film (rF) includes separating said dissolving step solvent from said final suspension at a temperature range and a pressure range sufficient to produce a separated and purified first dissolvable polymer; and wherein said separated and purified first dissolvable polymer comprises said first dissolvable base polymer and said particulate additives associated with said first dissolvable polymer dispersed in said separated and purified first dissolvable polymer at a concentration lower than said concentration of said particulate additives associated with said first dissolvable polymer in said first dissolvable polymer in said rF.
- a method for separating and purifying an ADH polymer from a reclaimed absorbent hygiene product includes separating said dissolving step solvent from said final suspension at a temperature range and a pressure range sufficient to produce a separated and purified ADH polymer; and wherein said separated and purified ADH polymer comprises said ADH base polymer and said particulate additives associated with said ADH polymer dispersed in said separated and purified ADH polymer at a concentration lower than said concentration of said particulate additives associated with said ADH polymer in said ADH polymer in said rAHP.
- a method for separating and purifying a PP polymer from a reclaimed absorbent hygiene product includes separating said dissolving step solvent from said final suspension at a temperature range and a pressure range sufficient to produce a separated and purified PP polymer; and wherein said separated and purified PP polymer comprises said first PP base polymer and said particulate additives associated with said PP polymer dispersed in said separated and purified PP polymer at a concentration lower than said concentration of said particulate additives associated with said PP polymer in said PP polymer in said rAHP.
- the separating step is at a temperature and at a pressure wherein the polymer precipitates from solution and is no longer dissolved in the dissolving step solvent.
- the separating step is accomplished by reducing the pressure at a fixed temperature.
- the separating step is accomplished by reducing the temperature at a fixed pressure.
- the separating step is accomplished by increasing the temperature at a fixed pressure.
- the separating step is accomplished by reducing both the temperature and pressure.
- the dissolving step solvent can be partially or completely converted from the liquid to the vapor phase by controlling the temperature and pressure.
- the precipitated polymer is separated from the dissolving step solvent without completely converting the dissolving step solvent into a 100% vapor phase by controlling the temperature and pressure of the dissolving step solvent during the separating step.
- the separating of the precipitated polymer is accomplished by any method of liquid-liquid or liquid-solid separation. Non-limiting examples of liquid-liquid or liquid-solid separations include filtration, decantation, centrifugation, and settling.
- a method for separating and purifying a PP polymer from an rAHP includes n-butane as the dissolving step solvent and the temperature range in the separating step is from about 0°C to about 220°C.
- a method for separating and purifying a PP polymer from an rAHP includes n-butane as the dissolving step solvent and the temperature range in the separating step is from about 100°C to about 220°C.
- a method for separating and purifying a PP polymer from an rAHP includes n-butane as the dissolving step solvent and the temperature range in the separating step is from about 130°C to about 180°C.
- a method for separating and purifying a PP polymer from an rAHP includes n-butane as the dissolving step solvent and the pressure range in the separating step is from about 0 psig (0 MPa) to about 2,000 psig (13.8 MPa).
- a method for separating and purifying a PP polymer from an rAHP includes n-butane as the dissolving step solvent and the pressure range in the separating step is from about 50 (0.34 MPa) to about 1,500 psig (10.3 MPa).
- a method for separating and purifying a PP polymer from an rAHP includes n- butane as the dissolving step solvent and the pressure range in the separating step is from about 75 psig (0.52 MPa) to about 1,000 psig (6.9 MPa).
- a method for separating and purifying a PP polymer from an rAHP includes propane as the dissolving step solvent and the temperature range in the separating step is from about - 42°C to about 220°C.
- a method for separating and purifying a PP polymer from an rAHP includes propane as the dissolving step solvent and the temperature range in the separating step is from about 0°C to about 150°C.
- a method for separating and purifying a PP polymer from an rAHP includes propane as the dissolving step solvent and the temperature range in the separating step is from about 50°C to about 130°C.
- a method for separating and purifying a PP polymer from an rAHP includes propane as the dissolving step solvent and the pressure range in the separating step is from about 0 psig (0 MPa) to about 6,000 psig (41.4 MPa).
- a method for separating and purifying a PP polymer from an rAHP includes propane as the dissolving step solvent and the pressure range in the separating step is from about 50 (0.34 MPa) to about 3,000 psig (20.7 MPa).
- a method for separating and purifying a PP polymer from an rAHP includes propane as the dissolving step solvent and the pressure range in the separating step is from about 75 psig (0.52 MPa) to about 1,000 psig (6.9 MPa).
