WO2024030025A1 - Procédé et appareil pour le recyclage de polychlorure de vinyle (pvc) - Google Patents

Procédé et appareil pour le recyclage de polychlorure de vinyle (pvc) Download PDF

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Publication number
WO2024030025A1
WO2024030025A1 PCT/NL2023/050412 NL2023050412W WO2024030025A1 WO 2024030025 A1 WO2024030025 A1 WO 2024030025A1 NL 2023050412 W NL2023050412 W NL 2023050412W WO 2024030025 A1 WO2024030025 A1 WO 2024030025A1
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WO
WIPO (PCT)
Prior art keywords
pvc
feed stream
range
waste
scco2
Prior art date
Application number
PCT/NL2023/050412
Other languages
English (en)
Inventor
Hendrik Wolters
Original Assignee
Cescco2 B.V.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Cescco2 B.V. filed Critical Cescco2 B.V.
Publication of WO2024030025A1 publication Critical patent/WO2024030025A1/fr

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Classifications

    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J11/00—Recovery or working-up of waste materials
    • C08J11/04—Recovery or working-up of waste materials of polymers
    • C08J11/06—Recovery or working-up of waste materials of polymers without chemical reactions
    • C08J11/08—Recovery or working-up of waste materials of polymers without chemical reactions using selective solvents for polymer components
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D11/00—Solvent extraction
    • B01D11/02—Solvent extraction of solids
    • B01D11/0203—Solvent extraction of solids with a supercritical fluid
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D11/00—Solvent extraction
    • B01D11/02—Solvent extraction of solids
    • B01D11/0215—Solid material in other stationary receptacles
    • B01D11/0223—Moving bed of solid material
    • B01D11/0226—Moving bed of solid material with the general transport direction of the solids parallel to the rotation axis of the conveyor, e.g. worm
    • 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
    • B29B17/02—Separating plastics from other materials
    • 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
    • B29B17/02—Separating plastics from other materials
    • B29B2017/0213—Specific separating techniques
    • B29B2017/0217—Mechanical separating techniques; devices therefor
    • B29B2017/0224—Screens, sieves
    • 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
    • B29B17/02—Separating plastics from other materials
    • B29B2017/0213—Specific separating techniques
    • B29B2017/0293—Dissolving the materials in gases or liquids
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2027/00—Use of polyvinylhalogenides or derivatives thereof as moulding material
    • B29K2027/06—PVC, i.e. polyvinylchloride
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/0005—Condition, form or state of moulded material or of the material to be shaped containing compounding ingredients
    • B29K2105/0038—Plasticisers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/0005—Condition, form or state of moulded material or of the material to be shaped containing compounding ingredients
    • B29K2105/0044—Stabilisers, e.g. against oxydation, light or heat

