WO2020188567A1 - Matériau polymère obtenu à partir de déchets - Google Patents

Matériau polymère obtenu à partir de déchets Download PDF

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Publication number
WO2020188567A1
WO2020188567A1 PCT/IL2020/050322 IL2020050322W WO2020188567A1 WO 2020188567 A1 WO2020188567 A1 WO 2020188567A1 IL 2020050322 W IL2020050322 W IL 2020050322W WO 2020188567 A1 WO2020188567 A1 WO 2020188567A1
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WO
WIPO (PCT)
Prior art keywords
weight percents
feedstock
polymeric material
weight
polypropylene
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PCT/IL2020/050322
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English (en)
Inventor
Yuval Tamir
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Infimer Technologies Ltd.
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Publication date
Application filed by Infimer Technologies Ltd. filed Critical Infimer Technologies Ltd.
Publication of WO2020188567A1 publication Critical patent/WO2020188567A1/fr

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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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B09—DISPOSAL OF SOLID WASTE; RECLAMATION OF CONTAMINATED SOIL
    • B09B—DISPOSAL OF SOLID WASTE NOT OTHERWISE PROVIDED FOR
    • B09B3/00—Destroying solid waste or transforming solid waste into something useful or harmless
    • B09B3/40—Destroying solid waste or transforming solid waste into something useful or harmless involving thermal treatment, e.g. evaporation
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B17/00—Recovery of plastics or other constituents of waste material containing plastics
    • B29B17/0026—Recovery of plastics or other constituents of waste material containing plastics by agglomeration or compacting
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L23/00—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers
    • C08L23/02—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers not modified by chemical after-treatment
    • C08L23/10—Homopolymers or copolymers of propene
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B17/00—Recovery of plastics or other constituents of waste material containing plastics
    • B29B17/04—Disintegrating plastics, e.g. by milling
    • B29B17/0412—Disintegrating plastics, e.g. by milling to large particles, e.g. beads, granules, flakes, slices
    • 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
    • C08J2323/00—Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers
    • C08J2323/02—Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers not modified by chemical after treatment
    • C08J2323/04—Homopolymers or copolymers of ethene
    • C08J2323/06—Polyethene
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L2205/00—Polymer mixtures characterised by other features
    • C08L2205/03—Polymer mixtures characterised by other features containing three or more polymers in a blend
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L2207/00—Properties characterising the ingredient of the composition
    • C08L2207/20—Recycled plastic
    • 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 in some embodiments thereof, relates to materials science and, more particularly, but not exclusively, to materials produced using waste material.
  • Blending of different polymeric materials may result in suboptimal properties due to incompatibilities between the polymeric materials.
  • many combinations of polymers are immiscible when blended, and such immiscibility typically results in coarse, unstable phase morphologies, in the absence of additives which increase the stability of the immiscible blend by lowering interfacial tension.
  • Polypropylene is the second most widely produced commodity plastic, after polyethylene, and is often used in packaging materials.
  • Polyolefin elastomers such as ethylene- 1 -butene copolymer and ethylene- 1-octene copolymer have been used to enhance impact strength of polypropylene.
  • International Patent Application Publication No. WO 2015/173806 describes a method of processing waste material so as to form a non-particulate processed material, by removing at least a portion of inorganic materials in the waste material, to thereby obtain a sorted material containing at least 90 weight percents of an organic material; providing a feedstock having a water content of at least 15 weight percents, wherein at least 50 weight percents of the dry weight of the feedstock is the sorted material; and subjecting the feedstock to mixing via shear forces and to heating.
  • International Patent Application Publication No. WO 2015/173806 further describes separating materials in waste material according to specific gravity, by contacting the waste material with a liquid selected such that at least a portion of the waste material sinks.
  • Additional background art includes International Patent Applications having Publication Nos. WO 2005/077630, WO 2005/092708, WO 2006/035441, WO 2006/079842 and WO 2010/082202; European Patent No. 1711323; U.S. Patent Nos. 3,850,771, 4,013,616, 4,772,430, 4,968,463, 5,217,655, 6,017,475, 6,253,527, 6,423,254 and 7,497,335; and U.S. Patent Applications having Publication No. 2004/0080072. SUMMARY OF THE INVENTION
  • a polymeric material comprising:
  • a concentration of the processed material in the polymeric material is at least 70 weight percents, and a concentration of the polyolefinic elastomer in the polymeric material is at least 1 weight percent.
  • a polypropylene-containing material comprising polypropylene and a polymeric material according to any of the respective embodiments described herein, wherein a concentration of polypropylene in the polypropylene-containing material is at least 40 weight percents.
  • an article-of-manufacturing comprising a polypropylene-containing material according to any of the respective embodiments described herein.
  • a process for preparing a polymeric material comprising:
  • a feedstock having a water content of at least 13 weight percents wherein at least 40 weight percents of the dry weight of the feedstock is waste material, at least 90 weight percents of the dry weight of the waste material being organic material, and at least 20 weight percents of the dry weight of the feedstock is polyethylene;
  • a polymeric material obtainable by a process according to any of the respective embodiments described herein.
  • At least 94 weight percents of the dry weight of the feedstock is organic material. According some of any of the embodiments of the invention, at least 90 weight percents of the dry weight of the feedstock is the waste material.
  • At least 30 weight percents of the dry weight of the feedstock is polyethylene.
  • At least 20 weight percents of the dry weight of the feedstock is low-density polyethylene (LDPE).
  • LDPE low-density polyethylene
  • the polyolefinic elastomer comprises a copolymer of ethylene and at least one additional alkene.
  • the polyolefinic elastomer is selected from the group consisting of ethylene propylene rubber (EPR), ethylene propylene diene methylene rubber (EPDM), ethylene butene copolymer, ethylene octene copolymer, butyl rubber, and copolymers thereof.
  • EPR ethylene propylene rubber
  • EPDM ethylene propylene diene methylene rubber
  • ethylene butene copolymer ethylene butene copolymer
  • ethylene octene copolymer ethylene octene copolymer
  • butyl rubber and copolymers thereof.
  • a concentration of the polyolefinic elastomer in the polymeric material is in a range of from 5 to 20 weight percents.
  • a concentration of the processed material in the polymeric material is at least 80 weight percents.
  • the polymeric material comprises water at a concentration in a range of from 0.03 to 1 weight percent.
  • the polymeric material comprises a water soluble salt at a concentration of at least 0.2 weight percent.
  • the polymeric material comprises sodium chloride at a concentration of at least 0.2 weight percent.
  • the polymeric material comprises salt in crystalline form.
  • the polymeric material has a density in a range of from 1.19 to 1.29 grams/cm 3 .
  • the polymeric material exhibits a plurality of melting points, the plurality of melting points being at temperatures of about 109 °C, about 126 °C, and/or about 163 °C.
  • concentration of the polymeric material is at least 10 weight percents.
  • the polypropylene-containing material has a notched Izod impact strength which is at least 10 % greater than a notched Izod impact strength of a corresponding material without the polymeric material.
  • the polypropylene-containing material has a notched Izod impact strength which is at least 10 % greater than a weighted average of the notched Izod impact strength of a corresponding material without the polymeric material and the notched Izod impact strength of the polymeric material.
  • the polypropylene-containing material has a notched Izod impact strength which is greater than each of the notched Izod impact strength of a corresponding material without the polymeric material and the notched Izod impact strength of the polymeric material.
  • the polypropylene-containing material has a notched Izod impact strength which is at least 80 J/m.
  • the polypropylene-containing material has a notched Izod impact strength which is at least 120 J/m.
  • the polypropylene-containing material has a density in a range of from 0.95 to 1.05 grams/cm 3 .
  • the article-of-manufacturing is selected from the group consisting of an animal bed, an animal house and/or transporter, a baby seat, a basket, a bench, a bin, a bookcase, a box, a bureau, a cabinet, a cage, a cart, a case, a chair, a chest, a composter, a cooler, a container, a drawer, a dresser, a footstool, a frame, a garden bed, a grill, a hamper, an ironing board, a minibar, an organizer, an ottoman, outdoor furniture, a pail, a picnic box, a pot, a playhouse, a pouf, a shed, a shelf, a sofa, a stool, a sun bed, a table, a toilet brush, a toolbox, a toy, a tub, and a wheelbarrow.
  • the process comprises contacting the polyolefinic elastomer with the feedstock prior to subjecting the feedstock to mixing via shear forces and to heating. According some of any of the embodiments of the invention relating to a process, the process comprises subjecting the feedstock to mixing via shear forces and to heating prior to subjecting the feedstock and the polyolefinic elastomer concomitantly to mixing via shear forces and to heating.
  • the process further comprises adding water to the feedstock and the polyolefinic elastomer during mixing via shear forces and heating.
  • the heating is effected at a temperature in a range of from 90 °C to 230 °C.
  • the process further comprises removing at least a portion of inorganic materials in a waste material, to thereby obtain waste material containing at least 90 weight percents of an organic material by dry weight.
  • removing at least a portion of inorganic materials comprises contacting the waste material with an aqueous liquid in which a portion of inorganic materials sink.
  • the aqueous liquid comprises an aqueous salt solution.
  • a concentration of salt in the solution is at least 15 weight percents.
  • the polymeric material is a polymeric material according to any of the respective embodiments described herein.
  • FIG. 1 presents an infrared absorption spectrum of two (duplicate) samples of exemplary polymeric materials.
  • FIGs. 2A-2E present photographic images of waste material from which at least a portion of inorganic materials have been removed (FIG. 2A), and exemplary polymeric material prepared by one (FIG. 2B), two (FIG. 2C) or three (FIG. 2D) passes through a single screw type-extruder, or by one pass through a twin screw-type extruder (FIG. 2E).
  • the present invention in some embodiments thereof, relates to materials science and, more particularly, but not exclusively, to materials produced using waste material.
  • the present inventor has uncovered that processed materials obtained by heating and mixing a feedstock comprising waste material (e.g., as described in International Patent Application Publication No. WO 2015/173806) can be efficiently utilized in providing improved performance when combined with other materials, such as, for example polypropylene.
  • a processed waster material as mentioned hereinabove is modified by combining therewith a moderate amount of a polyolefinic elastomer, it can be readily combined with polypropylene while retaining or even enhancing desirable properties of polypropylene.
  • exemplary polymeric materials prepared from waste material and modified by addition of a polyolefinic elastomer interact in a synergistic manner with polypropylene, resulting in enhanced impact strength.
  • Such a product may advantageously exhibit the low cost of using waste material as a prime ingredient and/or be highly compatible for specific uses involving polypropylene.
  • Embodiments of the present invention therefore relate to modified polymeric material obtained upon processing waste material, to processes of preparing same, to uses thereof in manufacturing articles in combination with polypropylene, and to articles-of-manufacturing.
  • a polymeric material comprising: a) a processed material prepared from a feedstock comprising waste material, according to any of the respective embodiments described herein; and b) a polyolefinic elastomer (POE) according to any of the respective embodiments described herein.
  • the processed material is prepared by subjecting a feedstock (and optionally also the polyolefinic elastomer) to mixing via shear forces and to heating, for example, according to any of the embodiments described herein relating to such processing.
  • polymeric material refers to a composition-of-matter comprising at least one polymer, and is not intended to be further limiting.
  • the polymeric material according to any of the embodiments described herein may optionally, but not necessarily, be a composite material.
  • Feedstock and waste material are fedstock and waste material:
  • feedstock refers to a material subjected to processing (material that is processed) according to any of the respective embodiments described herein (e.g., by heating and/or mixing).
  • the feedstock may comprise waste material according to any of the embodiments described herein, optionally combined (e.g., mixed) with one or more additional materials, as described herein.
  • the polyolefinic elastomer according to any of the respective embodiments described herein is considered to be distinct from the feedstock and processed material derived from the feedstock (e.g., when defining a weight or weight percentage of the feedstock and/or processed material), although the polyolefinic elastomer may optionally be thoroughly mixed with the components of the feedstock and/or otherwise physically incorporated into the feedstock and/or processed material derived therefrom.
  • waste material refers to substantially solid waste, and encompasses municipal solid waste, which, in some embodiments, is obtained mostly from domestic sources, and is also referred to as“trash” or“garbage”, as well as other sources of domestic waste (e.g., domestic waste selected for recycling, such as plastic bottles and/or other plastic items).
  • the waste material may include some waste from non-domestic sources, such as sludge (e.g., sewage sludge), industrial waste (e.g., discarded packaging material, waste originating from the paper industry) and/or agricultural waste.
  • the waste material may optionally be in the form it is received at a solid waste management facility or at a waste dump or from a landfill (referred to as“unsorted” waste material), or alternatively, waste material which has undergone sorting, that is, waste material (e.g., from the aforementioned sources) from which one or more components (e.g., magnetic materials, and/or readily recyclable items) are selectively removed (partially or entirely).
  • waste material e.g., from the aforementioned sources
  • one or more components e.g., magnetic materials, and/or readily recyclable items
  • the waste material may optionally be sorted, for example, by a sorting process according to any of the respective embodiments described herein relating to sorting waste material, and/or by any other suitable sorting process known in the art.
  • Refuse-derived fuel (referred to herein interchangeably as“RDF”) is a non-limiting example of sorted waste material known in the art, which may be utilized in embodiments of the invention.
  • “refuse-derived fuel” refers to waste material with a relatively high concentration of combustible components (e.g., plastics other than PVC, rubber, and/or paper products), obtainable by removing at least a portion of non-combustible components (e.g., inorganic materials and/or PVC) and components with low calorific value (e.g., components with a relatively high moisture content and/or low mass) from waste material such as municipal solid waste and/or industrial waste. Recyclable combustible materials (e.g., recyclable plastics) may optionally also be removed.
  • combustible components e.g., plastics other than PVC, rubber, and/or paper products
  • the waste material may optionally be derived from a single source and/or type of waste material, or alternatively, may comprise material derived from a plurality of sources and/or types of waste material.
  • the feedstock comprising waste material preferably comprises a substantial amount of water, e.g., the waste material in the feedstock is not dry.
  • the feedstock (prior to mixing and heating) has a water content of at least 10 weight percents, for example, from 10 to 70 weight percents. In some embodiments, the feedstock has a water content of at least 13 weight percents, for example, from 13 to 70 weight percents. In some embodiments, the feedstock has a water content of at least 15 weight percents, for example, from 15 to 70 weight percents. In some embodiments, the feedstock has a water content of at least 20 weight percents, for example, from 20 to 70 weight percents. In some of any of the respective embodiments described herein, the feedstock (prior to mixing and heating) has a water content of from 10 to 30 weight percents.
  • the feedstock has a water content of from 13 to 30 weight percents. In some embodiments, the feedstock has a water content of from 15 to 30 weight percents. In some embodiments, the feedstock has a water content of from 20 to 30 weight percents.
  • the feedstock (prior to mixing and heating) has a water content of from 30 to 70 weight percents. In some embodiments, the feedstock has a water content of from 40 to 70 weight percents. In some embodiments, the feedstock has a water content of from 50 to 70 weight percents. In some embodiments, the feedstock has a water content of from 60 to 70 weight percents.
  • the origin of water in the feedstock may optionally be the water content of a waste material, and/or water added to the waste material, for example, an aqueous liquid used for sorting waste material according to specific gravity (e.g., according to any of the respective embodiments described herein).
  • water is added to the waste material, and the feedstock has a water content which is higher than that of a waste material from which it is derived.
  • At least 40 weight percents of the dry weight of the feedstock is waste material, for example, from 40 to 99.9 weight percents, including any intermediate values and subranges therebetween.
  • at least 50 weight percents of the dry weight of the feedstock is waste material.
  • at least 60 weight percents of the dry weight of the feedstock is waste material.
  • at least 70 weight percents of the dry weight of the feedstock is waste material.
  • at least 80 weight percents of the dry weight of the feedstock is waste material.
  • at least 90 weight percents of the dry weight of the feedstock is waste material.
  • at least 95 weight percents of the dry weight of the feedstock is waste material.
  • at least 98 weight percents of the dry weight of the feedstock is waste material.
  • At least 80 weight percents of the dry weight of the waste material is organic material, for example, from 80 to 99.99 weight percents, including any intermediate values and subranges therebetween. In some embodiments, at least 85 weight percents of the dry weight of the waste material is organic material. In some embodiments, at least 90 weight percents of the dry weight of the waste material is organic material. In some embodiments, at least 92 weight percents of the dry weight of the waste material is organic material. In some embodiments, at least 94 weight percents of the dry weight of the waste material is organic material. In some embodiments, at least 96 weight percents of the dry weight of the waste material is organic material.
  • At least 98 weight percents of the dry weight of the waste material is organic material. In some embodiments, at least 99 weight percents of the dry weight of the waste material is organic material. In some embodiments, at least 99.5 weight percents of the dry weight of the waste material is organic material. In some embodiments, at least 99.8 weight percents of the dry weight of the waste material is organic material. In some embodiments, about 99.9 weight percents of the dry weight of the waste material is organic material.
  • organic material refers to compounds comprising at least one carbon atom bound to at least one hydrogen atom, optionally comprising one or more heteroatoms (of one or more species of heteroatom).