- a method for separating and purifying a PP polymer from an rAHP wherein said temperature range in said separating step is from about 0°C to about 220°C, and wherein said pressure range is from about 0 psig (0 MPa) to about 2,000 psig (13.8 MPa).
- the separated and purified polymer that is produced from the separating step comprises the base polymer and the particulate additives associated with the polymer dispersed in the separated and purified polymer at a concentration lower than the concentration of the particulate additives associated with the polymer dispersed in the base polymer in the rP.
- the separated and purified polymer that is produced from the separating step comprises the base polymer and the particulate additives associated with the polymer dispersed in the separated and purified polymer at a concentration lower than the concentration of the particulate additives associated with the polymer dispersed in the base polymer in the rAHP.
- the separated and purified polymer that is produced from the separating step comprises the base polymer and the particulate additives associated with the polymer dispersed in the separated and purified polymer at a concentration lower than the concentration of the particulate additives associated with the polymer dispersed in the base polymer in the rF.
- the concentration of the particulate additives associated with each dissolvable polymer dispersed in the dissolvable base polymer in the separated and purified dissolvable polymer is lower than the concentration of the particulate additives associated with the polymer dispersed in the base polymer in the rAHP. In another embodiment of the present invention, the concentration of said particulate additives associated with each dissolvable polymer dispersed in said each dissolvable base polymer in said separated and purified dissolvable polymer is less than about 3 wt%.
- the concentration of said particulate additives associated with each dissolvable polymer dispersed in said each dissolvable base polymer in said separated and purified dissolvable polymer is less than about 1 wt%. In even yet another embodiment of the present invention, the concentration of said particulate additives associated with each dissolvable polymer dispersed in said each dissolvable base polymer in said separated and purified dissolvable polymer is less than about 0.1 wt%. In one embodiment of the present invention, said each dissolvable polymer is essentially free of said particulate additives associated with each dissolvable base polymer in said separated and purified dissolvable polymer.
- said separating step is in batch mode. In another embodiment of the present invention, said separating step is in continuous mode.
- the dissolving step solvent which is separated in the separating step can be recycled back into the dissolving step, either as is or after purification, using methods well known to those skilled in the art.
- a method for separating and purifying polymers from a reclaimed product includes repeating the extracting step, dissolving step, settling step, purifying step, and separating step with each collection of settled particulate additives and said domains of all remaining polymers from the previous repeat of steps b through f to produce separated and purified dissolvable polymers via extracting, dissolving, settling, purifying, and separating said dissolvable base polymers singularly and in sequence, proceeding from said second dissolvable polymer through the additional dissolvable polymers, the sequence proceeding from the dissolvable base polymer with the lowest solubilization range to the highest solubilization range until each individual dissolvable polymer from said rP is produced in its separated and purified form and a final collection of settled particulate additives and said domains of all non-dissolvable base polymers is produced.
- a method for separating and purifying polymers from a reclaimed absorbent hygiene product includes repeating the extracting step, dissolving step, settling step, purifying step, and separating step with each collection of settled particulate additives and said domains of all remaining polymers from the previous repeat of steps b through f to produce separated and purified dissolvable polymers via extracting, dissolving, settling, purifying, and separating said dissolvable base polymers singularly and in sequence, proceeding from said second dissolvable polymer through the additional dissolvable polymers, the sequence proceeding from the dissolvable base polymer with the lowest solubilization range to the highest solubilization range until each individual dissolvable polymer from said rAHP is produced in its separated and purified form and a final collection of settled particulate additives and said domains of all non-dissolvable base polymers is produced.
- a method for separating and purifying polymers from a reclaimed film includes repeating the extracting step, dissolving step, settling step, purifying step, and separating step with each dissolving step collection of settled particulate additives and said domains of all remaining polymers from the previous repeat of the steps to produce separated and purified dissolvable polymers via extracting, dissolving, settling, purifying, and separating said dissolvable base polymers singularly and in sequence, proceeding from said second dissolvable polymer through the additional dissolvable polymers, the sequence proceeding from the dissolvable base polymer with the lowest solubilization range to the highest solubilization range until each individual dissolvable polymer from said rF is produced in its separated and purified form and a final collection of settled particulate additives and said domains of all non-dissolvable base polymers is produced.
