WO2024253656A1

WO2024253656A1 - Method for processing recycled polymers

Info

Publication number: WO2024253656A1
Application number: PCT/US2023/024831
Authority: WO
Inventors: Stephen M. Imfeld; Matthew A. SONNYCALB
Original assignee: Equistar Chemicals LP
Current assignee: Equistar Chemicals LP
Priority date: 2023-06-08
Filing date: 2023-06-08
Publication date: 2024-12-12
Anticipated expiration: 2025-12-08

Abstract

Provided are processes for blending virgin polymers and polymer recyclates. In one embodiment, virgin polymer is melted in a first melt mixing apparatus, polymer recyclate is melted in a second melt mixing apparatus followed by filtering, the virgin polymer melt and the filtered polymer recyclate melt are co-fed to a melt pump, and the recyclate blend is filtered. In another embodiment, polymer recyclate is melted in a first melt mixing apparatus followed by filtering, the filtered polymer recyclate melt is co-fed with a virgin polymer to a second melt mixing apparatus, the recyclate melt is optionally fed to a melt pump and is then filtered. In another embodiment, virgin polymer and polymer recyclate are blended and then melted in an melt mixing apparatus followed by filtering. Also provided are methods for retrofitting existing polymer production facilities with such processes.

Description

METHOD FOR PROCESSING REC YCLED POLYMERS

FIELD OF THE INVENTION

[0001] The present disclosure relates to processes for blending virgin polymers with polymer recyclates and methods for retrofitting existing polymer production facilities to implement such processes.

BACKGROUND OF THE INVENTION

[0002] Polyolefins, in particular polyethylene and polypropylene, are increasingly consumed in large amounts for many applications, including packaging for food and other goods, electronics, automotive components, and a great variety of manufactured articles. Large amounts of waste plastic materials are presently coming from differential recovery of municipal plastic wastes, mainly constituted of flexible packaging (cast film, blown film and BOPP film), rigid packaging, blow molded bottles and injection molded containers. Usually, through a step of separation from other polymers, such as PVC, PET or PS, two main polyolefinic fractions are obtained, namely polyethylenes (in particular, HDPE, LDPE, LLDPE) and polypropylenes (homopolymers, random copolymers, heterophasic copolymers). After such separation of polymer recyclate, different types of polymers are separated into various post-consumer recycle (PCR) resins.

[0003] There has been much research and development to improve the processability of PCR resins either alone or as a blend component with virgin polymers. Likewise, there has also been much effort by industry to develop end-use applications that incorporate PCR resins and have quality and/or performance similar or equal to corresponding end-use applications fabricated from virgin polymers, of articles fabricated from such PCR resins. Existing and new environmental regulations provide continued motivation to develop suitable commercial uses of PCR resins while reducing the amount of waste plastics landfill. Successful development of these commercial pathways will create demand for higher production rates of products incorporating blends of PCR resins with virgin polymers.

[0004] There is a need to provide processes for recycling of polymers at higher rates, in particular, blends of PCR resins with virgin polymers. Ideally, such processes could be implemented by retrofitting existing polymer production facilities with commonly used equipment and familiar techniques to produce useful blends of PCR resins with virgin polymers at commercial rates.

SUMMARY OF THE INVENTION

[0005] The present disclosure relates to processes for blending a virgin polymers with polymer recyclates. [0006] In some embodiments, a process comprises adding a virgin polymer to a first melt mixing apparatus to produce a virgin polymer melt. The process further comprises adding a polymer recyclate to a second melt mixing apparatus to produce a polymer recyclate melt. The process further comprises adding the polymer recyclate melt to a first melt filtration apparatus to produce a filtered polymer recyclate melt. The virgin polymer melt and the filtered polymer recyclate melt are co-fed to a melt pump to produce a recyclate blend melt, which is processed through a recyclate blend melt to a second melt filtration apparatus. A filtered recyclate blend product is withdrawn from the second melt filtration apparatus.

[0007] In some embodiments, a process comprises adding a virgin polymer to a first melt mixing apparatus. The process further comprises adding a polymer recyclate to a second melt mixing apparatus to produce a polymer recyclate melt and processing the polymer recyclate melt through a first melt filtration apparatus to produce a filtered polymer recyclate melt. The filtered polymer recyclate melt is added to an inlet to the first melt mixing apparatus. A recyclate blend melt is withdrawn from the first melt mixing apparatus and fed to a melt pump and then processed through a second melt filtration apparatus. A filtered recyclate blend product is withdrawn from the second melt filtration apparatus.

[0008] In some embodiments, a process comprises adding a virgin polymer to a first melt mixing apparatus. The process further comprises adding a polymer recyclate to a second melt mixing apparatus to produce a polymer recyclate melt and processing the polymer recyclate melt through a first melt filtration apparatus to produce a filtered polymer recyclate melt. The filtered polymer recyclate melt is fed to the first melt mixing apparatus. A recyclate blend melt is withdrawn from the first melt mixing apparatus and processed through a second melt filtration apparatus. A filtered recyclate blend product is w ithdrawn from the second melt filtration apparatus.