  • the organic material may comprise plant-derived or animal- derived material (e.g., lignocellulose, food), as defined herein, and/or synthetic material (e.g., synthetic polymers).
  • organic material encompasses all compounds which are not organic compounds as defined herein.
  • Examples of prominent organic materials which may optionally be present in the waste material include, without limitation, polyethylene - including, but not limited to, low-density polyethylene (LDPE), polypropylene, additional synthetic polymers, and lignocellulose. Such components may optionally also be added to the feedstock independently of the waste material.
  • LDPE low-density polyethylene
  • polypropylene polypropylene
  • additional synthetic polymers polymers
  • lignocellulose lignocellulose
  • the proportion of organic material in the feedstock may optionally be somewhat different than the proportion of organic material in the waste material in the feedstock.
  • the proportion of organic material in the feedstock may optionally be lowered by inclusion of organic material which is not waste material in the feedstock, and/or increased by inclusion of inorganic material which is not waste material in the feedstock (e.g., a salt according to any of the respective embodiments described herein).
  • At least 80 weight percents of the dry weight of the feedstock is organic material, for example, from 80 to 99.9 weight percents, including any intermediate values and subranges therebetween. In some embodiments, at least 85 weight percents of the dry weight of the feedstock is organic material. In some embodiments, at least 90 weight percents of the dry weight of the feedstock is organic material. In some embodiments, at least 92 weight percents of the dry weight of the feedstock is organic material. In some embodiments, at least 94 weight percents of the dry weight of the feedstock is organic material. In some embodiments, at least 96 weight percents of the dry weight of the feedstock is organic material.
  • At least 98 weight percents of the dry weight of the feedstock is organic material. In some embodiments, at least 99 weight percents of the dry weight of the feedstock is organic material. In some embodiments, at least 99.5 weight percents of the dry weight of the feedstock is organic material. In some embodiments, at least 99.8 weight percents of the dry weight of the feedstock is organic material.
  • At least 20 weight percents of the dry weight of the feedstock is polyethylene. In some such embodiments, at least 20 weight percents of the dry weight of the feedstock is low-density polyethylene (LDPE).
  • LDPE low-density polyethylene
  • At least 25 weight percents of the dry weight of the feedstock is polyethylene. In some such embodiments, at least 20 weight percents of the dry weight of the feedstock is LDPE. In some such embodiments, at least 25 weight percents of the dry weight of the feedstock is LDPE.
  • At least 30 weight percents of the dry weight of the feedstock is polyethylene. In some such embodiments, at least 20 weight percents of the dry weight of the feedstock is LDPE. In some such embodiments, at least 25 weight percents of the dry weight of the feedstock is LDPE. In some such embodiments, at least 30 weight percents of the dry weight of the feedstock is LDPE.
  • At least 35 weight percents of the dry weight of the feedstock is polyethylene. In some such embodiments, at least 20 weight percents of the dry weight of the feedstock is LDPE. In some such embodiments, at least 25 weight percents of the dry weight of the feedstock is LDPE. In some such embodiments, at least 30 weight percents of the dry weight of the feedstock is LDPE. In some such embodiments, at least 35 weight percents of the dry weight of the feedstock is LDPE.
  • At least 40 weight percents of the dry weight of the feedstock is polyethylene. In some such embodiments, at least 20 weight percents of the dry weight of the feedstock is LDPE. In some such embodiments, at least 25 weight percents of the dry weight of the feedstock is LDPE. In some such embodiments, at least 30 weight percents of the dry weight of the feedstock is LDPE. In some such embodiments, at least 35 weight percents of the dry weight of the feedstock is LDPE. In some such embodiments, at least 40 weight percents of the dry weight of the feedstock is LDPE.
  • At least 50 weight percents of the dry weight of the feedstock is polyethylene. In some such embodiments, at least 20 weight percents of the dry weight of the feedstock is LDPE. In some such embodiments, at least 25 weight percents of the dry weight of the feedstock is LDPE. In some such embodiments, at least 30 weight percents of the dry weight of the feedstock is LDPE. In some such embodiments, at least 35 weight percents of the dry weight of the feedstock is LDPE. In some such embodiments, at least 40 weight percents of the dry weight of the feedstock is LDPE.
  • At least 60 weight percents of the dry weight of the feedstock is polyethylene. In some such embodiments, at least 20 weight percents of the dry weight of the feedstock is LDPE. In some such embodiments, at least 25 weight percents of the dry weight of the feedstock is LDPE. In some such embodiments, at least 30 weight percents of the dry weight of the feedstock is LDPE. In some such embodiments, at least 35 weight percents of the dry weight of the feedstock is LDPE. In some such embodiments, at least 40 weight percents of the dry weight of the feedstock is LDPE.
  • the terms“low-density polyethylene” and“LDPE” refer to polyethylene having a density of no more than 0.940 grams/cm 3 .
  • no more than 80 weight percents (e.g., from 30 to 80 weight percents) of the dry weight of the feedstock is polyethylene. In some such embodiments, no more than 70 weight percents of the dry weight of the feedstock is polyethylene. In some embodiments, no more than 60 weight percents of the dry weight of the feedstock is polyethylene. In some such embodiments, no more than 50 weight percents of the dry weight of the feedstock is polyethylene. In some such embodiments, no more than 40 weight percents of the dry weight of the feedstock is polyethylene.
  • no more than 70 weight percents (e.g., from 20 to 70 weight percents) of the dry weight of the feedstock is LDPE. In some such embodiments, no more than 60 weight percents of the dry weight of the feedstock is LDPE. In some embodiments, no more than 50 weight percents of the dry weight of the feedstock is LDPE. In some embodiments, no more than 40 weight percents of the dry weight of the feedstock is LDPE. In some embodiments, no more than 30 weight percents of the dry weight of the feedstock is LDPE.
  • Polyethylene in the feedstock may be a component of a waste material, material added to a waste material (e.g., a waste material having a low concentration of polyethylene, or both, for example, a polyethylene-rich waste material (e.g., plastic collected for recycling) may be added to a waste material having a low concentration of polyethylene in order to obtain a desired polyethylene concentration (according to any of the respective embodiments described herein).
  • a polyethylene-rich waste material e.g., plastic collected for recycling
  • at least 10 weight percents (e.g., from 10 to 40 weight percents, including any intermediate values and subranges therebetween) of the feedstock is polypropylene.
  • At least 20 weight percents of the dry weight of the feedstock is polyethylene, according to any of the respective embodiments described herein. In some such embodiments, at least 25 weight percents of the dry weight of the feedstock is polyethylene, according to any of the respective embodiments described herein. In some such embodiments, at least 30 weight percents of the dry weight of the feedstock is polyethylene, according to any of the respective embodiments described herein. In some such embodiments, at least 35 weight percents of the dry weight of the feedstock is polyethylene, according to any of the respective embodiments described herein. In some such embodiments, at least 40 weight percents of the dry weight of the feedstock is polyethylene, according to any of the respective embodiments described herein.
  • At least 50 weight percents of the dry weight of the feedstock is polyethylene, according to any of the respective embodiments described herein. In some such embodiments, at least 60 weight percents of the dry weight of the feedstock is polyethylene, according to any of the respective embodiments described herein.
  • At least 20 weight percents (e.g., from 20 to 40 weight percents, including any intermediate values and subranges therebetween) of the feedstock is polypropylene.
  • at least 20 weight percents of the dry weight of the feedstock is polyethylene, according to any of the respective embodiments described herein.
  • at least 25 weight percents of the dry weight of the feedstock is polyethylene, according to any of the respective embodiments described herein.
  • at least 30 weight percents of the dry weight of the feedstock is polyethylene, according to any of the respective embodiments described herein.
  • At least 35 weight percents of the dry weight of the feedstock is polyethylene, according to any of the respective embodiments described herein. In some such embodiments, at least 40 weight percents of the dry weight of the feedstock is polyethylene, according to any of the respective embodiments described herein. In some such embodiments, at least 50 weight percents of the dry weight of the feedstock is polyethylene, according to any of the respective embodiments described herein. In some such embodiments, at least 60 weight percents of the dry weight of the feedstock is polyethylene, according to any of the respective embodiments described herein.
  • At least 30 weight percents (e.g., from 30 to 40 weight percents, including any intermediate values and subranges therebetween) of the feedstock is polypropylene.
  • at least 20 weight percents of the dry weight of the feedstock is polyethylene, according to any of the respective embodiments described herein.
  • at least 25 weight percents of the dry weight of the feedstock is polyethylene, according to any of the respective embodiments described herein.
  • at least 30 weight percents of the dry weight of the feedstock is polyethylene, according to any of the respective embodiments described herein.
  • At least 35 weight percents of the dry weight of the feedstock is polyethylene, according to any of the respective embodiments described herein. In some such embodiments, at least 40 weight percents of the dry weight of the feedstock is polyethylene, according to any of the respective embodiments described herein. In some such embodiments, at least 50 weight percents of the dry weight of the feedstock is polyethylene, according to any of the respective embodiments described herein. In some such embodiments, at least 60 weight percents of the dry weight of the feedstock is polyethylene, according to any of the respective embodiments described herein.
  • At least 40 weight percents of the feedstock is polypropylene. In some such embodiments, at least 20 weight percents of the dry weight of the feedstock is polyethylene, according to any of the respective embodiments described herein. In some such embodiments, at least 25 weight percents of the dry weight of the feedstock is polyethylene, according to any of the respective embodiments described herein. In some such embodiments, at least 30 weight percents of the dry weight of the feedstock is polyethylene, according to any of the respective embodiments described herein. In some such embodiments, at least 35 weight percents of the dry weight of the feedstock is polyethylene, according to any of the respective embodiments described herein.
  • At least 40 weight percents of the dry weight of the feedstock is polyethylene, according to any of the respective embodiments described herein. In some such embodiments, at least 50 weight percents of the dry weight of the feedstock is polyethylene, according to any of the respective embodiments described herein.
  • no more than 60 weight percents (e.g., from 10 to 60 weight percents) of the dry weight of the feedstock is polypropylene. In some such embodiments, no more than 50 weight percents of the dry weight of the feedstock is polypropylene. In some embodiments, no more than 40 weight percents of the dry weight of the feedstock is polypropylene. In some such embodiments, no more than 30 weight percents of the dry weight of the feedstock is polypropylene. In some such embodiments, no more than 20 weight percents of the dry weight of the feedstock is polypropylene.
  • the feedstock may optionally comprise additional synthetic polymers (other than polyethylene and polypropylene), which may be components of the waste material in the feedstock and/or synthetic polymers added to the waste material (e.g., an additional material described herein).
  • synthetic polymers refers to polymers other than those found in plant or animal material (e.g., lignin, carbohydrates, polypeptides) or polymers formed from heating and mixing plant or animal material as described herein (e.g., products of hydrolysis, caramelization and/or pyrolysis of carbohydrates, polypeptides, etc.).
  • synthetic polymers include, without limitation, polyolefins, polystyrene, polyvinylchloride, polyethylene terephthalate, polyacrylonitrile, polybutadiene, polystyrene, polycarbonate, polyesters (e.g., rayon), and nylon.
  • Polymers formed by chemical reactions of a natural polymer for example, cellulose which has been chemically treated (e.g., by carbon disulfide) and regenerated to form rayon, are considered herein to be synthetic polymers.
  • a natural polymer for example, cellulose which has been chemically treated (e.g., by carbon disulfide) and regenerated to form rayon.
  • the skilled person will be aware of additional synthetic polymers which may be found in waste material, and which consequently may be included in the feedstock described herein.
  • animal material refers to material which originates from an animal
  • plant material refers to material which originates from a plant or fungus. It is noted that coal and petroleum products and the like, which originate from organisms which lived only in the distant past, are not considered herein as animal or plant material.
  • At least 50 weight percents (e.g., from 50 to 99 weight percents, including any intermediate values and subranges therebetween) of the synthetic polymers in the feedstock is polyolefins (including any polyethylene and polypropylene in the feedstock, but excluding POE which is not part of the feedstock as defined herein).
  • at least 60 weight percents of the synthetic polymers is polyolefins.
  • at least 70 weight percents of the synthetic polymers is polyolefins.
  • at least 80 weight percents of the synthetic polymers is polyolefins.
  • at least 90 weight percents of the synthetic polymers is polyolefins.
  • thermoplastic polymers will comprise a substantial portion of the synthetic polymers in the sorted material and feedstock, due to the relatively low specific gravity of many thermoplastic polymers, including, but not limited to thermoplastic polyolefins (e.g., polyethylene, polypropylene, polymethylpentene, polybutene- 1).
  • the feedstock may optionally further comprise thermoplastic polymers added to the sorted material.
  • thermoplastic polymers, particularly thermoplastic synthetic polymers undergo softening and/or melting upon mixing and heating as described herein, which allows for a more homogeneous processed material.
  • thermoplastic synthetic polymers may optionally enhance the thermoplasticity of the processed material (e.g., a polymeric material described herein), and/or allow for recycling of the synthetic polymer.
  • At least 50 weight percents (e.g., from 50 to 99 weight percents, including any intermediate values and subranges therebetween) of the synthetic polymers in the feedstock is thermoplastic. In some embodiments, at least 60 weight percents of the synthetic polymers is thermoplastic. In some embodiments, at least 70 weight percents of the synthetic polymers is thermoplastic. In some embodiments, at least 80 weight percents of the synthetic polymers is thermoplastic. In some embodiments, at least 90 weight percents of the synthetic polymers is thermoplastic. In some embodiments, at least 95 weight percents of the synthetic polymers is thermoplastic.
  • At least 30 weight percents of the dry weight of the feedstock comprise or consist of synthetic polymers (including any polyethylene and polypropylene in the feedstock, but excluding POE which is not part of the feedstock as defined herein).
  • from 30 to 90 weight percents, including any intermediate values and subranges therebetween, of the dry weight comprise or consist of synthetic polymers.
  • from 30 to 80 weight percents, including any intermediate values and subranges therebetween, of the dry weight comprise or consist of synthetic polymers.
  • from 30 to 70 weight percents, including any intermediate values and subranges therebetween, of the dry weight comprise or consist of synthetic polymers.
  • weight percents of the dry weight comprise or consist of synthetic polymers.
  • weight percents of the dry weight comprise or consist of synthetic polymers.
  • weight percents of the dry weight comprise or consist of synthetic polymers.
  • weight percents of the dry weight comprise or consist of synthetic polymers.
  • from 30 to 40 weight percents of the dry weight comprise or consist of synthetic polymers.
  • at least 50 weight percents, or at least 60 weight percents, or at least 70 weight percents, or at least 80 weight percents, or at least 90 weight percents of the synthetic polymers is polyolefins, optionally up to 99 weight percents polyolefins.
  • At least 40 weight percents of the dry weight of the feedstock comprise or consist of synthetic polymers (including any polyethylene and polypropylene in the feedstock, but excluding POE which is not part of the feedstock as defined herein).
  • from 40 to 90 weight percents, including any intermediate values and subranges therebetween, of the dry weight comprise or consist of synthetic polymers.
  • from 40 to 80 weight percents, including any intermediate values and subranges therebetween of the dry weight comprise or consist of synthetic polymers.
  • from 40 to 70 weight percents, including any intermediate values and subranges therebetween, of the dry weight comprise or consist of synthetic polymers.
  • from 40 to 60 weight percents, including any intermediate values and subranges therebetween, of the dry weight comprise or consist of synthetic polymers.
  • from 40 to 50 weight percents of the dry weight comprise or consist of synthetic polymers.
  • at least 50 weight percents, or at least 60 weight percents, or at least 70 weight percents, or at least 80 weight percents, or at least 90 weight percents of the synthetic polymers is polyolefins, optionally up to 99 weight percents polyolefins.
  • At least 50 weight percents of the dry weight of the feedstock comprise or consist of synthetic polymers (including any polyethylene and polypropylene in the feedstock, but excluding POE which is not part of the feedstock as defined herein).
  • from 50 to 90 weight percents, including any intermediate values and subranges therebetween, of the dry weight comprise or consist of synthetic polymers.
  • from 50 to 80 weight percents, including any intermediate values and subranges therebetween, of the dry weight comprise or consist of synthetic polymers.
  • from 50 to 70 weight percents, including any intermediate values and subranges therebetween, of the dry weight comprise or consist of synthetic polymers.
  • from 50 to 60 weight percents of the dry weight comprise or consist of synthetic polymers.
  • at least 50 weight percents, or at least 60 weight percents, or at least 70 weight percents, or at least 80 weight percents, or at least 90 weight percents of the synthetic polymers is polyolefins, optionally up to 99 weight percents polyolefins.
  • At least 60 weight percents of the dry weight of the feedstock comprise or consist of synthetic polymers (including any polyethylene and polypropylene in the feedstock, but excluding POE which is not part of the feedstock as defined herein).
  • from 60 to 90 weight percents, including any intermediate values and subranges therebetween, of the dry weight comprise or consist of synthetic polymers.
  • from 60 to 80 weight percents, including any intermediate values and subranges therebetween, of the dry weight comprise or consist of synthetic polymers.
  • from 60 to 70 weight percents of the dry weight comprise or consist of synthetic polymers.