Definitions

  • the invention relates to the field of recycling waste products. More in particular, it relates to a method and apparatus for the upgrading of waste PVC, including the removal of additives therefrom and the separation from other solid impurities such as metal, rubber and/or polymer particles.
  • PVC Polyvinyl chloride
  • the PVC material is strong, durable, lightweight and versatile; it makes a perfect material for many applications. More than 75% of the total PVC is used in industrial applications and especially the building and construction sector where PVC products have long life span of over 10-years.
  • JP4685728 relates to a raw material recovery method for a lead-containing soft PVC material.
  • scCO2 and an alcoholic solvent are used to extract (phthalate) plasticizer from PVC resin while PVC is in the solid state and optionally pulverized or crushed.
  • the examples describe operating temperatures of 55°C.
  • US2009/056742A1 relates to a process for the radioactive decontamination, cleaning of a solid organic substrate contaminated, polluted, soiled by solid radioactive particulate inorganic contaminants, using dense pressurized CO2, in particular supercritical CO2. Exemplified is the removal of CeO2 from solid PVC disks using TBP as complexing agent.
  • the PVC is present as solid granules and it takes several hours to extract any components.
  • a third step comprising the separation of such solids from the PVC has to be carried out.
  • a chelating agent in the PVC feed stream, like an organophosphonate or an aminopolycarboxylate, allows for the simultaneous removal of toxic heavy metals such as lead based compounds.
  • the invention provides a method for recycling poly(vinylchloride) (PVC), comprising contacting a feed stream comprising waste PVC at a temperature in the range of 80-150°C with supercritical carbon dioxide (scCO2), followed by subjecting the feed stream to a melt filtration process.
  • PVC poly(vinylchloride)
  • scCO2 supercritical carbon dioxide
  • the melt filtration process is ideally performed under conditions allowing for the filtration of all solid components through the filter.
  • all materials solid under the conditions employed are separated from PVC through melt filtration.
  • scCO2 has a plasticizing effect on most polymers, thus decreasing the softening temperature. This effect is different for different polymers.
  • the process of the invention is performed under conditions where PVC flows as a melt while other (contaminating) polymer(s) remain solid, thereby achieving the desired separation.
  • the relatively low temperature ensures easy passage PVC through the filter whereas the filter removes solid particles (for example metals and rubbers) and contaminating polymer components like polyolefins (e.g. polyethylene and polypropylene) that are solid at the operating temperatures of the present invention.
  • a feed stream comprising waste PVC at a temperature in the range of 80-150°C is contacted with supercritical carbon dioxide (scCO2), followed by subjecting the feed stream to melt filtration, under conditions allowing for the removal of plasticizers and/or heavy metals.
  • scCO2 supercritical carbon dioxide
  • ES2796956A1 relates to a process for removing paint from a painted thermoplastic material, for example PVC, PE, PP, synthetic rubber, and mixtures thereof.
  • the process comprises introducing the painted material into a first extruder where a first stage of melt extrusion of the thermoplastic material takes place, during which a CO2 injection process is carried under supercritical conditions.
  • ES2796956A1 teaches to perform the first stage of melt extrusion between 160 and 280°C, which is significantly higher than the temperature of the process according to the present invention and which does not allow for the removal of contaminating polymers such as olefins.
  • the process of the present invention is performed at a temperature up to 140°C, or up to 135°C.
  • the temperature is at least 80°C to ensure that the viscosity of molten PVC is sufficiently low to allow smooth passage through the filter.
  • the temperature is at least 90°C, 100°C or 110°C. Good results were obtained in the range of 90-150°C, preferably 100-140°C, 110-145°C, 110-140°C, 120-140°C, 80-135°C or 80-130°C.
  • the process is performed at a temperature in the range of about 110-135°C, with a CO2 flow of 50 to 100 g/h.
  • the feed stream can contain from less than one percent PVC to more than ninety nine percent PVC.
  • the feed stream may comprise up to about 30 wt%, preferably up to about 20 wt, more preferably up to about 10 wt% of polymers other than PVC.
  • the other polymers comprise one or more selected from the group of elastomer type polymer (rubber) and polyolefins, such as polyethylene (PE) and polypropylene (PP).
  • a method of the invention is a particularly suitable for recycling and/or upgrading a feed stream comprising waste of a PVC product that was originally formulated with polyolefins and/or rubbers, such as waste insulation cable parts.
  • a preferred plastic waste material contains a mixture of PVC and rubber particles, for example up to 10wt% of ground tire rubber (GTR).