- a method for separating and purifying ADH, TPE, PP, PE, PET, cellulose, and PAA polymers from a reclaimed absorbent hygiene product includes repeating the extracting step, dissolving step, settling step, purifying step, and separating step with each dissolving step collection of settled particulate additives and domains of TPE, PP, PE, PET, cellulose, and PAA polymers from the previous repeat of the steps to produce separated and purified dissolvable polymers via extracting, dissolving, settling, purifying, and separating said TPE, PP, PE, and PET base polymers singularly and in sequence, proceeding from said TPE base polymer to said PP base polymer, then to said PE base polymer, and finally to said PET base polymer until a separated and purified TEP polymer is produced, a separated and purified PP polymer is produced, a separated and purified PE polymer is produced, a separated and purified PET polymer is produced, and a
- said final collection of domains comprises cellulose and PAA polymers. In another embodiment of the present invention, said final collection of domains is separated into said PAA polymer and said cellulose polymer. One of the purposes for separating the PAA polymer and the cellulose polymer is to reuse them in future AHP. In one embodiment of the present invention, said PAA polymer separated from said final collection of domains comprises water at a level exceeding 30 g water / g PAA polymer. In another embodiment of the present invention, said PAA polymer is further dehydrated to less than 1 g water / g PAA polymer via a dehydration process.
- Non-limiting examples of dehydration processes are contacting the PAA polymer with a salt solution, an acidic solution, a basic solution, and a solvent that forms an azeotrope with water; pressurization; and centrifugation.
- said dehydration process is selected from the group consisting of contacting said PAA polymer with a salt solution, an acidic solution, a basic solution, and a solvent that forms an azeotrope with water; pressurization; centrifugation; and mixtures thereof.
- Non-limiting examples of solvents that form an azeotrope with water are methanol, ethanol, n-propanol, isopropyl alcohol, n-butanol, isobutanol, and 2-butanol.
- said solvent is an alcohol selected from the group consisting of methanol, ethanol, n-propanol, isopropyl alcohol, n-butanol, isobutanol, 2-butanol, and mixtures thereof.
- said dehydrated PAA polymer is used to produce a new AHP.
- said PAA polymer is subjected to de-polymerization to produce monomeric acrylic acid (AA) or oligomeric acrylic acid (OAA).
- said AA or OAA is further polymerized to virgin PAA polymer and used to produce a new AHP.
- de-polymerization of PAA polymers are de-polymerization in the presence of dissolved CO2, de- polymerization using ultrasonics and solar irradiation, thermal degradation, and mechano- chemistry (e.g. applying mechanical forces to achieve de-polymerization).
- FIG. 1 is schematic of a process that follows the (a) obtaining step, (b) extracting step, (c) dissolving step, (d) settling step, (e) purifying step, (f) separating step, and the repeating of steps (b) through (f). Reducing the Size Step
- a method for separating and purifying polymers from a reclaimed product comprising said polymers and contaminants; wherein said polymer comprises a base polymer, particulate additives associated with said polymer, and extractable materials associated with said polymer; wherein said particulate additives associated with each polymer are dispersed in said base polymer at a concentration; wherein said polymer is selected from the group consisting of a dissolvable polymer, a non- dissolvable polymer, and mixtures thereof; wherein said contaminants comprise particulate matter associated with said contaminants and extractable materials associated with said contaminants; wherein said extractable materials in said rP comprise said extractable materials associated with said polymers and said extractable materials associated with said contaminants; and wherein said extractable materials in said rP are at a concentration in said rP.
- Said method comprises: (a) obtaining said rP; wherein said rP is selected from the group consisting of post-consumer use products, post-industrial use products, and combinations thereof; (b) reducing the size of said rP to particles with a largest dimension of less than about 10 mm; (c) solids separating each polymer of said rP in a polymer stream, and processing each polymer stream comprising a dissolvable polymer separately in a process comprising: (1) extracting said polymer stream comprising said dissolvable polymer with an extraction solvent at a temperature greater than about 100°C and at a pressure greater than about 150 psig (1 MPa); wherein said extraction solvent has a standard boiling point less than about 70°C; whereby an extracted polymer is produced; and wherein said extractable materials have a concentration in said extracted polymer which is lower than said concentration of said extractable materials in said rP; (2) dissolving said dissolvable polymer by contacting said extracted polymer with a dissolving step solvent at a temperature range
- the reducing the size step can be implemented in a variety of pieces of equipment, as it is well known to those skilled in the art.
- pieces of equipment for this step are shredders, crushers, grinders, pulverizers, choppers, shear slitters, etc.