  • At least 50 weight percents, or at least 60 weight percents, or at least 70 weight percents, or at least 80 weight percents, or at least 90 weight percents of the synthetic polymers is polyolefins, optionally up to 99 weight percents polyolefins.
  • At least 70 weight percents of the dry weight of the feedstock comprise or consist of synthetic polymers (including any polyethylene and polypropylene in the feedstock, but excluding POE which is not part of the feedstock as defined herein).
  • from 70 to 90 weight percents, including any intermediate values and subranges therebetween, of the dry weight comprise or consist of synthetic polymers.
  • from 70 to 80 weight percents of the dry weight comprise or consist of synthetic polymers.
  • At least 50 weight percents, or at least 60 weight percents, or at least 70 weight percents, or at least 80 weight percents, or at least 90 weight percents of the synthetic polymers is polyolefins, optionally up to 99 weight percents polyolefins.
  • a total concentration of thermoset polymers and synthetic polymers having a melting point of at least 250 °C (e.g., PET, PTFE) in the feedstock is no more than 10 weight percents (dry weight). In some such embodiments, the total concentration of thermoset polymers and synthetic polymers having a melting point of at least 250 °C in the feedstock is no more than 5 weight percents (dry weight). In some such embodiments, the total concentration of thermoset polymers and synthetic polymers having a melting point of at least 250 °C in the feedstock is no more than 2 weight percents (dry weight). In some such embodiments, the total concentration of thermoset polymers and synthetic polymers having a melting point of at least 250 °C in the feedstock is no more than 1 weight percent (dry weight).
  • thermoset refers to a synthetic polymer that has been irreversibly cured by any technique, including curing by heating, by chemical reaction (e.g., as in epoxies) or irradiation.
  • thermoset polymers include, without limitation, thermoset polyesters (e.g., as used in fiberglass), polyurethanes, vulcanized rubbers, phenol-formaldehydes (e.g., Bakelite® polymer), Duroplast, urea-formaldehydes (e.g., as used in plywood), melamine resins, epoxy resins, polyimides, cyanate esters and polycyanurates.
  • a concentration of PVC (polyvinyl chloride) in the feedstock is no more than 10 weight percents (dry weight). In some such embodiments, the concentration of PVC in the feedstock is no more than 5 weight percents (dry weight). In some such embodiments, the concentration of PVC is no more than 2 weight percents (dry weight). In some such embodiments, the concentration of PVC in the feedstock is no more than 1 weight percent (dry weight).
  • a total concentration of PVC, thermoset polymers and synthetic polymers having a melting point of at least 250 °C in the feedstock is no more than 10 weight percents (dry weight). In some such embodiments, the total concentration of PVC, thermoset polymers and synthetic polymers having a melting point of at least 250 °C in the feedstock is no more than 5 weight percents (dry weight). In some such embodiments, the total concentration of PVC, thermoset polymers and synthetic polymers having a melting point of at least 250 °C in the feedstock is no more than 2 weight percents (dry weight). In some such embodiments, the total concentration of PVC, thermoset polymers and synthetic polymers having a melting point of at least 250 °C in the feedstock is no more than 1 weight percent (dry weight).
  • thermoset polymers and/or synthetic polymers having a melting point of at least 250 °C e.g., PET, PTFE
  • a melting point of at least 250 °C e.g., PET, PTFE
  • At least 10 weight percents of the dry weight of the feedstock is lignocellulose. In some embodiments, from 10 to 60 weight percents of the dry weight is lignocellulose. In some embodiments, from 10 to 50 weight percents of the dry weight is lignocellulose. In some embodiments, from 10 to 40 weight percents of the dry weight is lignocellulose. In some embodiments, from 10 to 30 weight percents of the dry weight is lignocellulose. In some embodiments, from 10 to 20 weight percents of the dry weight is lignocellulose.
  • At least 40 weight percents (e.g., from 40 to 99 weight percents, including any intermediate values and subranges therebetween) of the lignocellulose is carbohydrates. In some embodiments, at least 60 weight percents of the lignocellulose is carbohydrates. In some embodiments, at least 80 weight percents of the lignocellulose is carbohydrates. In some embodiments, at least 90 weight percents of the lignocellulose is carbohydrate.
  • lignocellulose refers to dry matter derived from plants, which is composed primarily of carbohydrates (primarily cellulose and hemicelluloses) and lignin.
  • an amount of lignocellulose described herein may be considered a total amount of dry matter derived from plants, regardless of the proportions of, e.g., carbohydrates and lignin.
  • the proportion of carbohydrates in the lignocellulose may optionally be enhanced by limiting an amount of lignin-rich material in the waste material being processed, for example, by using waste material with no more than a limited amount of wood (e.g., tree trimmings, lumberyard waste).
  • At least 20 weight percents of the dry weight of the feedstock is lignocellulose. In some embodiments, from 20 to 60 weight percents, including any intermediate values and subranges therebetween of the dry weight is lignocellulose. In some embodiments, from 20 to 50 weight percents, including any intermediate values and subranges therebetween, of the dry weight is lignocellulose. In some embodiments, from 20 to 40 weight percents, including any intermediate values and subranges therebetween, of the dry weight is lignocellulose. In some embodiments, from 20 to 30 weight percents of the dry weight is lignocellulose.
  • At least 40 weight percents (e.g., from 40 to 99 weight percents, including any intermediate values and subranges therebetween) of the lignocellulose is carbohydrates. In some embodiments, at least 60 weight percents of the lignocellulose is carbohydrates. In some embodiments, at least 80 weight percents of the lignocellulose is carbohydrates. In some embodiments, at least 90 weight percents of the lignocellulose is carbohydrate.
  • At least 30 weight percents of the dry weight of the feedstock is lignocellulose. In some embodiments, from 30 to 60 weight percents, including any intermediate values and subranges therebetween, of the dry weight is lignocellulose. In some embodiments, from 30 to 50 weight percents, including any intermediate values and subranges therebetween, of the dry weight is lignocellulose. In some embodiments, from 30 to 40 weight percents of the dry weight is lignocellulose. In some of any of the aforementioned embodiments, at least 40 weight percents (e.g., from 40 to 99 weight percents, including any intermediate values and subranges therebetween) of the lignocellulose is carbohydrates.
  • At least 60 weight percents of the lignocellulose is carbohydrates. In some embodiments, at least 80 weight percents of the lignocellulose is carbohydrates. In some embodiments, at least 90 weight percents of the lignocellulose is carbohydrate.
  • At least 40 weight percents of the dry weight of the feedstock is lignocellulose. In some embodiments, from 40 to 60 weight percents, including any intermediate values and subranges therebetween of the dry weight is lignocellulose. In some embodiments, from 40 to 50 weight percents of the dry weight is lignocellulose. In some of any of the aforementioned embodiments, at least 40 weight percents (e.g., from 40 to 99 weight percents, including any intermediate values and subranges therebetween) of the lignocellulose is carbohydrates. In some embodiments, at least 60 weight percents of the lignocellulose is carbohydrates. In some embodiments, at least 80 weight percents of the lignocellulose is carbohydrates. In some embodiments, at least 90 weight percents of the lignocellulose is carbohydrate.
  • At least 50 weight percents of the dry weight of the feedstock is lignocellulose. In some embodiments, from 50 to 60 weight percents of the dry weight is lignocellulose. In some of any of the aforementioned embodiments, at least 40 weight percents (e.g., from 40 to 99 weight percents, including any intermediate values and subranges therebetween) of the lignocellulose is carbohydrates. In some embodiments, at least 60 weight percents of the lignocellulose is carbohydrates. In some embodiments, at least 80 weight percents of the lignocellulose is carbohydrates. In some embodiments, at least 90 weight percents of the lignocellulose is carbohydrate.
  • the waste material may optionally further comprises animal material and/or plant material (as defined herein), optionally derived from waste such as sewage (e.g., in the form of sewage sludge), agricultural waste (e.g., sorted agricultural waste), food industry waste, gardening byproducts and/or carpentry byproducts, and/or paper waste (e.g., as collected part of a recycling program).
  • animal material which may be present include, without limitation, fecal material (e.g., sewage solids, manure), corpses, animal organs, feathers, hair (e.g., wool), meat, animal fat, dairy products, egg shells, and bones.
  • plant material examples include, without limitation, hay, grass clippings, cuttings, trimmings, inedible portions of crops, leaves, sawdust, wood chips, leaves bark, fruit, vegetables, grains, vegetable oil, textiles (e.g., cotton, linen, hemp, jute) and paper products (e.g., paper, cardboard).
  • a waste material (and/or an amount thereof) included in the feedstock, and an additional material (and/or an amount thereof) included in the feedstock are selected so as to be complementary, for example, wherein an expected composition of the aforementioned waste material is expected to differ from a desired composition of the feedstock (e.g., according to any of the embodiments described herein pertaining to a composition of the feedstock).
  • the additional material may comprise another waste material (e.g., from a different source, and/or of a different type), or be a material which is not a waste material (e.g., a commercially available polymer).
  • the waste material comprises a relatively high percentage of plant and/or animal material (e.g., in a form of agricultural waste, trimmings, cuttings, leaves, cardboard, sewage sludge and the like), and consequently has less synthetic polymer (e.g., polyolefin) than desired in the feedstock (e.g., in accordance with a feedstock composition described herein), and the additional material is selected to comprise a synthetic polymer (e.g., in a form of a polymer-rich waste material and/or a commercial synthetic polymer), to thereby obtain the desired feedstock composition (e.g., while also facilitating recycling of the aforementioned waste material).
  • synthetic polymer e.g., polyolefin
  • the additional material is selected to comprise a synthetic polymer (e.g., in a form of a polymer-rich waste material and/or a commercial synthetic polymer), to thereby obtain the desired feedstock composition (e.g., while also facilitating recycling of the aforementioned waste material).
  • an additional material a material consisting primarily (e.g., more than 50 weight percents) of water, for example, water or an aqueous solution, is added to the waste material to form a feedstock, for example, to increase a water content of the feedstock.
  • polyolefinic elastomer and “POE”, used herein interchangeably, refer to an elastomer (i.e., elastic polymer) composed primarily of simple olefins, that is, at least 50 % (by molar ratio) of the monomers incorporated into the polymer are simple olefins.
  • the elasticity of the POE is such that a Young’s modulus of the POE is no more than 100 MPa, or no more than 500 MPa, or even no more than 250 MPa.
  • concise olefin refers to an unsubstituted hydrocarbon having a single unsaturated carbon-carbon double bond.
  • incorporation of such a hydrocarbon into a polymer entails replacement of the unsaturated bond with saturated bonds to two adjacent monomers, such that the residue of a simple olefin (as defined herein) in a polymer will be a saturated hydrocarbon moiety.
  • Suitable simple olefins include, without limitation, ethylene, propylene, butene (e.g., 1-butene), isobutylene, and octene (e.g., 1-octene).
  • the POE is a copolymer (optionally a random copolymer) of one or more monomers, at least portion of which are simple olefins (representing at least 50 % of the total proportion of monomers, according to the definition of“POE” herein).
  • the POE is optionally a copolymer of ethylene and at least one additional alkene (e.g., having 3-10 carbon atoms, or 3-4 carbon atoms), for example, a simple olefin, a substituted alkene comprising one unsaturated bond, and/or a substituted or unsubstituted alkene comprising more than one unsaturated bond (e.g., isoprene, ethylidene norbomene, vinyl norbornene, dicyclopentadiene).
  • additional alkene e.g., having 3-10 carbon atoms, or 3-4 carbon atoms
  • POE copolymers comprising ethylene include ethylene propylene rubber (EPR), ethylene propylene diene rubber (EPDM), ethylene butene copolymer, ethylene octene copolymer, and copolymers thereof.
  • EPR ethylene propylene rubber
  • EPDM ethylene propylene diene rubber
  • ethylene butene copolymer ethylene butene copolymer
  • ethylene octene copolymer ethylene octene copolymer
  • Butyl rubber (a copolymer of isobutylene and a smaller amount of isoprene) is a non limiting example of a POE copolymer which is not based on ethylene.
  • polyolefinic elastomers typically, the elasticity of polyolefinic elastomers is associated with the relative absence of either large side chains or crystallinity.
  • Crystallinity comprises an arrangement of polymer molecules tightly bound in a relatively orderly arrangement.
  • the tight binding of the polymer molecules in a crystalline arrangement prevents polymer molecules from passing over each other.
  • Irregular positioning of side chains e.g., by random polymerization of two monomers
  • a POE molecule e.g., a copolymer of ethylene
  • the POE may optionally be combined (e.g., using conventional compounding techniques) with a processed material derived from a feedstock (according to any of the respective embodiments described herein) subsequently to processing of the feedstock, so as to obtain a polymeric material according to any of the respective embodiments described herein.
  • the POE (according to any of the respective embodiments described herein) may optionally be combined with a feedstock (according to any of the respective embodiments described herein) prior to processing of the feedstock (such that the POE is subjected to the same processing conditions as is the feedstock), to obtain a polymeric material described herein.
  • determination of a concentration of POE and/or processed material (i.e., material derived from processing of a feedstock as defined herein) in the obtained polymeric material may optionally assume that the amount of POE does not change during processing, and that any changes in weight during processing reflect a difference between the weight of a feedstock and a weight of a processed material derived from feedstock (e.g., due to loss of water during processing).
  • a concentration of POE (according to any of the respective embodiments described herein) in the polymeric material is at least 0.5 weight percent, for example, from 0.5 to 30 weight percents, or from 0.5 to 20 weight percents. In some embodiments, a concentration of the POE in the polymeric material is at least 1 weight percent, for example, from 1 to 30 weight percents, or from 1 to 20 weight percents. In some embodiments, a concentration of the POE in the polymeric material is at least 2 weight percents, for example, from 2 to 30 weight percents, or from 2 to 20 weight percents.
  • a concentration of the POE in the polymeric material is at least 3 weight percents, for example, from 3 to 30 weight percents, or from 3 to 20 weight percents. In some embodiments, a concentration of the POE in the polymeric material is at least 4 weight percents, for example, from 4 to 30 weight percents, or from 4 to 20 weight percents. In some embodiments, a concentration of the POE in the polymeric material is at least 5 weight percents, for example, from 5 to 30 weight percents, or from 5 to 20 weight percents. In some embodiments, a concentration of the POE in the polymeric material is at least 6 weight percents, for example, from 6 to 30 weight percents, or from 6 to 20 weight percents.
  • a concentration of the POE in the polymeric material is at least 8 weight percents, for example, from 8 to 30 weight percents, or from 8 to 20 weight percents. In some embodiments, a concentration of the POE in the polymeric material is at least 10 weight percents, for example, from 10 to 30 weight percents, or from 10 to 20 weight percents. In some embodiments, a concentration of the POE in the polymeric material is at least 12 weight percents, for example, from 12 to 30 weight percents, or from 12 to 20 weight percents. In some embodiments, a concentration of the POE in the polymeric material is at least 14 weight percents, for example, from 14 to 30 weight percents, or from 14 to 20 weight percents.
  • a concentration of POE in the polymeric material is about 10 weight percents or about 15 weight percents.
  • a concentration of processed material (according to any of the respective embodiments described herein) in the polymeric material is at least 70 weight percents, optionally in a range of from 70 to 99 weight percents, including any intermediate values and subranges therebetween. In some embodiments, the concentration of processed material in the polymeric material is at least 75 weight percents. In some embodiments, the concentration of processed material in the polymeric material is at least 80 weight percents. In some embodiments, the concentration of processed material in the polymeric material is at least 85 weight percents. In some embodiments, the concentration of processed material in the polymeric material is at least 90 weight percents. In some embodiments, the concentration of processed material in the polymeric material is at least 95 weight percents.
  • Additional ingredients may optionally added to the processed material and POE according to any of the respective embodiments described herein.
  • suitable additional ingredients include, without limitation, stabilizers (e.g., antioxidants and/or absorbers of UV light), fillers (e.g., starch, cellulose, wood flour, and/or minerals such as calcium carbonate (e.g., chalk), talc, and zinc oxide), plasticizers (e.g., non-volatile oily compounds), desiccants (e.g., calcium oxide, silica gel and/or zeolite) and colorants.
  • stabilizers e.g., antioxidants and/or absorbers of UV light
  • fillers e.g., starch, cellulose, wood flour, and/or minerals such as calcium carbonate (e.g., chalk), talc, and zinc oxide
  • plasticizers e.g., non-volatile oily compounds
  • desiccants e.g., calcium oxide, silica gel and/or zeolite
  • a total concentration of POE and processed material (according to any of the respective embodiments described herein) in the polymeric material is at least 90 weight percents. In some embodiments, the total concentration of POE and processed material in the polymeric material is at least 95 weight percents. In some embodiments, the total concentration of POE and processed material in the polymeric material is at least 98 weight percents. In some embodiments, the total concentration of POE and processed material in the polymeric material is at least 99 weight percents. In some embodiments, the polymeric material consists essentially of POE and processed material (according to any of the respective embodiments described herein).
  • the polymeric material according to some of any of the respective embodiments optionally comprises residual amounts of water, for example, at a concentration of at least 0.03 weight percent, at least 0.1 weight percent, or at least 0.3 weight percent.