[0009] In some embodiments, a process comprises adding a virgin polymer and a polymer recyclate to a first melt mixing apparatus to produce a recyclate blend melt and processing the recyclate blend melt through a melt filtration apparatus. A filtered recyclate blend product is withdrawn from the second melt filtration apparatus.

[0010] The present disclosure further relates to methods for retrofitting existing polymer production facilities to implement the processes for blending a virgin polymers with polymer recyclates, as disclosed herein. The methods for retrofitting a polymer production facility to add a processing capacity for polymer recyclate. The polymer production facility comprises a virgin polymer feed apparatus fluidly connected to an inlet to first melt mixing apparatus, the first melt mixing apparatus having an outlet fluidly connected to an inlet to a first melt pump, the melt pump having an outlet fluidly connected to an inlet to a melt filtration apparatus, the melt filtration apparatus having an outlet adapted for withdrawal of a polymer product. The polymer production facility has a first throughput rate.

[0011] In some embodiments, a method for retrofitting a polymer production facility comprises adding a polymer recyclate feed system. The polymer recyclate system comprises a polymer recyclate feed apparatus fluidly connected to an inlet to a second melt mixing apparatus. The second melt mixing apparatus as an outlet fluidly connected to a second melt filtration apparatus, the second melt filtration apparatus having an outlet. The polymer recyclate system has a second throughput rate.

[0012] The method for retrofitting a polymer production facility further comprises replacing the first melt pump and the first melt filtration apparatus with a recyclate blend system. The recyclate blend system comprises a second melt pump having an inlet fluidly connected to the outlet from the first melt pump and the outlet from the second melt filtration apparatus and an outlet fluidly connected to an inlet to a third melt filtration apparatus. The third melt filtration apparatus has an outlet adapted for withdrawal of a recyclate blend product. The recyclate blend system has a third throughput rate, wherein the third throughput rate is the sum of the first throughput rate and the second throughput rate.

[0013] In some embodiments, a method for retrofitting a polymer production facility comprises adding a polymer recyclate feed system. The polymer recyclate feed system comprises a polymer recyclate feed apparatus fluidly connected to an inlet to a second melt mixing apparatus. The second melt mixing apparatus has an outlet fluidly connected to a second melt filtration apparatus. The second melt filtration apparatus has an outlet. The polymer recyclate feed system has a second throughput rate.

[0014] The method for retrofitting a polymer production facility further comprises fluidly connecting the outlet of the second melt filtration apparatus to a second inlet to the first melt mixing apparatus.

[0015] The method for retrofitting a polymer production facility further comprises adding a control system, wherein the control system provides for maintaining the sum of a virgin polymer feed rate and a polymer recyclate feed rate being less than or equal to the first throughput rate.

[0016] In some embodiments, a method for retrofitting a polymer production facility comprises adding a polymer recyclate feed system. The polymer recyclate feed system comprises a polymer recyclate feed apparatus fluidly connected to an inlet to a second melt mixing apparatus. The second melt mixing apparatus has an outlet fluidly connected to a second melt filtration apparatus. The second melt filtration apparatus has an outlet. The polymer recyclate feed system has a second throughput rate. [0017] The method for retrofiting a polymer production facility further comprises replacing the first melt mixing apparatus, the first melt pump, and the first melt filtration apparatus with a recyclate blend system. The recyclate blend system comprises a second melt mixing apparatus. The second melt mixing apparatus has one or more inlets fluidly connected to the virgin polymer feed apparatus and the outlet from the second melt filtration apparatus. The second melt mixing apparatus has an outlet fluidly connected to a second melt filtration apparatus. The second melt filtration apparatus as an outlet adapted for withdrawal of a recyclate blend product. The recyclate blend system has a third throughput rate, wherein the third throughput rate is the sum of the first throughput rate and the second throughput rate.

[0018] In some embodiments, a method for retrofiting a polymer production facility comprises converting the virgin polymer feed apparatus to a recyclate blend feed apparatus by adapting the virgin polymer feed apparatus to accept the virgin polymer feed and a polymer recyclate feed and increasing the throughput rate of the virgin polymer feed apparatus to accept a second throughput rate of the polymer recyclate in addition to the first throughput rate of the virgin polymer.

[0019] The method for retrofiting a polymer production facility further comprises replacing the first melt mixing apparatus, the first melt pump, and the first melt filtration apparatus with a recyclate blend system. The recyclate blend system comprises a second melt mixing apparatus. The second melt mixing apparatus has an inlet fluidly connected to the recyclate blend feed apparatus and an outlet fluidly connected to a second melt filtration apparatus. The second melt filtration apparatus has an outlet adapted for withdrawal of a recyclate blend product. The recyclate blend system has a third throughput rate, wherein the third throughput rate is the sum of the first throughput rate and the second throughput rate.