  • the feed stream comprises one or more of LDPE (low-density polyethylene), LLDPE (linear low-density polyethylene) and HDPE (high-density polyethylene).
  • LDPE low-density polyethylene
  • LLDPE linear low-density polyethylene
  • HDPE high-density polyethylene
  • a method as provided herein is suitably used to remove heavy metals and/or plasticizers from a feed stream comprising PVC.
  • tribasic lead sulfate is one of the most frequently used lead stabilizer, while dibasic lead phosphite and phthalate, dibasic lead carbonate (DBLC), dibasic lead stearate (DBLS) were also commonly used.
  • the desired lead stabilizer is chosen for each specific PVC application.
  • lead phosphite is used to increase light stability or weatherability. Combinations of different lead stabilizers are also possible to achieve the desired properties.
  • lead stabilizers are present in low amounts up to 6 to 12 weight percent with respect to the net amount of PVC (phr, parts per hundred resin).
  • Exemplary plasticizers comprise phthalate and adipate plasticizers such as dioctyl phthalate/adipate, diisooctyl phthalate/adipate and dialkyl (C7 -C9)- phthalate/adipate.
  • SFE supercritical fluid extraction
  • a method of the invention may further comprise contacting said PVC feed stream with scCO2 in the presence of a chelating agent, in particular a chelating agent that is soluble in scCO2 under the employed (temperature and pressure) conditions.
  • the chelating agent is a phosphonate or amino-containing compound which is soluble in the scCO2 phase under the employed experimental conditions.
  • it is an organophosphonate or an aminopolycarboxylate.
  • the melt filtration process is typically performed using a filter unit equipped with a set of filters.
  • the mesh size of the filter depends on the dimensions of the solid impurities that are present and to be removed. However, the finer the filter mesh, the higher the pressure drop and the more energy is required for the melt filtration process. Thus, the choice of the optimal filter is a trade-off; it must be fine enough to remove the unwanted solids yet not too fine to control the energy costs.
  • the fine filter preferably has a mesh size in the range of 180 to 350 gm.
  • the coarse filter preferably has a mesh size in the range of 1000 to 1300 gm, such as 1100, 1200 or 1300 gm.
  • the filter unit comprises a filter in the range 190-300 gm supported by two filters of about 1100 pm filters.
  • the invention also relates to a reaction mixture comprising a PVC waste stream in admixture with scCO2. Furthermore, it provides a purified or semi-purified PVC composition obtainable by a method as herein disclosed, preferably wherein said PVC composition is characterized by a Pb-content up to 5 wt% and / or a phthalate content up to 30 wt%.
  • a still further aspect relates to an apparatus that is specifically designed for performing a method for recycling waste PVC as taught herein.
  • the invention provides an apparatus for recycling/upgrading waste PVC, comprising an extruder provided with a melt filtration unit for receiving a plastic melt issuing from the extruder, wherein the melt filtration unit comprises a fine metal (iron; stainless steel) wire mesh supported on each side by (sandwiched in between) two coarse metal wire mesh filters.
  • the extruder is equipped with a pressure vessel containing supercritical carbon dioxide.
  • FIG. 1A showing a schematic drawing of an exemplary PVC recycling apparatus comprising a co-rotating twin screw extruder module, operably connected to a module comprising a filtration unit and extrusion head.
  • the heating of each module can be controlled independently with a heating system.
  • the extruder is equipped with a scCO2 vessel supplying scCO2 into the extruder. Also indicated is a feed hopper for the direct feeding of a PVC feed stream into the modified extruder.
  • Co-rotating twin screw extruder comprise with two symmetrical screws driven by motor either directly or indirectly in the barrel casing.
  • the two screws can rotate synchronously in the same direction, either clockwise or counterclockwise.
  • the screw surface set with alternating screw flight.
  • This kind of co-rotating twin-screws has been widely used in the food industry and in feed manufacturing. Good results are obtained with an apparatus comprising a twin-screw extruder with a screw length-to-diameter ratio (L/D) in the range of 25-35, preferably about 30.
  • Figure IB shows an alternative design of an apparatus for recycling/up grading waste PVC, wherein a first module comprising a feed hopper and an extruder is operably connected to a second module comprising a static mixer and a filtration unit for receiving a plastic melt issuing from the static mixer.
  • the second module is equipped with a pressure vessel containing scCO2.
  • scCO2 may be injected in between the extruder and the static mixer, or in the static mixer.
  • a one-way valve may be present before the scCO2 injection zone. This design is fundamentally different from ES2796956A1.