  • the concentration of water in the polymeric material is no more than 1 weight percent (e.g., from 0.03 to 1 weight percent, including any intermediate values and subranges therebetween), optionally no more than 0.3 weight percent (e.g., from 0.03 to 0.3 weight percent), and optionally no more than 0.1 weight percent (e.g., from 0.03 to 0.1 weight percent, including any intermediate values and subranges therebetween).
  • Water in the polymeric material may optionally be presumed to be derived from the water of the feedstock, thus representing a component of the processed material derived from the feedstock (e.g., when determining an amount of processed material in the polymeric material).
  • the polymeric material according to some of any of the respective embodiments optionally comprises a water soluble salt, optionally an inorganic salt, for example, at a concentration of at least 0.2 weight percent (e.g., from 0.2 to 5 weight percents or from 0.2 to 2 weight percents, including any intermediate values and subranges therebetween), at least 0.5 weight percent (e.g., from 0.5 to 5 weight percents or from 0.5 to 2 weight percents, including any intermediate values and subranges therebetween), or at least 1 weight percent (e.g., from 1 to 5 weight percents or from 1 to 2 weight percents, including any intermediate values and subranges therebetween).
  • at least a portion of the salt is in a crystalline form, for example, salt crystals observable by electron microscopy.
  • the water soluble salt comprises sodium chloride.
  • a concentration of sodium chloride in the polymeric material is at least 0.2 weight percent (e.g., from 0.2 to 5 weight percents or from 0.2 to 2 weight percents, including any intermediate values and subranges therebetween), optionally at least 0.5 weight percent (e.g., from 0.5 to 5 weight percents or from 0.5 to 2 weight percents, including any intermediate values and subranges therebetween), and optionally or at least 1 weight percent (e.g., from 1 to 5 weight percents or from 1 to 2 weight percents, including any intermediate values and subranges therebetween).
  • Water soluble salt in the polymeric material may optionally be presumed to represent a component (e.g., inorganic component) of the processed material derived from the feedstock (e.g., when determining an amount of processed material in the polymeric material), for example, wherein the feedstock comprises an aqueous salt solution.
  • a component e.g., inorganic component
  • the feedstock comprises an aqueous salt solution.
  • water soluble refers to a compound (e.g., salt) which exhibits a solubility of at least 1 gram/liter in aqueous solution (e.g., pure water) at pH 7 (e.g., at a temperature of 20 or 25 °C); and in some of any of the respective embodiments, the solubility is least 10 grams/liter, and optionally at least 100 grams/liter, in such an aqueous solution.
  • aqueous solution e.g., pure water
  • pH 7 e.g., at a temperature of 20 or 25 °C
  • a density of the polymeric material is no more than 1.29 grams/cm 3 , for example in a range of from 1.15 to 1.29 grams/cm 3 , or from 1.19 to 1.29 grams/cm 3 .
  • a density of the polymeric material is no more than 1.25 grams/cm 3 , for example in a range of from 1.15 to 1.25 grams/cm 3 , or from 1.19 to 1.25 grams/cm 3 , or from 1.23 to 1.25 grams/cm 3 .
  • the polymeric material according to any of the embodiments of the invention typically comprises a mixture of compounds, due to the diversity nature of the material (e.g., waste material) from which it is prepared.
  • a mixture may optionally be manifested by the polymeric material exhibiting a plurality of melting points (e.g., temperatures at which a phase change is observed by absorption of energy upon increase in temperature), for example, melting points at about 109 °C (e.g., associated with melting of polyethylene), about 126 °C (e.g., associated with melting of polyethylene), and/or about 163 °C (e.g., associated with melting of polypropylene).
  • melting points e.g., temperatures at which a phase change is observed by absorption of energy upon increase in temperature
  • melting points at about 109 °C e.g., associated with melting of polyethylene
  • about 126 °C e.g., associated with melting of polyethylene
  • 163 °C e.g., associated with melting of polyprop
  • the polymeric material is a non-particulate material.
  • non-particulate refers to a solid material which is not composed of discrete particles (e.g., particles adhered to one another, or optionally aggregates thereof) having a volume of more than 0.2 mm 3 , that is, the material is not formed of particles of the aforementioned volume characterized by visible boundaries and/or particles consisting of different substances than their adjacent surroundings.
  • the non-particulate material is not composed of discrete particles having a volume of more than 0.04 mm 3 . In some embodiments, the non-particulate material is not composed of discrete particles having a volume of more than 0.01 mm 3 . It is to be understood that a non-particulate material may comprise some discrete particles embedded therein, but that the bulk of the material comprises a continuous non-particulate matrix.
  • less than 20 weight percents of the non-particulate polymeric material consists of discrete particles (particles according to any of the respective embodiments described herein). In some embodiments, less than 10 weight percents of the non-particulate polymeric material consists of discrete particles (particles according to any of the respective embodiments described herein). In some embodiments, less than 5 weight percents of the non-particulate polymeric material consists of discrete particles (particles according to any of the respective embodiments described herein). In some embodiments, less than 2 weight percents of the non-particulate polymeric material consists of discrete particles (particles according to any of the respective embodiments described herein). In some embodiments, less than 1 weight percents of the non-particulate polymeric material consists of discrete particles (particles according to any of the respective embodiments described herein).
  • At least 80 weight percents of the polymeric material is organic material (as defined herein), for example, from 80 to 99.9 weight percents, including any intermediate values and subranges therebetween.
  • at least 85 weight percents of the polymeric material is organic material.
  • at least 90 weight percents of the polymeric material is organic material.
  • at least 92 weight percents of the polymeric material is organic material.
  • at least 94 weight percents of the polymeric material is organic material.
  • at least 96 weight percents of the polymeric material is organic material.
  • at least 98 weight percents of the polymeric material is organic material.
  • at least 99 weight percents of the polymeric material is organic material.
  • at least 99.5 weight percents of the polymeric material is organic material.
  • at least 99.8 weight percents of the polymeric material is organic material.
  • At least 30 weight percents of the polymeric material is synthetic polymers (including POE). In some such embodiments, from 30 to 90 weight percents, including any intermediate values and subranges therebetween, of the polymeric material is synthetic polymers. In some embodiments, from 30 to 80 weight percents, including any intermediate values and subranges therebetween, of the polymeric material is synthetic polymers. In some embodiments, from 30 to 70 weight percents, including any intermediate values and subranges therebetween, of the polymeric material is synthetic polymers. In some embodiments, from 30 to 60 weight percents, including any intermediate values and subranges therebetween, of the polymeric material is synthetic polymers.
  • from 30 to 50 weight percents, including any intermediate values and subranges therebetween, of the polymeric material is synthetic polymers. In some embodiments, from 30 to 40 weight percents of the polymeric material is synthetic polymers. In some of any of the aforementioned embodiments, embodiments, at least 50 weight percents, or at least 60 weight percents, or at least 70 weight percents, or at least 80 weight percents, or at least 90 weight percents of the synthetic polymers is polyolefins, optionally up to 99 weight percents polyolefins.
  • At least 40 weight percents of the polymeric material is synthetic polymers. In some such embodiments, from 40 to 90 weight percents, including any intermediate values and subranges therebetween, of the polymeric material is synthetic polymers. In some embodiments, from 40 to 80 weight percents, including any intermediate values and subranges therebetween, of the polymeric material is synthetic polymers. In some embodiments, from 40 to 70 weight percents, including any intermediate values and subranges therebetween, of the polymeric material is synthetic polymers. In some embodiments, from 40 to 60 weight percents, including any intermediate values and subranges therebetween, of the polymeric material is synthetic polymers. In some embodiments, from 40 to 50 weight percents of the polymeric material is synthetic polymers.
  • At least 50 weight percents, or at least 60 weight percents, or at least 70 weight percents, or at least 80 weight percents, or at least 90 weight percents of the synthetic polymers is polyolefins, optionally up to 99 weight percents polyolefins.
  • At least 50 weight percents of the polymeric material is synthetic polymers. In some such embodiments, from 50 to 90 weight percents, including any intermediate values and subranges therebetween, of the polymeric material is synthetic polymers. In some embodiments, from 50 to 80 weight percents, including any intermediate values and subranges therebetween, of the polymeric material is synthetic polymers. In some embodiments, from 50 to 70 weight percents, including any intermediate values and subranges therebetween, of the polymeric material is synthetic polymers. In some embodiments, from 50 to 60 weight percents of the polymeric material is synthetic polymers.
  • At least 50 weight percents, or at least 60 weight percents, or at least 70 weight percents, or at least 80 weight percents, or at least 90 weight percents of the synthetic polymers is polyolefins, optionally up to 99 weight percents polyolefins.
  • At least 60 weight percents of the polymeric material is synthetic polymers. In some such embodiments, from 60 to 90 weight percents, including any intermediate values and subranges therebetween, of the polymeric material is synthetic polymers. In some embodiments, from 60 to 80 weight percents, including any intermediate values and subranges therebetween, of the polymeric material is synthetic polymers. In some embodiments, from 60 to 70 weight percents of the polymeric material is synthetic polymers.
  • At least 50 weight percents, or at least 60 weight percents, or at least 70 weight percents, or at least 80 weight percents, or at least 90 weight percents of the synthetic polymers is polyolefins, optionally up to 99 weight percents polyolefins.
  • At least 70 weight percents of the polymeric material is synthetic polymers. In some such embodiments, from 70 to 90 weight percents, including any intermediate values and subranges therebetween, of the polymeric material is synthetic polymers. In some embodiments, from 70 to 80 weight percents of the polymeric material is synthetic polymers. In some of any of the aforementioned embodiments, embodiments, at least 50 weight percents, or at least 60 weight percents, or at least 70 weight percents, or at least 80 weight percents, or at least 90 weight percents of the synthetic polymers is polyolefins, optionally up to 99 weight percents polyolefins.
  • a concentration of inorganic material in the polymeric material is no more than 10 weight percents (e.g., from 0.1 to 10 weight percents). In some embodiments, the concentration of inorganic material in the polymeric material is no more than 5 weight percents. In some embodiments, the concentration of inorganic material in the polymeric material is no more than 3 weight percents. In some embodiments, the concentration of inorganic material in the polymeric material is no more than 2 weight percents. In some embodiments, the concentration of inorganic material in the polymeric material is no more than 1 weight percents. In some embodiments, the concentration of inorganic material in the polymeric material is no more than 0.5 weight percent.
  • At least 50 weight percents, or at least 60 weight percents, or at least 70 weight percents, or at least 80 weight percents, or at least 90 weight percents of the inorganic material in the polymeric material is a water soluble salt.
  • a concentration of carbon in the polymeric material is at least 57.5 weight percents, for example, in a range of from 57.5 to 80 weight percents, including any intermediate values and subranges therebetween. In some embodiments, the concentration of carbon is at least 60 weight percents. In some embodiments, the concentration of carbon is at least 62.5 weight percents. In some embodiments, the concentration of carbon is at least 65 weight percents. In some embodiments, the concentration of carbon is at least 67.5 weight percents. In some embodiments, the concentration of carbon is at least 70 weight percents.
  • a total concentration of carbon and hydrogen in the polymeric material is at least 67.5 weight percents, for example, in a range of from 67.5 to 90 weight percents, including any intermediate values and subranges therebetween.
  • the concentration of carbon and hydrogen is at least 70 weight percents.
  • the concentration of carbon and hydrogen is at least 72.5 weight percents.
  • the concentration of carbon and hydrogen is at least 75 weight percents.
  • the concentration of carbon and hydrogen is at least 77.5 weight percents.
  • the concentration of carbon and hydrogen is at least 80 weight percents.
  • the concentration of carbon and hydrogen is at least 82.5 weight percents.
  • a concentration of oxygen in the polymeric material is at least 18 weight percents, for example, in a range of from 18 to 36 weight percents, including any intermediate values and subranges therebetween. In some embodiments, the concentration of oxygen is at least 20 weight percents. In some embodiments, the concentration of oxygen is at least 22 weight percents. In some embodiments, the concentration of oxygen is at least 24 weight percents. In some embodiments, the concentration of oxygen is at least 26 weight percents. In some embodiments, the concentration of oxygen is at least 28 weight percents.
  • a total concentration of carbon and oxygen in the polymeric material is at least 80 weight percents, for example, in a range of from 80 to 95 weight percents, including any intermediate values and subranges therebetween.
  • the concentration of carbon and oxygen is at least 82 weight percents.
  • the concentration of carbon and oxygen is at least 84 weight percents.
  • the concentration of carbon and oxygen is at least 86 weight percents.
  • the concentration of carbon and oxygen is at least 88 weight percents.
  • the concentration of carbon and oxygen is at least 90 weight percents.
  • a total concentration of carbon, hydrogen and oxygen in the polymeric material is at least 90 weight percents, for example, in a range of from 90 to 99.9 weight percents, including any intermediate values and subranges therebetween.
  • the concentration of carbon, hydrogen and oxygen is at least 92 weight percents.
  • the concentration of carbon, hydrogen and oxygen is at least 94 weight percents.
  • the concentration of carbon, hydrogen and oxygen is at least 96 weight percents.
  • the concentration of carbon, hydrogen and oxygen is at least 98 weight percents.
  • a total concentration of carbon, hydrogen, oxygen, nitrogen, alkali metal and halogen atoms in the polymeric material is at least 94 weight percents, for example, in a range of from 94 to 99.9 weight percents, including any intermediate values and subranges therebetween.
  • the concentration of carbon, hydrogen, oxygen, nitrogen, alkali metal and halogen atoms is at least 95 weight percents.
  • the concentration of carbon, hydrogen, oxygen, nitrogen, alkali metal and halogen atoms is at least 96 weight percents.
  • the concentration of carbon, hydrogen, oxygen, nitrogen, alkali metal and halogen atoms is at least 97 weight percents.
  • the concentration of carbon, hydrogen, oxygen, nitrogen, alkali metal and halogen atoms is at least 98 weight percents. In some embodiments, the concentration of carbon, hydrogen, oxygen, nitrogen, alkali metal and halogen atoms is at least 99 weight percents. It is to be appreciated that a relatively high total concentration of carbon, hydrogen, oxygen, nitrogen, alkali metal and halogen atoms indicates a relatively low concentration of inorganic material other than water-soluble inorganic salts (which typically comprise an alkali metal action and/or a halogen anion).
  • a molar concentration of alkali metals in the polymeric material is at least 50 % higher than a molar concentration of alkali metals in the dry weight of the waste material.
  • the molar concentration of alkali metals is at least 100 % higher (i.e., two-fold).
  • the molar concentration of alkali metals is at least 150 % higher.
  • the molar concentration of alkali metals is at least 200 % higher.
  • the molar concentration of alkali metals is at least 300 % higher.
  • the molar concentration of alkali metals is at least 400 % higher.
  • the molar concentration of alkali metals is at least 600 % higher.
  • the molar concentration of alkali metals is at least 900 % higher (i.e., ten-fold).
  • a molar concentration of halogens in the polymeric material is at least 50 % higher than a molar concentration of halogens in the dry weight of the waste material. In some embodiments, the molar concentration of halogens is at least 100 % higher. In some embodiments, the molar concentration of halogens is at least 150 % higher. In some embodiments, the molar concentration of halogens is at least 200 % higher. In some embodiments, the molar concentration of halogens is at least 300 % higher. In some embodiments, the molar concentration of halogens is at least 400 % higher. In some embodiments, the molar concentration of halogens is at least 600 % higher. In some embodiments, the molar concentration of halogens is at least 900 % higher.
  • a molar concentration of alkali metals and/or halogens in the polymeric material is no more than a thousand-fold a molar concentration alkali metals and/or halogens, respectively, in the dry weight of the waste material.
  • the phrase“molar concentration” refers to a number (e.g., in mole units) of molecules or atoms (e.g., alkali metal atoms, halogen atoms) per volume.
  • a molar concentration in the dry weight of waste material refers to a molar concentration in the waste material when dried (e.g., by evaporation) until substantially dry (e.g., no more than 1 weight percent water), for example, wherein a water content of the dried waste material is substantially the same as the water content of the polymeric material to which it is being compared.
  • a tensile modulus of the polymeric material is at least 150 MPa, for example, from 150 to 1300 MPa, or from 150 to 1000 MPa, or from 150 to 800 MPa, or from 150 to 600 MPa, including any intermediate values and subranges therebetween.
  • the tensile modulus of the polymeric material is at least 200 MPa, for example, from 200 to 1300 MPa, or from 200 to 1000 MPa, or from 200 to 800 MPa, or from 200 to 600 MPa, including any intermediate values and subranges therebetween.
  • the tensile modulus of the polymeric material is at least 300 MPa, for example, from 300 to 1300 MPa, or from 300 to 1000 MPa, or from 300 to 800 MPa, or from 300 to 600 MPa, including any intermediate values and subranges therebetween.
  • Polymeric materials according to some exemplary embodiments exhibited a tensile modulus in a range of from about 300 to about 700 MPa, including any intermediate values and subranges therebetween.
  • a yield strength of the polymeric material is at least 4 MPa, for example, from 4 to 16 MPa, or from 4 to 12 MPa, or from 4 to 11 MPa, or from 4 to 10 MPa, or from 4 to 9 MPa, including any intermediate values and subranges therebetween.