- said particles have a largest dimension of less than about 50 mm. In another embodiment of the present invention, said particles have a largest dimension of less than about 25 mm. In yet another embodiment of the present invention, said particles have a largest dimension of less than about 10 mm. In even yet another embodiment of the present invention, said particles have a largest dimension of less than about 5 mm. In one embodiment of the present invention, said particles have a largest dimension of less than about 1 mm.
- said solids separating step comprises separating said rP particles into said polymers with a gravimetric technique.
- said gravimetric technique comprises a series of float / sink tanks each filled with a liquid that has a density between the densities of the polymers that are fed into the tank and separated at the exit of the tank. For example, to separate PP from PET, a stream containing PP and PET particles is fed into a tank containing water (with density of 1 g/mL), where PP, with density of about 0.905 g/mL, will float and PET, with density of about 1.38 g/mL, will sink.
- a stream containing PP and PE particles is fed into a tank containing 40 wt% isopropyl alcohol in water (with density 0.926 g/mL), where PP, with density of about 0.905 g/mL, will float and PE, with density of about 0.95 g/mL, will sink.
- said solids separating step comprises separating said rP particles into said polymers with an optical technique.
- FIG. 2 is schematic of a process that follows the (a) obtaining step, (b) reducing size step, (c) solids separating step, (1) extracting step, (2) dissolving step, (3) settling step, (4) purifying step, and (5) separating step for each polymer stream that comprises a dissolvable polymer.
- test methods described herein are used to measure the effectiveness of various methods for purifying polymers. Specifically, the methods described demonstrate the effectiveness of a given purification method at improving color and translucency/clarity (i.e. making the color and opacity of the reclaimed polymer closer to that of an uncolored virgin polymer), reducing or eliminating elemental contamination (i.e. removing heavy metals), reducing or eliminating non- combustible contamination (i.e. inorganic fillers), reducing or eliminating volatile compounds (especially volatile compounds that contribute to the malodor of reclaimed products), and reducing or eliminating polymeric contamination (e.g. polyethylene contamination in polypropylene).
- elemental contamination i.e. removing heavy metals
- non- combustible contamination i.e. inorganic fillers
- volatile compounds especially volatile compounds that contribute to the malodor of reclaimed products
- polymeric contamination e.g. polyethylene contamination in polypropylene
- the color and opacity/translucency of a polymer are important parameters that determine whether or not a polymer can achieve the desired visual aesthetics of an article manufactured from the polymer.
- reclaimed polypropylene especially post-consumer derived reclaimed polypropylene, is typically dark in color and opaque due to residual pigments, fillers, and other contamination.
- color and opacity measurements are important parameters in determining the effectiveness of a method for purifying polymers.
- samples of either polymeric powders or pellets Prior to color measurement, samples of either polymeric powders or pellets are compression molded into 30 mm wide x 30 mm long x 1 mm thick square test specimens (with rounded corners). Powder samples are first densified at room temperature (ca. 20 - 23°C) by cold pressing the powder into a sheet using clean, un-used aluminum foil as a contact-release layer between stainless steel platens.
- the flash around the sample on at least one side is peeled to the mold edge and then the sample is pushed through the form.
- Each test specimen is visually evaluated for voids / bubble defects and only samples with no defects in the color measurement area (0.7" (17.78 mm) diameter minimum) are used for color measurement.
- the color of each sample is characterized using the International Commission on Illumination (CIE) L* a* b* three dimensional color space.
- the dimension a* is a measure of the red or green color of a sample with positive values of a* corresponding with a red color and negative values of a* corresponding with a green color.
- the dimension b* is a measure of the blue or yellow color of a sample with positive values of b* corresponding with a blue color and negative values of b* corresponding with a yellow color.
- the L*a*b* values of each 30 mm wide x 30 mm long x 1 mm thick square test specimen sample are measured on a HunterLab model LabScan XE spectrophotometer (Hunter Associates Laboratory, Inc., Reston, VA 20190-5280, USA).
- the spectrophotometer is configured with D65 as the standard illuminant, an observer angle of 10°, an area diameter view of 1.75" (44.45 mm), and a port diameter of 0.7" (17.78 mm).