  • the invention also provides an apparatus for recycling/up rading waste PVC, wherein a first module comprising an extruder is operably connected to a second module comprising a static mixer and a filtration unit for receiving a plastic melt issuing from the static mixer, and wherein the second module is equipped with a pressure vessel containing scCO2.
  • the melt filtration unit in an apparatus of the invention preferably comprises a fine metal (iron; stainless steel) wire mesh supported on each side by (sandwiched in between) two coarse metal wire mesh filters, preferably a 190-300 pm filter supported by about 1100 pm filters. See Figure 2.
  • the invention also relates to the use of the apparatus in a PVC recycling/up grading method as herein disclosed.
  • Figure 1 (A) Schematic set-up of an exemplary apparatus comprising an extruder provided with a scCO2 supply and a filtration unit. (B) Schematic set-up of an exemplary apparatus comprising a first module comprising an extruder operably connected to a second module comprising a static mixer and a sandwich filtration unit Fl for receiving a plastic melt issuing from the static mixer.
  • the second module is equipped with a pressure vessel containing scCO2.
  • Optional filter F2 and one-way valve V may be present upstream of the static mixer.
  • Figure 2 close-up of a representative filtration unit showing a fine mesh filter sandwiched between two coarse supporting filters and stainless steel rings.
  • Figure 3 dimensions of the specimens used in the tensile tests.
  • Figure 4 representative FTIR (Fourier Transform Infrared) analysis of PVC formulated with about 30wt% of di-octylphtalate. The grey curve shows the typical string absorption of the plasticizers at about 1730 cm-1. After melt extrusion in the presence of scCO2 (black curve), the peak at 1730 cm-1 (see arrow) clearly decreases in intensity with respect to others typical of PVC, e.g. at 1430 cm-1.
  • FTIR Fast Transform Infrared
  • Waste PVC was delivered by nearby companies and originated from different sources, including wire insulation cable (TRH Recycling B.V., Emmen) and waste LP vinyl records (Deepgrooves, Leeuwarden).
  • Organophosphonates trioctylphosphine oxide 99% (TOPO), bis(2,4,4- trimethylpentyl) monothiophosphinic acid 85% (Cyanex 302) and Ethylenediaminetetraacetic acid (EDTA) were purchased from Sigma Aldrich and used as delivered.
  • PVC producer Shin-Etsu supplied two PVC feed streams containing known concentrations of lead compounds and plasticizer. The feed stream compositions are given below.
  • Supercritical fluid extraction (SFE) experiments were conducted in an ExtrateX extraction setup containing a CO2 flow which is continuously recycled.
  • This experimental scale setup was equipped with a 100 mL extraction vessel and a 300 mL separation vessel.
  • the pressure, temperature, scCCL mass flowrate and extraction time could be set to the desired level in a wide range, e.g. up to 700 bar, 150 °C and 100 gram/min scCO2.
  • the temperature inside the separation vessel was be set to the desired value in a small range (approximately 30 to 70 °C), while the pressure was fixed and similar to the pressure in the CO2 vessel.
  • Organophosphorus chelating agent was added together with the waste PVC in the extraction vessel and collected in the separation vessel. Either a solely dynamic extraction or a static extraction followed by dynamic extractions were performed. In case of static extraction, the inlet and outlet of the reactor are closed as soon as the desired pressure is reached. In dynamic extraction, all lines are open and CO2 is continuously circulated. The extraction period was started as soon as pressure and mass flow were stabilized (in case of dynamic extraction), while temperature was increased during the first 5 to 10 minutes of the experiment to reach the set level. The extraction vessel was filled up to about 90 Vol.% and contained initially about 45 gram waste PVC particles of a few millimeters in size.
  • the extruder was equipped with a SCCO2 supply.
  • the extruder contains five independently controlled heating zones, a feed hopper and a pressure indicator.
  • a tube with a screwable head comprising a set of selected iron meshes served as a filtration unit. This filtration head was heated using a temperature adjustable heat gun.
  • Figure 2 shows a close-up of the filtration unit.
  • three different iron mesh filters are used: 1100 pm, 300 pm and 190 pm.
  • Two supporting filters with a large size opening (1100 gm) were used to "sandwich” one finer filter (e.g. 300 or 190 gm).
  • GTR ground tire rubber
  • the rubber was efficiently separated from the PVC.
  • the rubber content in the extrudate was 1.1 wt % as opposed to the initial 4 wt %.
  • Total initial mass waste PVC Figure 4 shows a representative FTIR (Fourier Transform Infrared) analysis.
  • a PVC formulated with about 30wt% of di-octylphtalate plasticizer shows the typical string absorption of the plasticizers at about 1730 cm-1. After extrusion (black curve), the peak at 1730 cm-1 clearly decreases in intensity with respect to others typical of PVC, for example the one at 1430 cm-1. Based on the peak absorbance, the extraction efficiency (i.e. the fraction of plasticizer extracted) was estimated to be around 80-90%.
  • HDPE high density polyethylene