  • the yield strength of the polymeric material is at least 6 MPa, for example, from 6 to 16 MPa, or from 6 to 12 MPa, or from 6 to 11 MPa, or from 6 to 10 MPa, or from 6 to 9 MPa, including any intermediate values and subranges therebetween.
  • the yield strength of the polymeric material is at least 8 MPa, for example, from 8 to 16 MPa, or from 8 to 12 MPa, or from 8 to 11 MPa, or from 8 to 10 MPa, or from 8 to
  • a strength at break of the polymeric material is at least 3 MPa, for example, from 3 to 15 MPa, or from 3 to 12 MPa, or from 3 to 11 MPa, or from 3 to 10 MPa, or from 3 to 9 MPa, or from 3 to 8 MPa, including any intermediate values and subranges therebetween.
  • the strength at break of the polymeric material is at least 5 MPa, for example, from 5 to 15 MPa, or from 5 to 12 MPa, or from 5 to 11 MPa, or from 5 to 10 MPa, or from 5 to 9 MPa, or from 5 to 8 MPa, including any intermediate values and subranges therebetween.
  • the strength at break of the polymeric material is at least 6 MPa, for example, from 6 to 15 MPa, or from 6 to 12 MPa, or from 6 to 11 MPa, or from 6 to 10 MPa, or from 6 to 9 MPa, or from 6 to 8 MPa, including any intermediate values and subranges therebetween.
  • an elongation at yield of the polymeric material is at least 3 %, for example, from 3 to 15 %, or from 3 to 12 %, or from 3 to
  • the elongation at yield of the polymeric material is at least 5 %, for example, from 5 to 15 %, or from 5 to 12 %, or from 5 to 10 %, or from 5 to 8 %, including any intermediate values and subranges therebetween.
  • the elongation at yield of the polymeric material is at least 6 %, for example, from 6 to 15 %, or from 6 to 12 %, or from 6 to 10 %, or from 6 to 8 %, including any intermediate values and subranges therebetween.
  • an elongation at break of the polymeric material is at least 10 %, for example, from 10 to 50 %, or from 10 to 40 %, or from 10 to 30 %, including any intermediate values and subranges therebetween.
  • the elongation at break of the polymeric material is at least 15 %, for example, from 15 to 50 %, or from 15 to 40 %, or from 15 to 30 %, including any intermediate values and subranges therebetween.
  • the elongation at break of the polymeric material is at least 20 %, for example, from 20 to 50 %, or from 20 to 40 %, or from 20 to 30 %, including any intermediate values and subranges therebetween.
  • the elongation at break of the polymeric material is at least 30 %, for example, from 30 to 50 %, or from 30 to 40 %, including any intermediate values and subranges therebetween.
  • Tensile modulus, strength at yield and/or break, and elongation at yield and/or break may optionally be determined according to standard procedures used in the art, e.g., as exemplified herein.
  • the polymeric material is obtainable by a process as described in International Patent Application Publication No. WO 2015/173806, the contents of which are hereby incorporated by reference, including any of the embodiments described therein relating to preparing such a material from a waste material.
  • polymeric materials according to embodiments of the invention may be particularly suitable in combination with polypropylene, for example, for enhancing the mechanical properties of the polypropylene and/or reducing the cost of a polypropylene-containing material.
  • a polypropylene-containing material comprising polypropylene and a polymeric material according to any of the respective embodiments described herein.
  • the polypropylene-containing according to any of the embodiments described herein is also referred to herein as a composite material.
  • a concentration of polypropylene in the polypropylene- containing material is at least 40 weight percents, for example, in a range of from 40 to 95 weight percents, including any intermediate values and subranges therebetween.
  • a concentration of polypropylene in the polypropylene-containing material is at least 50 weight percents. In some embodiments, a concentration of polypropylene in the polypropylene-containing material is at least 60 weight percents. In some embodiments, a concentration of polypropylene in the polypropylene- containing material is at least 70 weight percents.
  • a concentration of polymeric material (according to any of the respective embodiments described herein) in the polypropylene-containing material is at least 10 weight percents, for example, from 10 to 80 weight percents, including any intermediate values and subranges therebetween. In some embodiments, a concentration of polymeric material (according to any of the respective embodiments described herein) is at least 20 weight percents. In some embodiments, a concentration of polymeric material (according to any of the respective embodiments described herein) is at least 30 weight percents. In some embodiments, a concentration of polymeric material (according to any of the respective embodiments described herein) is at least 40 weight percents.
  • a concentration of polymeric material is at least 50 weight percents.
  • Exemplary polypropylene-containing materials described herein comprise about 30 weight percents polymeric material or about 50 weight percents polymeric material.
  • polypropylene-containing materials such as described herein may exhibit relatively high impact strength, e.g., relative to polypropylene.
  • Impact strength may optionally be characterized by a standard Izod (notched) impact strength test for plastics, as is well-known in the art (e.g., according to ASTM D256). In such a test, impact strength is determined by releasing a pivoting arm from a specific height, such that the arm hits a notched sample, breaking the specimen. The energy absorbed by the sample ay then be calculated from the height the arm swings back to after hitting the sample, and expressed as lost energy per unit thickness at the notch (e.g., in units of J/m).
  • the polypropylene- containing material has a notched Izod impact strength which is at least 10 % greater than (i.e., 110 % of) a notched Izod impact strength of a corresponding material without the polymeric material, that is, polypropylene (of the same grade as in the polypropylene-containing material) and any other additional ingredients (if any) of the polypropylene-containing material.
  • the polypropylene-containing material has a notched Izod impact strength which is at least 20 % greater than a notched Izod impact strength of a corresponding material without the polymeric material.
  • the polypropylene-containing material has a notched Izod impact strength which is at least 30 % greater than a notched Izod impact strength of a corresponding material without the polymeric material. In some embodiments, the polypropylene-containing material has a notched Izod impact strength which is at least 50 % greater than a notched Izod impact strength of a corresponding material without the polymeric material. In some embodiments, the polypropylene-containing material has a notched Izod impact strength which is at least 75 % greater than a notched Izod impact strength of a corresponding material without the polymeric material.
  • the polypropylene-containing material has a notched Izod impact strength which is at least 100 % greater than (i.e., two-fold) a notched Izod impact strength of a corresponding material without the polymeric material. In some embodiments, the polypropylene-containing material has a notched Izod impact strength which is at least 150 % greater than a notched Izod impact strength of a corresponding material without the polymeric material. In some embodiments, the polypropylene-containing material has a notched Izod impact strength which is at least 200 % greater than (i.e., three-fold) a notched Izod impact strength of a corresponding material without the polymeric material. In some embodiments, the polypropylene-containing material has a notched Izod impact strength which is up to ten-fold a notched Izod impact strength of a corresponding material without the polymeric material.
  • the polypropylene- containing material has a notched Izod impact strength which is greater than a weighted average of the notched Izod impact strength of a corresponding material without the polymeric material (as defined herein) and the notched Izod impact strength of the polymeric material. Such an increase over the weighted average is indicative of a synergistic interaction between the materials.
  • weighted average it is meant that the Izod impact strength of each material (polymeric material or corresponding material) contributes to the average proportionally to the respective amount of the material (by weight) in the polypropylene-containing material.
  • weighted average impact strength of a mixture of 70 % polypropylene and 30 % polymeric material would be 0.7*(polypropylene impact strength) + 0.3* (polymeric material impact strength).
  • an impact strength of the polypropylene-containing material which is above the weighted average may optionally be below that of the corresponding material.
  • an impact strength of the polypropylene-containing material which is above the weighted average may optionally be below that of the polymeric material.
  • an impact strength of the polypropylene-containing material is greater than each of the impact strength of the corresponding material without polymeric material and the impact strength of the polymeric material (and thus by definition also greater than the weighted average).
  • the polypropylene- containing material has a notched Izod impact strength which is at least 10 % greater than (i.e., 110 % of) a weighted average of the notched Izod impact strength of a corresponding material without the polymeric material (as defined herein) and the notched Izod impact strength of the polymeric material.
  • the polypropylene-containing material has a notched Izod impact strength which is at least 20 % greater than the aforementioned weighted average.
  • the polypropylene-containing material has a notched Izod impact strength which is at least 30 % greater than the aforementioned weighted average.
  • the polypropylene-containing material has a notched Izod impact strength which is at least 50 % greater than the aforementioned weighted average. In some embodiments, the polypropylene- containing material has a notched Izod impact strength which is at least 75 % greater than the aforementioned weighted average. In some embodiments, the polypropylene-containing material has a notched Izod impact strength which is at least 100 % greater than (i.e., two-fold) the aforementioned weighted average. In some embodiments, the polypropylene-containing material has a notched Izod impact strength which is up to ten-fold a weighted average of the notched Izod impact strength of a corresponding material without the polymeric material.
  • a notched Izod impact strength of the polypropylene-containing material is at least 80 J/m, for example, in a range of from 80 to 1000 J/m, including any intermediate values and subranges therebetween. In some embodiments, the notched Izod impact strength is at least 90 J/m. In some embodiments, the notched Izod impact strength is at least 100 J/m. In some embodiments, the notched Izod impact strength is at least 110 J/m. In some embodiments, the notched Izod impact strength is at least 120 J/m. In some embodiments, the notched Izod impact strength is at least 130 J/m.
  • the notched Izod impact strength is at least 140 J/m. In some embodiments, the notched Izod impact strength is at least 150 J/m. In some embodiments, the notched Izod impact strength is at least 160 J/m. In some embodiments, the notched Izod impact strength is at least 170 J/m. In some embodiments, the notched Izod impact strength is at least 180 J/m. In some embodiments, the notched Izod impact strength is at least 190 J/m. In some embodiments, the notched Izod impact strength is at least 200 J/m.
  • the notched Izod impact strength of the polypropylene-containing material is greater than the notched Izod impact strength of the corresponding material without polymeric material (optionally polypropylene per se), for example, at least 10 % greater, at least 20 % greater, at least 30 % greater, at least 50 % greater, at least 75 % greater, or at least 100 % greater than the impact strength of the corresponding material (according to any of the respective embodiments described herein).
  • the density of the polypropylene-containing material is optionally dependent on the proportion of polypropylene (and density thereof, typically in a range of from 0.895 to 0.92 grams/cm 3 for commercial PP) and the proportion (and density) of polymeric material, whose density may be according to any of the respective embodiments described herein.
  • a density of the polypropylene-containing material is at least 0.95 grams/cm 3 , optionally in a range of from 0.95 to 1.15 grams/cm 3 , optionally in a range of from 0.95 to 1.15 grams/cm 3 (e.g., in embodiments wherein a concentration if PP is about 70 weight percents, according to any of the respective embodiments described herein), and optionally in a range of from 1.00 to 1.15 grams/cm 3 (e.g., in embodiments wherein a concentration if PP is about 50 weight percents, according to any of the respective embodiments described herein), including any intermediate values and subranges therebetween.
  • polypropylene-containing material described herein in any of the respective embodiments can be advantageously used in the preparation of a myriad of articles that are known to contain plastic materials such as polypropylene, either instead of the plastic material or in addition thereto.
  • an article-of-manufacturing comprising a polypropylene-containing material according to any of the respective embodiments described herein.
  • the article-of-manufacturing may be, for example, any article-of-manufacturing in which polypropylene per se is known in the art to be a suitable material.
  • the article-of-manufacturing may optionally be composed in its entirety of the polypropylene-containing material, or alternatively, may include one or more components composed of the polypropylene-containing material.
  • components which are suitable for comprising (and optionally consisting essentially of) a polypropylene-containing material include, without limitation, structural components (e.g., as opposed to specialized components for electrical and/or high-temperature functions), in which mechanical strength, durability, and/or relatively light weight or low cost (e.g., relative to metal) are of particular importance.
  • suitable articles-of-manufacturing include, without limitation, an animal bed, house and/or transporter (e.g., for a pet, such as a dog or cat), a baby seat (e.g., high chair), a basket, a bench, a bin (e.g., a waste bin, optionally with a lid controlled by a pedal), a bookcase, a box, a bureau, a cabinet, a cage (e.g., for a small pet animal), a cart, a case (e.g., a tool case), a chair, a chest, a composter, a cooler, a container, a drawer, a dresser, a footstool, a frame (e.g., for a picture and/or mirror), a garden bed, a grill (e.g., in a structural component not subjected to high temperature), a hamper (e.g., laundry hamper), an ironing board (e.g., in a structural component not subjected,
  • a process for preparing a polymeric material comprises providing a feedstock according to any of the embodiments described herein, and subjecting the feedstock to mixing via shear forces and to heating.
  • the feedstock is preferably subjected to the mixing and the heating without being dried beforehand (i.e., the water content of the feedstock is not decreased).
  • a polyolefinic elastomer (POE) according to any of the embodiments described herein is subjected concomitantly with the feedstock to mixing via shear forces and to heating.
  • a polymeric material comprising POE according to any of the respective embodiments described herein may be obtained upon completion of the concomitant mixing and heating of the feedstock and POE.
  • heating is performed subsequent to mixing. In some embodiments, heating is performed prior to mixing. In some embodiments, the feedstock is subjected to mixing and heating simultaneously.
  • the POE is contacted (e.g., by mixing) with the feedstock prior to mixing and/or heating according to any of the respective embodiments described herein, such that subjecting the feedstock and POE concomitantly to mixing and heating encompasses all of the mixing and heating.
  • the feedstock is subjected to some mixing and heating prior to being contacted (e.g., by mixing) with the POE, optionally followed by concomitantly subjecting the feedstock and POE to mixing and/or heating according to any of the respective embodiments described herein.
  • the feedstock immediately prior to mixing and heating is a shredded feedstock.
  • Feedstock may optionally be obtained in a shredded form (e.g., in a form of a shredded sorted material and/or additional material as described herein), or the method may optionally further comprise shredding the feedstock prior to the mixing and heating described herein.
  • the feedstock is substantially devoid of relatively large particles. Particles above a certain size may be removed, for example, by sieving.
  • solid particles in the feedstock are less than 50 mm in diameter, optionally less than 20 mm in diameter. In some embodiments, the solid particles are less than 10 mm in diameter. In some embodiments, the solid particles are less than 5 mm in diameter. In some embodiments, the solid particles are less than 2 mm in diameter.
  • the heating of the feedstock is at a temperature of no more than 230 °C. In some embodiments, the heating of the feedstock is at a temperature of no more than 220 °C. In some embodiments, the heating of the feedstock is at a temperature of no more than 210 °C. In some embodiments, the heating of the feedstock is at a temperature of no more than 200 °C. In some embodiments, the heating of the feedstock is at a temperature of no more than 190 °C. In some embodiments, the heating of the feedstock is at a temperature of no more than 180 °C.
  • the heating of the feedstock is at a temperature of at least 90 °C.
  • temperature is in a range of from 90 to 230 °C.
  • temperature is in a range of from 90 to 220 °C.
  • temperature is in a range of from 90 to 210 °C.
  • temperature is in a range of from 90 to 200 °C.
  • temperature is in a range of from 90 to 190 °C.
  • temperature is in a range of from 90 to 180 °C.
  • temperature is in a range of from 90 to 170 °C.
  • temperature is in a range of from 90 to 160 °C.
  • the heating of the feedstock is at a temperature of at least 110 °C.
  • temperature is in a range of from 110 to 230 °C.
  • temperature is in a range of from 110 to 220 °C.
  • temperature is in a range of from 110 to 210 °C.
  • temperature is in a range of from 110 to 200 °C.
  • temperature is in a range of from 110 to 190 °C.
  • temperature is in a range of from 110 to 180 °C.
  • temperature is in a range of from 110 to 170 °C.
  • temperature is in a range of from 110 to 160 °C.
  • the heating of the feedstock is at a temperature of at least 130 °C.
  • temperature is in a range of from 130 to 230 °C.
  • temperature is in a range of from 130 to 220 °C.
  • temperature is in a range of from 130 to 210 °C.
  • temperature is in a range of from 130 to 200 °C.
  • temperature is in a range of from 130 to 190 °C.
  • temperature is in a range of from 130 to 180 °C.
  • temperature is in a range of from 130 to 170 °C.
  • temperature is in a range of from 130 to 160 °C.
  • the heating of the feedstock is at a temperature of at least 140 °C.
  • temperature is in a range of from 140 to 230 °C.
  • temperature is in a range of from 140 to 220 °C.
  • temperature is in a range of from 140 to 210 °C.
  • temperature is in a range of from 140 to 200 °C.
  • temperature is in a range of from 140 to 190 °C.
  • temperature is in a range of from 140 to 180 °C.
  • temperature is in a range of from 140 to 170 °C.
  • temperature is in a range of from 140 to 160 °C.
  • the heating of the feedstock is at a temperature of at least 150 °C.
  • temperature is in a range of from 150 to 230 °C.
  • temperature is in a range of from 150 to 220 °C.
  • temperature is in a range of from 150 to 210 °C.
  • temperature is in a range of from 150 to 200 °C.
  • temperature is in a range of from 150 to 190 °C.
  • temperature is in a range of from 150 to 180 °C.