- the opacity of each sample which is a measure of how much light passes through the sample (i.e. a measure of the sample's translucency), is determined using the aforementioned HunterLab spectrophotometer using the contrast ratio opacity mode. Two measurements are made to determine the opacity of each sample. One to measure the brightness value of the sample backed with a white backing, YwhiteBacking, and one to measure the brightness value of the sample backed with a black backing, YBiackBacking. The opacity is then calculated from the brightness values using the following Equation 3:
- the samples are digested using an Ultrawave Microwave Digestion protocol consisting of a 20 min ramp to 125°C, a 10 min ramp to 250°C, and a 20 min hold at 250°C.
- Digested samples are cooled to room temperature.
- the digested samples are diluted to 50 mL after adding 0.25 mL of 100 ppm Ge and Rh as the internal standard.
- pre-digestion spikes are prepared by spiking virgin polymer. Virgin polymer spiked samples are weighed out using the same procedure mentioned above and spiked with the appropriate amount of each single element standard of interest, which included the following: Na, Al, Ca, Ti, Cr, Fe, Ni, Cu, Zn, Cd, and Pb.
- Spikes are prepared at two different levels: a "low level spike” and a "high level spike”. Each spike is prepared in triplicate. In addition to spiking virgin polymer, a blank is also spiked to verify that no errors occurred during pipetting and to track recovery through the process. The blank spiked samples are also prepared in triplicate at the two different levels and are treated in the same way as the spiked virgin polymer and the test samples.
- a 9 point calibration curve is made by making 0.05, 0.1, 0.5, 1, 5, 10, 50, 100, and 500 ppb solutions containing Na, Al, Ca, Ti, Cr, Fe, Ni, Cu, Zn, Cd, and Pb.
- the monitored m/z for each analyte and the collision cell gas that as used for analysis is as follows: Na, 23 m/z, 3 ⁇ 4; Al, 27 m/z, 3 ⁇ 4; Ca, 40 m/z, 3 ⁇ 4; Ti, 48 m/z, 3 ⁇ 4; Cr, 52 m/z, He; Fe, 56 m/z, 3 ⁇ 4; Ni, 60 m/z; no gas; Cu, 65 m/z, no gas; Zn, 64 m/z, He; Cd, 112 m/z; H 2 ; Pb, sum of 206 > 206, 207 > 207, 208 > 208 m/z, no gas; Ge, 72 m/z, all modes; Rh, 103 m/z, all modes. Ge is used as an internal standard for all elements ⁇ 103 m/z and Rh is used for all elements > 103 m/z.
- TGA Thermogravimetric analysis
- polymeric contamination for example polyethylene contamination in polypropylene
- polypropylene may influence the physical properties of the polymer due to the presence of heterogeneous phases and the resulting weak interfaces.
- the polymeric contamination may also increase the opacity of the polymer and have an influence on the color.
- measuring the amount of polymeric contamination is important when determining the effectiveness of a method for purifying polymers.
- DSC Differential Scanning Calorimetry
- each sample is sealed in an aluminum DSC pan and analyzed on a TA Instruments model Q2000 DSC with the following method: Equilibrate at 30.00°C; Ramp 20.00°C/min to 200.00°C; Mark end of cycle 0; Ramp 20.00°C/min to 30.00°C; Mark end of cycle 1; Ramp 20.00°C/min to 200.00°C; Mark end of cycle 2; Ramp 20.00°C/min to 30.00°C; Mark end of cycle 3; Ramp 5.00°C/min to 200.00°C; and Mark end of cycle 4.
- the enthalpy of melting for the HDPE peak around 128°C is calculated for each sample of known HDPE content using the 5.00°C/min DSC thermogram.
- a linear calibration curve is established via plotting enthalpy of melting versus known HDPE concentration (wt%).
- Samples, having unknown PE content, are analyzed using the same aforementioned DSC equipment and method.
- PE content is calculated using the aforementioned calibration curve.
- the specific HDPE used to generate the calibration curve will more than likely have a different degree of crystallinity than the polyethylene (or polyethylene blend) contamination that may be present in a reclaimed polypropylene sample.
- the degree of crystallinity may independently influence the measured enthalpy of melting for polyethylene and thus influence the resulting calculation of polyethylene content.
- the DSC test method described herein is meant to serve as a relative metric to compare the effectiveness of different methods to purify polymers and is not meant to be a rigorous quantification of the polyethylene content in a polymer blend.
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JP2019530489A JP6853360B2 (en) | 2016-12-20 | 2017-12-13 | How to separate and purify polymers from recycled products |
RU2019113691A RU2723639C1 (en) | 2016-12-20 | 2017-12-13 | Method of separating polymers from regenerated product and cleaning thereof |
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