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  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Engineering & Computer Science (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Sustainable Development (AREA)
  • Health & Medical Sciences (AREA)
  • Medicinal Chemistry (AREA)
  • Polymers & Plastics (AREA)
  • Organic Chemistry (AREA)
  • Environmental & Geological Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Separation, Recovery Or Treatment Of Waste Materials Containing Plastics (AREA)

Abstract

L'invention concerne le domaine du recyclage de déchets, plus particulièrement un procédé et un appareil pour la valorisation de déchets de PVC, comprenant l'élimination d'additifs de ceux-ci et la séparation d'autres impuretés solides telles que des particules de métal, de caoutchouc et/ou de polymère. L'invention fournit un procédé de recyclage de PVC, comprenant la mise en contact d'un flux d'alimentation comprenant des déchets de PVC avec du dioxyde de carbone supercritique (scCO2), suivi d la soumission du flux d'alimentation à un processus de filtration à l'état fondu.
PCT/NL2023/050412 2022-08-02 2023-08-02 Procédé et appareil pour le recyclage de polychlorure de vinyle (pvc) WO2024030025A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
NL2032662 2022-08-02
NL2032662A NL2032662B1 (en) 2022-08-02 2022-08-02 Method and apparatus for recycling of polyvinylchloride (PVC).

Publications (1)

Publication Number Publication Date
WO2024030025A1 true WO2024030025A1 (fr) 2024-02-08

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WO (1) WO2024030025A1 (fr)

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1997005194A1 (fr) * 1995-08-01 1997-02-13 Cf Technologies, Incorporated Procede et appareil permettant de separer un polymere d'un plastic, et polymere separe ainsi obtenu
US20090056742A1 (en) 2006-02-24 2009-03-05 Bruno Fournel Process for Decontaminating an Organic Solid Substrate Contaminated by Solid Radioactive Particulate Inorganic Contaminants, Using Dense Pressurized CO2
JP4685728B2 (ja) 2005-08-31 2011-05-18 日機装株式会社 鉛含有軟質ポリ塩化ビニル素材の原料回収方法
ES2796956A1 (es) 2019-05-29 2020-11-30 Asociacion De Investigacion De Mat Plasticos Y Conexas Proceso para la eliminacion de pintura de materiales termoplasticos

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1997005194A1 (fr) * 1995-08-01 1997-02-13 Cf Technologies, Incorporated Procede et appareil permettant de separer un polymere d'un plastic, et polymere separe ainsi obtenu
JP4685728B2 (ja) 2005-08-31 2011-05-18 日機装株式会社 鉛含有軟質ポリ塩化ビニル素材の原料回収方法
US20090056742A1 (en) 2006-02-24 2009-03-05 Bruno Fournel Process for Decontaminating an Organic Solid Substrate Contaminated by Solid Radioactive Particulate Inorganic Contaminants, Using Dense Pressurized CO2
ES2796956A1 (es) 2019-05-29 2020-11-30 Asociacion De Investigacion De Mat Plasticos Y Conexas Proceso para la eliminacion de pintura de materiales termoplasticos

Non-Patent Citations (2)

* Cited by examiner, † Cited by third party
Title
ASHRAF-KHORASSANI M ET AL: "Supercritical fluid extraction of metal ions and metal chelates from different environments", JOURNAL OF CHROMATOGRAPHY A, ELSEVIER, AMSTERDAM, NL, vol. 774, no. 1-2, 11 July 1997 (1997-07-11), pages 37 - 49, XP004084277, ISSN: 0021-9673, DOI: 10.1016/S0021-9673(97)00358-0 *
WAI C M ET AL: "Supercritical fluid extraction: metals as complexes", JOURNAL OF CHROMATOGRAPHY A, ELSEVIER, AMSTERDAM, NL, vol. 785, no. 1-2, 17 October 1997 (1997-10-17), pages 369 - 383, XP004097580, ISSN: 0021-9673, DOI: 10.1016/S0021-9673(97)00679-1 *

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