  • temperature is in a range of from 150 to 170 °C.
  • the heating of the feedstock is at a temperature of at least 160 °C.
  • temperature is in a range of from 160 to 230 °C.
  • temperature is in a range of from 160 to 220 °C.
  • temperature is in a range of from 160 to 210 °C.
  • temperature is in a range of from 160 to 200 °C.
  • temperature is in a range of from 160 to 190 °C.
  • temperature is in a range of from 160 to 180 °C.
  • the heating of the feedstock is at a temperature of at least 170 °C. In some embodiments, temperature is in a range of from 170 to 230 °C. In some embodiments, temperature is in a range of from 170 to 220 °C. In some embodiments, temperature is in a range of from 170 to 210 °C. In some embodiments, temperature is in a range of from 170 to 200 °C. In some embodiments, temperature is in a range of from 170 to 190 °C.
  • the heating of the feedstock is at a temperature of at least 180 °C. In some embodiments, temperature is in a range of from 180 to 230 °C. In some embodiments, temperature is in a range of from 180 to 220 °C. In some embodiments, temperature is in a range of from 180 to 210 °C. In some embodiments, temperature is in a range of from 180 to 200 °C.
  • the heating may optionally be at a constant temperature throughout the heating process. Alternatively, the temperature may vary during the heating process.
  • Subjecting the feedstock (optionally with POE) to mixing may optionally be performed prior to, concomitant with, and/or subsequent to subjecting the feedstock to heating.
  • subjecting the feedstock to mixing e.g., via shear forces
  • subjecting the feedstock to mixing is performed concomitantly with subjecting the feedstock to heating.
  • the step of subjecting the feedstock to mixing e.g., via shear forces
  • the step of subjecting the feedstock to heating are referred to herein as“mixing and/or heating”.
  • the phrase“mixing and/or heating” refers to heating with temperatures described herein and to mixing (e.g., with shear forces) according to any of the respective embodiments described herein.
  • Mixing may optionally be effected by any method which generates shear forces.
  • “shear force” refers to a force which causes a stress in a material in a direction which is parallel to a cross-section of the material.
  • solid components with large surface areas e.g., a screw, a propeller
  • solid components with large surface areas e.g., a screw, a propeller
  • shear forces are generated by a compounder, such as, without limitation, an extruder, an internal mixer (a Banbury® mixer), a co-kneader, and/or a continuous mixer etc.
  • a compounder such as, without limitation, an extruder, an internal mixer (a Banbury® mixer), a co-kneader, and/or a continuous mixer etc.
  • the shear forces and mixing time should be sufficient such that the obtained processed material is essentially evenly dispersed matter throughout the mass/body thereof.
  • the shear forces are characterized by a shear rate of at least 1 second 1 , optionally at least 2 second 1 , optionally in a range of from 3 second 1 to 300 second 1 .
  • the shear rate is in a range of from 1 to 30 second 1 . In some embodiments the shear rate is in a range of from 30 to 100 second 1 . In some embodiments the shear rate is in a range of from 100 to 200 second 1 . In some embodiments the shear rate is in a range of from 200 to 300 second 1 .
  • mixing is effected by rotation of one or more screw, e.g., one or two screw.
  • the screw is optionally in a barrel (e.g., the barrel forming a closed container).
  • the barrel may optionally be heated (e.g., by an electric heater) in order to effect heating along with mixing.
  • the screw may optionally be heated (e.g., by a flow of heated fluid inside the screw) in order to effect heating along with mixing.
  • mixing is effected by rotation of at least one screw in an extruder (e.g., as described herein).
  • the extruder is equipped with a venting zone. In some embodiments, the extruder is equipped with more than one venting zone. In some embodiments the nozzle of the extruder is chilled during the extrusion process.
  • the feedstock is processed through at least one screen during the mixing and/or heating.
  • a plurality of screens are used (the screens being the same or different in dimensions), such that the material being processed is passed through screens at more than one stage of the heating and/or mixing.
  • the term“screen” encompasses any apparatus having spaces which selectively allows the passage of solid material with sufficiently small dimensions.
  • the spaces in the screen are no more than 10 mm in width.
  • the spaces in the screen are no more than 5 mm in width.
  • the spaces are about 3 mm in width.
  • mixing and/or heating is performed under conditions with relatively low oxygen concentrations.
  • Low oxygen concentrations may optionally be obtained by performing the mixing and/or heating in a closed container having a low volume of air.
  • the volume of air in the container is less than 30% of the container volume, optionally less than 20% of the container volume, optionally less than 10% of the container volume, optionally less than 5% of the container volume, optionally less than 2% of the container volume, and optionally less than 1% of the container volume.
  • the feedstock is compressed prior to heating and mixing, thereby lowering the volume of air included within the feedstock itself.
  • An extruder may optionally be used to compress the feedstock.
  • the feedstock may enter a first extruder to be subjected to heating and mixing, while a tandem extruder (e.g., perpendicular to the first extruder) compresses the feedstock entering the first extruder in order to remove air.
  • the tandem extruder may comprise, for example, a conical extruder and/or an internal mixer (e.g., a Banbury® mixer).
  • gases released during mixing and/or heating are removed.
  • the gases include steam (gaseous water), and may further include additional gases, such as vapors of volatile organic compounds.
  • removal of gases is effected using suction, e.g., via a pump.
  • removing gases is effected more than once (i.e., at more than one stage of the mixing and/or heating), for example, twice, three times, four times, and even more. In some embodiments, gases are removed twice.
  • Water in the feedstock is typically eliminated largely via removal of steam formed by the heating and/or mixing (e.g., via removal of evaporated water during removal of gases).
  • water may optionally be further eliminated via chemical reactions (e.g., hydrolysis, in which a water molecule reacts with another molecule, resulting in cleavage of a covalent bond). Consequently, the water content is reduced during the process.
  • mixing and/or heating are performed until the water content of the material being processed by mixing and/or heating is reduced to a level desired for the obtained polymeric material, e.g., a polymeric material water content according to any of the embodiments described herein.
  • Water content may be measured, for example, using a commercially available moisture gauge.
  • mixing and/heating is optionally performed at a suitable temperature and a suitable length of time which result in sufficient evaporation of water.
  • gas removal is optionally performed at a rate suitable for eliminating substantially all of the generated water vapor, until the water content of the waste material is reduced to a desired level.
  • the majority of the water in the feedstock is eliminated via a first gas removal, such that the water content of the processed material obtained after the first gas removal is less than 50 % of the water content of the feedstock before effecting the process.
  • any additional gas removals effect a further reduction of the water content to a low concentration such as described herein (e.g., less than 1 weight percent).
  • mixing, heating and removal of gases are performed until the water content of the material being processed is reduced to a level desired for the obtained polymeric material, e.g., a polymeric material water content according to any of the embodiments described herein.
  • the net elimination of water during mixing and/or heating is reduced by supplementation of the material being processed with water (e.g., after a portion or essentially all of the water of the feedstock has been eliminated).
  • the amount of water supplemented is sufficient to raise the total water content of the material being subjected to mixing and/or heating to at least 3 weight percents, optionally from 3 to 30 weight percents, or from 3 to 20 weight percents, or from 3 to 10 weight percents, or from 10 to 30 weight percents.
  • Water supplementation may be effected once or more than once (e.g., twice or thrice).
  • mixing and/or heating comprises a plurality of cycles of mixing and/or heating, each cycle being effected according to any of the respective embodiments described herein.
  • the mixing and/or heating may comprise, for example, 2 cycles, 3 cycles, 4 cycles, 5 cycles, and even more, of mixing and/or heating as described herein, wherein each cycle produces a new processed material, until a final polymeric material (according to any of the respective embodiments described herein) is produced by the final cycle.
  • At least some of the plurality of cycles may optionally be effected by a plurality of apparatuses configured for providing different conditions, for example, using different types and/or configurations of screws (e.g., wherein at least one cycle is effected using a single screw configuration and at least one cycle is effected using a twin screw configuration).
  • some of the cycles may be effected using the same apparatus, e.g., using essentially identical apparatuses in sequence, and/or using a single apparatus for more than one cycle.
  • the preparation comprises two or three cycles of mixing and/or heating, as described herein.
  • a first material obtained from the first cycle of mixing and/or heating is subjected to a second cycle of mixing and/or heating, thereby producing a polymeric material as described herein or a second material which is subjected to a third cycle of mixing and/or heating, thereby producing a polymeric material as described herein.
  • the various cycles of mixing and/or heating may be effected by moving the material being processed between different zones for mixing and/or heating.
  • each of the cycles of mixing and/or heating further comprises removing gases (e.g., as described herein) released during the cycle.
  • the preparation may optionally comprise sequential cycles (e.g., 2 or 3 cycles), each comprising mixing and/or heating, as described herein and removing gases, as described herein.
  • one or more cycles comprise both mixing and/or heating and removing gases and the other cycles comprise only mixing and/or heating, as described herein.
  • a final cycle of mixing and/or heating does not comprise removing gases released during the cycle (e.g., wherein little or no gases are released during the final cycle).
  • the method may optionally comprise sequential cycles (e.g., 2 or 3 cycles) of mixing and/or heating and removing gases, followed by a final cycle (e.g., a third cycle) of mixing and/or heating without removing gases.
  • the feedstock is subjected as described herein to mixing and to heating, at certain conditions (e.g., certain mixing technology and a certain temperature, as described hereinabove, which can be referred to in this context as a first temperature).
  • certain conditions e.g., certain mixing technology and a certain temperature, as described hereinabove, which can be referred to in this context as a first temperature.
  • a first removal of gases is effected, as described herein.
  • a second cycle of mixing and heating is effected, as described herein, at certain conditions (e.g., certain mixing technology and a certain temperature, as described hereinabove, which can be referred to in this context as a second temperature.
  • a second removal of gases is effected during the second cycle, as described herein.
  • the above is repeated for as many cycles as desired.
  • the material resulting from a second cycle of mixing and heating (e.g., as described hereinabove) is then subjected to a third cycle of mixing and heating, as described herein, at certain conditions (e.g., a certain mixing technology and a certain temperature, as described hereinabove, which can be referred to in this context as a third temperature).
  • the conditions for mixing and heating can be the same or different.
  • mixing is the same in each of cycles.
  • the temperatures of at least some of the cycles are different.
  • the first temperature is higher than the second temperature.
  • the first temperature is lower than the second temperature.
  • the second temperature is higher than the third temperature.
  • the second temperature is lower than the third temperature.
  • the first temperature is higher than the third temperature.
  • the first temperature is lower than the third temperature.
  • the first temperature and second temperature are achieved by the same heating mechanism, and the difference between the two temperatures is a result of changes in the properties of the material being processed (e.g., the lower second temperature reflecting an increasingly endothermic reaction).
  • the material e.g., POE and/or water
  • the material is added between cycles of mixing and/or heating (e.g., between a first and second cycle, between a second and third cycle, and/or between a third and fourth cycle).
  • the material e.g., POE and/or water
  • the material is supplemented to a container where heating and mixing is performed (e.g., during an individual cycle described herein), at a desired section of the container.
  • the total duration (i.e., including all cycles) of heating of feedstock (optionally with POE) is at least 5 minutes. In some embodiments, total duration of heating of feedstock (optionally with POE) is at least 10 minutes. In some embodiments, the total duration of heating of feedstock (optionally with POE) is at least 15 minutes. In some embodiments, the total duration of heating of feedstock (optionally with POE) is at least 20 minutes. In some embodiments, the total duration of heating of feedstock (optionally with POE) is at least 30 minutes. In some embodiments, the total duration of heating of feedstock (optionally with POE) is at least 40 minutes. In some embodiments, the total duration of heating of feedstock (optionally with POE) is at least 60 minutes.
  • composition of the processed material will be similar to the feedstock composition (e.g., a feedstock composition described herein) with the water removed, but will typically be somewhat different than the feedstock composition due to chemical reactions induced, for example, by the heating and mixing described herein.
  • carbohydrates such as polysaccharides in the feedstock undergo hydrolysis when subjected to heating and mixing as described herein, resulting in a mixture of monosaccharides, disaccharides, trisaccharides and/or oligosaccharides which may comprise, for example, glucose (which may be derived, for example, from cellulose, hemicellulose and/or starch), and/or xylose, mannose, galactose, rhamnose, and/or arabinose (which may be derived, for example, from hemicellulose).
  • glucose which may be derived, for example, from cellulose, hemicellulose and/or starch
  • xylose mannose, galactose, rhamnose, and/or arabinose (which may be derived, for example, from hemicellulose).
  • the substantial degree of hydrolysis is believed to be due to the initial presence of substantial amounts of water in the feedstock (such as described herein).
  • pyrolysis of polysaccharides may also result in monosaccharides, disaccharides, trisaccharides and/or oligosaccharides.
  • carbohydrates in the feedstock further undergo polymerization and other forms of covalent bond formation (e.g., by caramelization and/or Maillard type reactions), resulting in the formation of polymeric materials (e.g., carbohydrates and derivatives thereof) which are not present in the feedstock prior to processing.
  • polymeric materials e.g., carbohydrates and derivatives thereof
  • pyrolysis further alters the structure of polymeric materials in the feedstock during processing; thereby further forming polymeric materials which are not present in the feedstock prior to processing.
  • the degree of hydrolysis is believed to gradually decrease as the material being processed becomes progressively drier upon heating during processing, whereas the relative degree of other reactions (e.g., caramelization, pyrolysis) is believed to gradually increase as the material being processed becomes progressively drier.
  • the processed polymeric material comprises polymers other than those present in the feedstock prior to processing.
  • at least 1 weight percent of the polymeric material in the processed material consists of polymers other than those present in the feedstock prior to processing.
  • at least 5 weight percents of the polymeric material consists of polymers other than those present in the feedstock.
  • at least 10 weight percents of the polymeric material consists of polymers other than those present in the feedstock.
  • at least 20 weight percents of the polymeric material consists of polymers other than those present in the feedstock.
  • at least 50 weight percents of the polymeric material consists of polymers other than those present in the feedstock.
  • at least 75 weight percents of the polymeric material consists of polymers other than those present in the feedstock.
  • the processing described herein results in a loss of the structure which characterizes plant and animal material in the waste material.
  • microscopic examination of plant and animal material typically shows structures such as cell walls and fibrous structures (e.g., collagen fibers), whereas in the processed material, such structures are optionally substantially absent upon microscopic examination.
  • osmotic stress induced by a solute e.g., a salt
  • a solution used for separating according to specific gravity e.g., as described herein
  • Such osmotic stress may occur during separation according to specific gravity and/or after separation according to specific gravity (e.g., due to solute remaining in the sorted material).
  • the waste material in a feedstock optionally comprises (and optionally consists of) waste material from which at least a portion of materials (e.g., inorganic materials) in the waste material have been removed.
  • materials e.g., inorganic materials
  • Such a waste material is referred to herein interchangeably as a “sorted material”, and removing at least a portion of materials from waste material is referred to herein interchangeably as“sorting” the waste material.
  • the sorted material is a subset of waste material which remains after sorting. Removal of material (e.g., inorganic material) may optionally be such that a waste material content according to any of the respective embodiments described herein is obtained.
  • the process further comprises removing at least a portion of inorganic materials in a waste material, to thereby obtain a waste material containing, e.g., at least 90 weight percents of an organic material by dry weight (according to any of the respective embodiments described herein).
  • the sorted material is prepared by separating materials in the waste material according to specific gravity. In some embodiments, separating is effected by contacting the waste material with a liquid selected such that a portion of the waste material sinks in the liquid (and another portion does not sink).
  • the sorted material is enriched in material having a specific gravity within a pre selected range, and the liquid is optionally selected in accordance with the pre-selected range (e.g., selection of a suitable concentration for an aqueous salt solution, as discussed in further detail herein below).
  • the sorted material contains at least 90 weight percents of material having a specific gravity within a pre-selected range. In some embodiments, the sorted material contains at least 95 weight percents of material having a specific gravity within a pre-selected range. In some embodiments, the sorted material contains at least 98 weight percents of material having a specific gravity within a pre-selected range. In some embodiments, the sorted material contains at least 99 weight percents of material having a specific gravity within a pre-selected range. Any value between 90 and 99.9 weight percents is also contemplated according to these embodiments.
  • the term“specific gravity” refers to a ratio of density of a material to a density of pure water under the same conditions (e.g., temperature, pressure).
  • the specific gravity of pure water is defined as 1.
  • the specific gravity is a specific gravity at room temperature (e.g., 25 °C) and atmospheric pressure.
  • specific gravity is a ratio, it is less sensitive than density to changes in conditions (e.g., temperature, pressure).
  • the specific gravity is a specific gravity under working conditions.
  • ambient temperature under working conditions may vary, for example, within a range of about 0 °C to 50 °C, and ambient pressure may vary according to altitude of the location.
  • a pre-selected range for the specific gravity may optionally be characterized by an upper limit and a lower limit, or alternatively, the range may optionally be an open-ended range, for example, characterized by an upper limit with no lower limit, or by a lower limit with no upper limit.
  • the pre-selected range is no more than 1.25, that is, the upper limit of the pre-selected range is no more than 1.25, such that the entire range is no more than 1.25. In some embodiments, the pre-selected range is no more than 1.225. In some embodiments, the pre-selected range is no more than 1.20. In some embodiments, the pre-selected range is no more than 1.175. In some embodiments, the pre selected range is no more than 1.15. In some embodiments, the pre-selected range is no more than 1.125. In some embodiments, the pre-selected range is no more than 1.10.
  • preparation of the sorted material comprises removing at least a portion of certain organic materials (e.g., synthetic polymers, as defined herein) in the waste.
  • the preparation comprises removing at least a portion of polyvinyl chloride, synthetic polymers having a relatively high melting point (e.g., at least 250 °C) and/or thermoset polymers (e.g., as described herein).
  • thermoset polymers synthetic polymers having a melting point of at least 250 °C (e.g., PET, PTFE) and polyvinyl chloride (PVC) are typically characterized by a relatively high specific gravity.
  • PET which is particularly widespread in waste material, e.g., due to its use in food and liquid containers
  • PTFE typically exhibits a specific gravity in a range of 2.1-2.2.
  • polyvinyl chloride typically exhibits a specific gravity in a range of from 1.35-1.45 in its rigid, relatively pure forms
  • flexible forms of polyvinyl chloride typically exhibit a lower specific gravity (e.g., in a range of from 1.1-1.3) due to a presence of plasticizers.
  • a liquid with a specific gravity below about 1.1 may be suitable for removing substantially all polyvinyl chloride
  • a liquid with a moderately higher specific gravity e.g., in a range of from 1.1-1.3
  • thermoset polymers typically comprise a considerable amount of heteroatoms (e.g., nitrogen, oxygen, sulfur), for example, in ester groups, urethane groups, and sulfur cross links of vulcanized rubber, which increase the specific gravity of the polymer.
  • heteroatoms e.g., nitrogen, oxygen, sulfur
  • the sorted material is enriched (relative to the original waste material from which it is derived) in material having a specific gravity below a specific gravity of the liquid.
  • the sorted material is prepared by removing materials which sink in the liquid from the waste material, to thereby obtain the sorted material.
  • the sorted material is enriched (relative to the original waste material from which it is derived) in material having a specific gravity above a specific gravity of the liquid.
  • the sorted material is prepared by removing materials which do not sink in the liquid from the waste material, to thereby obtain the sorted material.
  • the sorted material is enriched (relative to the original waste material from which it is derived) in material having a specific gravity below a specific gravity of a first liquid (e.g., an aqueous salt solution) and above a specific gravity of a second liquid (e.g., water or a dilute aqueous salt solution).
  • a first liquid e.g., an aqueous salt solution
  • a second liquid e.g., water or a dilute aqueous salt solution.
  • the sorting comprises a stage of removing materials which sink in the first liquid from the waste material, as well as a stage of removing materials which do not sink in the second liquid from the waste material.
  • the term“sink” encompasses sinking to a bottom of a liquid (e.g., sedimenting), as well as sinking below a surface of the liquid.
  • a liquid e.g., sedimenting
  • sinking below a surface of the liquid.
  • at least a portion of the inorganic materials of a waste material (which are frequently denser than organic materials) sink to a bottom of the liquid.
  • materials which sink to the bottom are removed (e.g., by removing sediment), and substantially all other materials are collected.
  • materials which float in the liquid are collected (e.g., by skimming a surface of the liquid), and substantially all other materials are removed.
  • Separation of waste material according to specific gravity optionally comprises removing substantially all of the material from the liquid (e.g., both the collected sorted material and the material removed from the waste material in order to obtain the sorted material removed from the liquid), such that the liquid can be reused to separate more waste material according to specific gravity.
  • Removal from the liquid can be for example, by skimming floating material from a surface, removing sedimented material, and/or filtering out material which sinks below a surface of the liquid but does not sink to the bottom.
  • the waste material is stirred in the liquid, for example, by rotation of at least one paddle (e.g., rotation of a paddle wheel).
  • Stirring is optionally selected to be sufficiently vigorous to facilitate separation of different types of material (which may be stuck to one another, for example), while being sufficiently gentle to allow separation of materials in the liquid.
  • stirring comprises perturbation (e.g., rotation, vibration, agitation) at a frequency of 120 per minute or less. In some embodiments, stirring comprises perturbation at a frequency of 60 per minute or less. In some embodiments, stirring comprises perturbation at a frequency of 30 per minute or less. In some embodiments, stirring comprises perturbation at a frequency of 20 per minute or less.
  • perturbation e.g., rotation, vibration, agitation
  • stirring comprises perturbation at a frequency of 10 per minute or less.
  • the liquid may be any type of liquid, including a pure liquid, a solution, and a suspension.
  • the liquid is an aqueous liquid.
  • an aqueous liquid to sort waste material is particularly suitable in the context of provision of a feedstock comprising waste material and a relatively high water content (e.g., as described herein), as the incorporation of water from the aqueous liquid into the sorted material is not necessarily a problem when using such a feedstock.
  • aqueous liquid refers to a liquid in which at least 50 weight percents of the liquid compound(s) therein (e.g., excluding solid materials suspended and/or dissolved in the liquid) is water. In some embodiments, at least 60 weight percents is water. In some embodiments, at least 70 weight percents is water. In some embodiments, at least 80 weight percents is water. In some embodiments, at least 90 weight percents is water. In some embodiments, at least 95 weight percents is water. In some embodiments, at least 98 weight percents is water. In some embodiments, at least 99 weight percents is water. In some embodiments, the liquid component substantially consists of water.
  • the liquid is a solution, for example, an aqueous solution.
  • Suitable solutes for a solution include water-soluble salts, that is, any compound which form ions in water (e.g., sodium chloride, potassium chloride, sodium bromide, potassium bromide, calcium chloride, calcium nitrate, potassium carbonate) and water-soluble carbohydrates (e.g., glucose, sucrose, lactose, fructose).
  • the solute is a salt, that is, the liquid is an aqueous salt solution (solution of ions).
  • the salt comprises sodium chloride.
  • the sodium chloride may optionally be substantially pure.
  • the sodium chloride is mixed with other salts, for example, as in sea salt.
  • the liquid comprises sea water (e.g., sea water diluted with fresh water and/or concentrated sea water, that is, sea water from which a portion of the water has been removed).
  • sea water e.g., sea water diluted with fresh water and/or concentrated sea water, that is, sea water from which a portion of the water has been removed.
  • the liquid consists essentially of sea water.
  • the liquid is a suspension, for example, an aqueous suspension.
  • Suitable suspended materials for a suspension include water-insoluble salts and/or metallic substances, such as, for example, calcium carbonate, iron powder and ferrosilicon (FeSi).
  • the suspended material is magnetic, which facilitates removal its removal from separated waste materials (e.g., for reuse).
  • the specific gravity may be selected in accordance with the materials which are desired to be separated from the waste material and/or with the materials which are desired to be retained in the waste material (e.g., for further processing).
  • the specific gravity of a solution or a suspension can be finely controlled in accordance with the separation requirements, by controlling the concentration of the solute or suspended material.
  • a solution or suspension with a relatively high specific gravity (yet lower than that of the materials to be separated) is to be used, and therefore, a high concentration of the solute or suspended material is included.
  • a specific gravity of the liquid is in a range of from 1.00 to 2.50.
  • a specific gravity of up to 2.50 may be suitable, for example, for removing all or almost all inorganic materials which may be present in the waste material.
  • window glass has a specific gravity of approximately 2.58
  • silica has a specific gravity of approximately 2.65
  • aluminum has a specific gravity of approximately 2.7
  • specific gravities of other minerals and metals are typically even higher.
  • the specific gravity of the liquid is at least 2.00, for example, in a range of from 2.00 to 2.50.
  • a specific gravity of at least 2.00 may be suitable, for example, for retaining all or almost all organic materials, such as plant materials, animal materials, and polymeric materials (e.g., rubber and plastics).
  • the specific gravity of the liquid is at least 1.50, for example, in a range of from 1.50 to 2.00.
  • a specific gravity of at least 1.50 may be suitable, for retaining a large majority of organic materials.
  • the specific gravity is at least 1.60.
  • the specific gravity is at least 1.70.
  • the specific gravity is at least 1.80.
  • the specific gravity is at least 1.90.
  • the specific gravity of the liquid is at least 1.20, for example, in a range of from 1.20 to 1.50.
  • a specific gravity of at least 1.20 may be suitable, for retaining many or even most organic materials, while removing some organic materials (e.g., synthetic polymers).
  • the specific gravity of the liquid is at least 1.25. In some embodiments, the specific gravity of the liquid is at least 1.30. In some embodiments, the specific gravity of the liquid is at least 1.35. In some embodiments, the specific gravity of the liquid is at least 1.40. In some embodiments, the specific gravity of the liquid is at least 1.45.
  • the specific gravity of the liquid is at least 1.01, for example, in a range of from 1.01 to 1.20.
  • a specific gravity in a range of 1.01 to 1.20 may be suitable, for retaining many or even most animal materials and plant materials, while removing many synthetic polymers, such as thermoset polymers, synthetic polymers having a melting point of at least 250 °C (e.g., polyethylene terephthalate (PET), polytetrafluoroethylene (PTFE)) and polyvinyl chloride (PVC).
  • PET polyethylene terephthalate
  • PTFE polytetrafluoroethylene
  • PVC polyvinyl chloride
  • the specific gravity of the liquid is no more than about 1.25 (e.g., about the specific gravity of a saturated aqueous solution of sea salt). In some embodiments, the specific gravity is no more than 1.20. In some embodiments, the specific gravity is no more than 1.15.
  • the specific gravity of the liquid is at least 1.05. In some embodiments, the specific gravity is in a range of from 1.05 to 1.25. In some embodiments, the specific gravity is in a range of from 1.05 to 1.20. In some embodiments, the specific gravity is in a range of from 1.05 to 1.15.
  • the specific gravity of the liquid is at least 1.06. In some embodiments, the specific gravity is in a range of from 1.06 to 1.25. In some embodiments, the specific gravity is in a range of from 1.06 to 1.20. In some embodiments, the specific gravity is in a range of from 1.06 to 1.15.
  • the specific gravity of the liquid is at least 1.07 (e.g., an aqueous sodium chloride solution at a concentration of about 10 weight percents). In some embodiments, the specific gravity is in a range of from 1.07 to 1.25. In some embodiments, the specific gravity is in a range of from 1.07 to 1.20. In some embodiments, the specific gravity is in a range of from 1.07 to 1.15.
  • the specific gravity of the liquid is at least 1.08. In some embodiments, the specific gravity is in a range of from 1.08 to 1.25. In some embodiments, the specific gravity is in a range of from 1.08 to 1.20. In some embodiments, the specific gravity is in a range of from 1.08 to 1.15.
  • the specific gravity of the liquid is at least 1.09. In some embodiments, the specific gravity is in a range of from 1.09 to 1.25. In some embodiments, the specific gravity is in a range of from 1.09 to 1.20. In some embodiments, the specific gravity is in a range of from 1.09 to 1.15.
  • the specific gravity of the liquid is at least 1.10. In some embodiments, the specific gravity is in a range of from 1.10 to 1.25. In some embodiments, the specific gravity is in a range of from 1.10 to 1.20. In some embodiments, the specific gravity is in a range of from 1.10 to 1.15.
  • the specific gravity of the liquid is at least 1.11 (e.g., an aqueous sodium chloride solution at a concentration of about 15 weight percents). In some embodiments, the specific gravity is in a range of from 1.11 to 1.25. In some embodiments, the specific gravity is in a range of from 1.11 to 1.20.
  • the specific gravity of the liquid is at least 1.12. In some embodiments, the specific gravity is in a range of from 1.12 to 1.25. In some embodiments, the specific gravity is in a range of from
  • the specific gravity of the liquid is at least 1.13. In some embodiments, the specific gravity is in a range of from 1.13 to 1.25. In some embodiments, the specific gravity is in a range of from
  • the specific gravity of the liquid is at least 1.14. In some embodiments, the specific gravity is in a range of from 1.14 to 1.25. In some embodiments, the specific gravity is in a range of from
  • the specific gravity of the liquid is at least 1.15 (e.g., an aqueous sodium chloride solution at a concentration of about 20 weight percents). In some embodiments, the specific gravity is in a range of from 1.15 to 1.25. In some embodiments, the specific gravity is in a range of from 1.15 to 1.20.
  • the specific gravity of the liquid is at least 1.175. In some embodiments, the specific gravity is in a range of from 1.175 to 1.25. In some embodiments, the specific gravity is in a range of from 1.175 to 1.20.
  • the specific gravity of the liquid is at least 1.20. In some embodiments, the specific gravity is in a range of from 1.20 to 1.25.
  • the specific gravity of the liquid is approximately 1.03 or less, for example, in a range of from 1.01 to 1.03.
  • a specific gravity in a range may conveniently and inexpensively be obtained, for example, using sea water or diluted sea water, as sea water has a specific gravity in a range of from 1.02 to 1.03, typically approximately 1.025.
  • liquids with relatively low specific gravities are relatively convenient to prepare and use, they may readily be obtained from solutions of common and inexpensive materials.
  • specific gravities of aqueous sodium chloride solutions range from 1.00 to about 1.20, depending on concentration.
  • Relatively low specific gravities are particularly suitable for efficiently removing inorganic materials, including for example, composite materials (e.g., fiberglass and polymers with glass filler) which have a lower specific gravity than pure inorganic materials, as well as relatively dense organic materials such as PVC, PET, PTFE and thermoset polymers (e.g., as described herein).
  • specific gravities of at least 1.20, optionally at least 1.25 are obtained using high density water- soluble salts such as calcium salts, magnesium salts, transition metal salts, bromide salts and/or using suspensions.
  • the concentration of salt (e.g., sodium chloride, sea salt) in the salt solution is at least 3 weight percents. In some embodiments, the concentration of salt is in a range of from 3 to 35 weight percents. In some embodiments, the concentration of salt is in a range of from 3 to 30 weight percents. In some embodiments, the concentration of salt is in a range of from 3 to 25 weight percents.
  • the concentration of salt (e.g., sodium chloride, sea salt) in a salt solution is at least 5 weight percents. In some embodiments, the concentration of salt is in a range of from 5 to 35 weight percents. In some embodiments, the concentration of salt is in a range of from 5 to 30 weight percents. In some embodiments, the concentration of salt is in a range of from 5 to 25 weight percents. In some of any of the respective embodiments, the concentration of salt (e.g., sodium chloride, sea salt) in a salt solution (e.g., aqueous salt solution) is at least 10 weight percents.
  • the concentration of salt is in a range of from 10 to 35 weight percents. In some embodiments, the concentration of salt is in a range of from 10 to 30 weight percents. In some embodiments, the concentration of salt is in a range of from 10 to 25 weight percents.
  • the concentration of salt (e.g., sodium chloride, sea salt) in a salt solution is at least 15 weight percents. In some embodiments, the concentration of salt is in a range of from 15 to 35 weight percents. In some embodiments, the concentration of salt is in a range of from 15 to 30 weight percents. In some embodiments, the concentration of salt is in a range of from 15 to 25 weight percents.
  • the concentration of salt (e.g., sodium chloride, sea salt) in a salt solution is at least 20 weight percents. In some embodiments, the concentration of salt is in a range of from 20 to 35 weight percents. In some embodiments, the concentration of salt is in a range of from 20 to 30 weight percents. In some embodiments, the concentration of salt is in a range of from 20 to 25 weight percents.
  • cellulose and other compounds from animal material or plant material are characterized by a specific gravity of approximately 1.5, but that animal materials and plant materials typically exhibit considerably lower specific gravities as a result of porosity (for, example, the voids in wood, which reduce the specific gravity of most wood to less than 1) and/or a considerable amount of water therein (which results in a specific gravity close to 1).
  • porosity for, example, the voids in wood, which reduce the specific gravity of most wood to less than 1
  • a considerable amount of water therein which results in a specific gravity close to 1).
  • a specific gravity of many materials is indicative of its water content and/or porosity.
  • removal of materials with a relatively high specific gravity may increase a water content of the sorted material (e.g., by removing relatively dry animal material and/or plant material, while retaining relatively moist animal material and/or plant material), resulting in the obtained sorted material having a water content higher than that of the waste material (e.g., even without absorption of water during the separation process).
  • removal of materials as described herein may be used to increase water content of the obtained sorted material (e.g., to a water content described herein), relative to the original waste material, by facilitating absorption of water and/or by removing relatively dry materials.
  • removal of materials with a relatively high specific gravity may result in the sorted material having a reduced (average) specific gravity, for example, less than 1.30, optionally less than 1.35, optionally less than 1.20, optionally less than 1.15, optionally less than 1.10, optionally less than 1.05, and optionally less than 1.00.
  • the waste material is a shredded waste material, that is, obtained in a shredded form, for example, waste material has been subjected to crushing (e.g., by a hammer mill).
  • the shredded waste material is further shredded as described herein.
  • the terms “shred”, “shredded” and “shredding” and the further grammatical diversions thereof refer to reduction in size of the solid components of material (e.g., waste material, sorted material) by any mechanical means, including chopping, dicing, grinding, crumbling, cutting, tearing and crushing.
  • a variety of devices are available in the art for shredding waste material, including, without limitation, industrial shredders, grinders, chippers and granulators.
  • the device used for shredding is designed to be suitable for handling the presence of hard substances such as metal, glass, clay and stone in waste material, for example, by using blades or plates made of robust materials such as stainless steel or titanium.
  • shredder encompasses all devices configured for shredding, as defined herein.
  • waste material is shredded prior to removal of materials by contacting with a liquid (e.g., as described herein for, e.g., sorting), for example, so as to facilitate separation of different types of material which are attached to one another (e.g., metal attached to plastic) and/or to facilitate escape of gases and entry of liquid to crevices in particles of waste material.
  • a liquid e.g., as described herein for, e.g., sorting
  • solid particles in the shredded material are less than 50 mm in diameter, optionally less than 20 mm in diameter, when materials are removed. In some embodiments, the solid particles are less than 10 mm in diameter when materials are removed.
  • shredding prior to removal of materials is effected by hammers (e.g., crushing), for example, by a hammer mill.
  • hammers are relatively resistant to damage associated with a presence of hard materials (e.g., inorganic materials such as mineral, ceramic, glass, metal) in waste material which has not yet been subjected to removal of such materials.
  • hard materials e.g., inorganic materials such as mineral, ceramic, glass, metal
  • a sorted material is shredded subsequent to removal of materials by contacting with a liquid (e.g., by shredding to a particle size described herein), for example, so as to remove hard and dense materials (e.g., inorganic materials) which may damage an apparatus effecting shredding, and/or so that particles of the waste material will not be so small as to interfere with removal of materials.
  • a liquid e.g., by shredding to a particle size described herein
  • small particles generally separate according to specific gravity more slowly than do large particles.
  • the solid particles are at least 2 mm in diameter when materials are removed. In some embodiments, the solid particles are at least 5 mm in diameter when materials are removed. In some embodiments, the solid particles are at least 10 mm in diameter when materials are removed.
  • shredding subsequent to removal of materials is effected by cutting (e.g., by blades and/or plates), for example, in an industrial shredder.
  • such a shredding technique is particularly suitable for forming relatively small particles, which may be more suitable for further processing (e.g., by mixing and heating as described herein), but may be relatively susceptible to hard and dense materials (e.g., inorganic materials), and therefore suitable for sorted material which has a reduced amount of such materials.
  • waste material is shredded prior to removal of materials to a relatively large particle size (e.g., at least 10 mm in diameter), for example, using crushing, hammers and/or similar techniques.
  • a relatively large particle size e.g., at least 10 mm in diameter
  • the sorted material is then optionally further shredded to smaller particles of a size (e.g., less than 10 mm in diameter) selected as suitable for further processing (e.g., mixing and heating as described herein).
  • the method comprises more than one cycle of separating materials according to specific gravity.
  • waste material is contacted with an aqueous liquid (e.g., as described herein) to thereby obtain a partially sorted material, and the partially sorted waste material is further subjected to at least one additional cycle of separating materials according to specific gravity, to thereby obtain a sorted material.
  • the separating comprises contacting the partially sorted waste material with an additional liquid (e.g., a liquid described herein for separating materials).
  • each cycle may be effected with a liquid (e.g., an aqueous salt solution) which is the same or different than a liquid (e.g., an aqueous salt solution) used in another cycle, and that each cycle may independently comprise removing the high-density materials (e.g., materials which sink in the liquid) from the waste material or removing the low- density materials (e.g., materials which float in the liquid) from the waste material.
  • a liquid e.g., an aqueous salt solution
  • a liquid e.g., an aqueous salt solution
  • At least one cycle of separating materials according to specific gravity comprises removing material which sinks in the liquid of that cycle.
  • at least one cycle other than the first cycle i.e., at least one additional cycle
  • comprises removing material which sinks in the liquid of that cycle i.e., an additional liquid described herein.
  • a first cycle comprises removing material which sinks in the liquid of that cycle.
  • a first cycle and at least one additional cycle comprises removing material which sinks in the liquid of that cycle.
  • At least one cycle of separating materials according to specific gravity comprises removing material which floats in the liquid of that cycle.
  • a first cycle comprises removing material which sinks in the liquid of that cycle, and at least one later cycle comprises removing material which floats in the liquid of that cycle.
  • Each cycle may be independently optionally further comprise shredding the obtained sorted material (optionally partially sorted material after cycles other than the final cycle) subsequent to contact with the liquid of that cycle (e.g., as described herein).
  • at least one cycle other than the first cycle i.e., at least one additional cycle
  • at least one cycle other than the first cycle further comprises shredding of the sorted material subsequent to contact with the liquid of that cycle (i.e., an additional liquid described herein).
  • the final cycle comprises shredding of the sorted material (i.e., after contact with the liquid of the final cycle).
  • each cycle comprises shredding of the obtained sorted material (including partially sorted material after cycles other than the final cycle).
  • removal of liquid is performed subsequent to at least one cycle of separating materials according to specific gravity.
  • the removal of liquid may optionally be effected by drainage (e.g., gravity-driven drainage) and/or compression of the sorted material, for example, using a screw press.
  • at least a portion of the removed liquid is reused for separating materials as described herein.
  • the salt e.g., alkali metals and/or halogens
  • elements of the salt e.g., alkali metals and/or halogens
  • carbon and hydrogen e.g., because oxygen and nitrogen may be depleted due to their presence in inorganic materials and/or organic materials having a relatively high specific gravity
  • compositions, method or structure may include additional ingredients, steps and/or parts, but only if the additional ingredients, steps and/or parts do not materially alter the basic and novel characteristics of the claimed composition, method or structure.
  • a compound or“at least one compound” may include a plurality of compounds, including mixtures thereof.
  • range format is merely for convenience and brevity and should not be construed as an inflexible limitation on the scope of the invention. Accordingly, the description of a range should be considered to have specifically disclosed all the possible subranges as well as individual numerical values within that range. For example, description of a range such as from 1 to 6 should be considered to have specifically disclosed subranges such as from 1 to 3, from 1 to 4, from 1 to 5, from 2 to 4, from 2 to 6, from 3 to 6 etc., as well as individual numbers within that range, for example, 1, 2, 3, 4, 5, and 6. This applies regardless of the breadth of the range.
  • method refers to manners, means, techniques and procedures for accomplishing a given task including, but not limited to, those manners, means, techniques and procedures either known to, or readily developed from known manners, means, techniques and procedures by practitioners of the chemical arts.
  • Ethylene- 1 -butene copolymer (LC175) was obtained from Polyram (Israel).
  • Low-density polyethylene (recycled) was obtained from a local recycling service.
  • Polypropylene (Capilene® SW 75) was obtained from Carmel Olefins Ltd. (Israel).
  • RDL reuse-derived fuel
  • Hiriya Recycling Park Israel
  • This RDL is depleted in recyclable plastic relative to raw waste material.
  • the RDL was therefore supplemented with 30 weight percents polyethylene (low-density, recycled) in order to simulate raw waste material. Similar results (not shown) were obtained using municipal waste material (without supplementation by polyethylene) obtained from Cohen Zvi & Bros. (Israel). Izod impact strength testing:
  • Impact strengths were determined according to a standard Izod impact strength test for plastics (ASTM D256). Results are presented in units of J/m (joules (energy lost) per meter (thickness)).
  • Tensile modulus, tensile strength at break, tensile strength at yield, elongation at break, and elongation at yield were determined according to standard procedures (ISO 527). Extension rate was typically 50 mm/minute, except for tensile modulus measurement, which was effected using a 1 mm/minute rate.
  • Waste material in the form of RDF (refuse derived fuel) was subjected to a separation process in an aqueous salt solution, such that materials which sank in the solution (e.g., inorganic materials) were removed.
  • the remaining waste material was compressed with a screw press, and then (while still wet) supplemented with recycled LDPE (low density polyethylene) at a ratio of 70 parts RDF per 30 parts LDPE (by dry weight).
  • the obtained mixture was then subjected to heating and shear forces for about 5-15 minutes in a single screw-type extruder (EREMA) once, twice or three times; optionally followed by treatment with heating and shear forces in a twin screw-type extruder (Coperion).
  • EREMA single screw-type extruder
  • the POE was added by co-extrusion in the single screw-type extruder (at the first step in which such an extruder was used), or by co-extrusion in the twin screw-type extruder (in a portion of the experiments in which such an extruded was used).
  • processed material without added POE was also prepared, referred to herein as“1000”.
  • Tested samples of 1400 material exhibited a tensile modulus of 701 MPa, a yield strength of 8.8 MPa, a strength at break of 7.4 MPa, an elongation at yield of 5.6 %, and an elongation at break of 21.0 %.
  • Tested samples of 1415 material exhibited a tensile modulus of 568 MPa, a yield strength of 9.1 MPa, a strength at break of 6.7 MPa, an elongation at yield of 7.6 %, and an elongation at break of 32 %.
  • tested samples of 1000 material exhibited a tensile modulus of 994 MPa, a yield strength of 12 MPa, a strength at break of 11 MPa, an elongation at yield of 4.5 %, and an elongation at break of 9.1 %.
  • the obtained polymeric material comprising processed waste material and POE was then compounded with PP (polypropylene) at a ratio of 30:70 or 50:50 (processed waste material: PP), and the mechanical properties of the obtained products was determined (according to procedures described hereinabove). For comparison, the mechanical properties of the polymeric material per se and PP per se were also tested.
  • PP polypropylene
  • the impact strength (as determined by notched Izod test) of the 1400 polymeric material generally correlated with the number of processing steps performed (e.g., when comparing samples differing only in the number of processing steps performed), indicating that the impact strength was associated with the processing and not by the raw waste material.
  • the impact strength (as determined by notched Izod test) of the 1400 polymeric material was greater than that of the polypropylene, and the impact strength of the 70:30 polypropylene-processed waste material blend was closer to that of the polymeric material per se than to that of the polypropylene (when comparing samples prepared with identical processing steps, i.e., single screw x3 and no twin screw), even though the polypropylene represented the majority of the material.
  • the impact strength of the 50:50 polypropylene- 1400 polymeric material blend was greater than that of either the 1400 polymeric material or polypropylene (when comparing samples prepared with identical processing steps).
  • Table 2 Izod notched impact strength for materials with various proportions of polypropylene and control (1000) polymeric material (without added polyolefin elastomer), prepared by 3 passes through a single screw-type extruder, optionally followed by a pass through a twin screw-type extruder (to aid comparison, highlighted values are for samples with same processing steps)
  • the impact strength (as determined by notched Izod test) of the 1415 polymeric material was considerably greater than that of the polypropylene, and the impact strength of the 70:30 polypropylene- 1415 polymeric material blend was closer to that of the 1415 polymeric material than to that of the polypropylene (when comparing samples prepared with identical processing steps, i.e., single screw x3 and no twin screw), even though the polypropylene represented the majority of the material.
  • the impact strength of the 50:50 polypropylene- 1415 polymeric material blend was greater than that of either the 1415 polymeric material or polypropylene (when comparing samples prepared with identical processing steps).
  • the density of the processed waste material was 1.24 gram/cm 3 ; whereas upon being compounded with polypropylene at a 70:30 ratio (PP: processed waste material), the density was about 1 gram/cm 3 .
  • the processed waste material was then analyzed by infrared (IR) spectroscopy and thermal analysis.
  • polyethylene e.g., which exhibits a prominent pair of peaks in the range of 2800-3000 cm 1
  • polypropylene e.g., which exhibit a peak at about 1400 cm 1
  • cellulose e.g., calcium carbonate
  • calcium carbonate a common filler for polypropylene and paper
  • traces of talc another filler
  • the processed material exhibited peaks associated with melting at about 109 °C and about 126 °C (consistent with the melting points of different varieties of commercial polyethylene), and at about 163 °C (consistent with the melting point of commercial polypropylene), as well as a much smaller peak at about 253 °C (consistent with the melting point of commercial polyethylene terephthalate). As further shown therein, after cooling and heating the sample a second time, no peak was observed at 253 °C, although peaks at about 109, 126 and 163 °C remained.
  • Table 4 Thermal analysis of heat flow of an exemplary polymeric material (8.8 mg) prepared from waste material, upon heating from -80 °C to 320 °C, followed by cooling from 320 °C to - 30 °C, and then heating a second time from -30 °C to 320 °C; melting points were observed as peaks at indicated temperatures, and the heat associated with phase transition (AH) was calculated as the area of the peak (when multiple peaks overlapped, a single AH value was calculated for the overlapping peaks, and the peak with the highest amplitude is indicated by underlining)
  • AH heat associated with phase transition
  • the processed material comprises polyethylene and polypropylene, with only much smaller amounts of denser polyethylene terephthalate.
  • the processed waste material is composed largely of relatively light components of municipal waste material (polyethylene, polypropylene and cellulose), which may be attributed to the separation process using a salt solution, which can remove polymers with a relatively high density (e.g., polyvinyl chloride and/or polyethylene terephthalate and other polyesters) in addition to inorganic materials such as metal and glass.
  • a salt solution which can remove polymers with a relatively high density (e.g., polyvinyl chloride and/or polyethylene terephthalate and other polyesters) in addition to inorganic materials such as metal and glass.
  • Processed waste material was prepared according to procedures such as described hereinabove, using one, two or three passes in a single screw-type extruder, or one pass in a twin screw-type extruder (without prior processing in single screw-type extruder), and without addition of POE.
  • FIGs. 2A-2E The effect of processing is shown in FIGs. 2A-2E.
  • RDF which was subjected to a separation process in an aqueous salt solution (20 weight percents sea salt) is shown in FIG. 2A. This RDF (while wet) was then supplemented with 30 % LDPE to form a feedstock.
  • processing with one (FIG. 2B), two (FIG. 2C) or three (FIG. 2D) passes through an extruder resulted in a processed material which was clearly different than and more homogeneous than the feedstock, and homogeneity increased in accordance with the number of passes through an extruder.
  • a homogeneous processed material was also obtained upon one pass through a twin screw-type extruder.
  • Polymeric materials comprising POE and processed waste material were prepared according to procedures such as described in Example 1, comprising 10 or 15 weight percents of POE (similar to the 1400 and 1415 materials described in Example 1).
  • the polymeric materials further comprised, as additional ingredients, a desiccant (80 % CaO in a polyethylene carrier), and a hydrophobic substance - calcium stearate or epoxidized soybean oil (ESBO).
  • a desiccant 80 % CaO in a polyethylene carrier
  • ESBO hydrophobic substance - calcium stearate or epoxidized soybean oil

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Abstract

L'invention concerne un matériau polymère, comprenant un élastomère polyoléfinique (au moins 1 pour cent en poids) et un matériau traité (au moins 70 pour cent en poids) préparé en soumettant une charge d'alimentation à un mélange par l'intermédiaire de forces de cisaillement et à un chauffage. La charge d'alimentation possède une teneur en eau d'au moins 13 % en poids, et en poids sec au moins 40 % en poids de la charge d'alimentation sont des déchets, au moins 90 % en poids des déchets étant un matériau organique, et au moins 20 % en poids de la charge d'alimentation étant du polyéthylène. L'invention concerne en outre un matériau contenant du polypropylène comprenant du polypropylène et le matériau polymère, des articles manufacturés le comprenant, ainsi que des procédés de préparation d'un matériau polymère par soumission de la charge d'alimentation et de l'élastomère polyoléfinique de manière concomitante à un mélange par l'intermédiaire de forces de cisaillement et à un chauffage, ainsi que des matériaux polymères pouvant être obtenus par un tel procédé.
PCT/IL2020/050322 2019-03-18 2020-03-18 Matériau polymère obtenu à partir de déchets WO2020188567A1 (fr)

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WO2022169916A1 (fr) * 2021-02-02 2022-08-11 EcoGensus LLC Compositions contenant des déchets solides
US11964314B2 (en) 2021-02-02 2024-04-23 EcoGensus LLC Powders comprising solid waste materials
JP7474994B2 (ja) 2019-05-24 2024-04-26 パナソニックＩｐマネジメント株式会社 エネルギ移動回路、及び蓄電システム

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WO2010082202A2 (fr) * 2009-01-15 2010-07-22 Novarena Technologies Ltd. Matériau composite et procédé de préparation de celui-ci à partir de déchets sensiblement non triés
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EP1201391A1 (fr) * 2000-10-25 2002-05-02 Yves Adelhanoff Procédé pour le traitement et la récupération de déchets de matières synthétiques
WO2010082202A2 (fr) * 2009-01-15 2010-07-22 Novarena Technologies Ltd. Matériau composite et procédé de préparation de celui-ci à partir de déchets sensiblement non triés
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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP7474994B2 (ja) 2019-05-24 2024-04-26 パナソニックＩｐマネジメント株式会社 エネルギ移動回路、及び蓄電システム
WO2022169916A1 (fr) * 2021-02-02 2022-08-11 EcoGensus LLC Compositions contenant des déchets solides
US11692082B2 (en) 2021-02-02 2023-07-04 EcoGensus LLC Compositions containing solid waste material
US11964314B2 (en) 2021-02-02 2024-04-23 EcoGensus LLC Powders comprising solid waste materials

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