[0020] The foregoing has outlined rather broadly the features and technical advantages of the present invention in order that the detailed description of the invention that follows may be beter understood. Additional features and advantages of the invention will be described hereinafter, which form the subject mater of the claims of the invention. It should be appreciated by those skilled in the art that the conception and specific embodiments disclosed may be readily utilized as a basis for modifying or designing other film structures and/or processes for carrying out the same purposes of the present invention. It should also be realized by those skilled in the art that such equivalent constructions do not depart from the spirit and scope of the invention as set forth in the appended claims. The novel features which are believed to be characteristic of the invention, both as to its structure and method of manufacture, together with further objects and advantages will be beter understood from the following description. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] The claimed subject matter may be understood by reference to the following description taken in conjunction with the accompanying drawings, in which like reference numerals identify like elements, and in which:

[0022] FIG. 1 shows a simplified flow diagram of a conventional polyolefins production facility;

[0023] FIG. 2 shows a simplified flow diagram of a polyolefins production facility according to embodiments of the invention, wherein a conventional polyolefins production facility is modified by addition of a polyolefin recy elate extruder and replacement of the melt pump and melt filtration apparatus with a larger melt pump and melt filtration apparatus;

[0024] FIG. 3 shows a simplified flow diagram of a polyolefins production facility according to embodiments of the invention, wherein a conventional polyolefins production facility is modified by addition of a polyolefin recy elate extruder feeding into the original extruder;

[0025] FIG. 4 shows a simplified flow diagram of a polyolefins production facility according to embodiments of the invention, wherein a conventional polyolefins production facility is modified by addition of a polyolefin recy elate extruder and replacement of the extruder, melt pump and melt filtration apparatus with a larger extruder and melt filtration apparatus; and

[0026] FIG. 5 shows a simplified flow diagram of a polyolefins production facility according to embodiments of the invention, wherein a conventional polyolefins production facility is modified by replacement of the extruder, melt pump and melt filtration apparatus with a larger extruder and melt filtration apparatus.

[0027] While the disclosed process and composition are susceptible to various modifications and alternative forms, the drawings illustrate specific embodiments herein described in detail by way of example It should be understood, however, that the description herein of specific embodiments is not intended to limit the invention to the particular forms disclosed, but on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the appended claims.

DETAILED DESCRIPTION OF THE INVENTION

[0028] Illustrative embodiments of the subject matter claimed below will now be disclosed. In the interest of clarity, some features of some actual implementations may not be described in this specification. It will be appreciated that in the development of any such actual embodiments, numerous implementation-specific decisions must be made to achieve the developer’s specific goals, such as compliance with system-related and business-related constraints, which will vary from one implementation to another. Moreover, it will be appreciated that such a development effort, even if complex and time-consuming, would be a routine undertaking for those of ordinary skill in the art having the benefit of this disclosure.

[0029] The words and phrases used herein should be understood and interpreted to have a meaning consistent with the understanding of those words and phrases by those skilled in the relevant art. No special definition of a term or phrase, i.e., a definition that is different from the ordinary and customary' meaning as understood by those skilled in the art, is intended to be implied by consistent usage of the term or phrase herein. To the extent that a term or phrase is intended to have a special meaning, i.e., a meaning other than the broadest meaning understood by skilled artisans, such a special or clarifying definition will be expressly set forth in the specification in a definitional manner that provides the special or clarifying definition for the term or phrase. It must also be noted that, as used in the specification and the appended claims, the singular forms "a," "an," and "the" include plural references unless otherwise specified.

[0030] For example, the following discussion contains a non-exhaustive list of definitions of several specific terms used in this disclosure (other terms may be defined or clarified in a definitional manner elsewhere herein). These definitions are intended to clarify the meanings of the terms used herein. It is believed that the terms are used in a manner consistent with their ordinary meaning, but the definitions are nonetheless specified here for clarity.

Definitions

[0031] As used herein, “advanced filtration technology” in polymer processing is a set of techniques and equipment used to improve the quality of recycled polymers by removing contaminants and impurities from the polymer melt. Recycled polymers can contain various contaminants such as residual monomers, oligomers, pigments, additives, and particulate matter, which can affect the physical, chemical, and mechanical properties of the final product. Advanced filtering technology aims to remove these contaminants and produce high-quality recycled polymers that can be used in various applications. In some embodiments, advanced filtering technologies includes melt filtration, which involves passing the polymer melt through a filter to remove contaminants. Melt filtration can be performed using different types of filters, such as screen changers, candle filters, and disc filters. In some embodiments, advanced filtering technology includes membrane filtration, which uses a semi-permeable membrane to separate and remove contaminants from the polymer melt. Membrane filtration can be performed using different types of membranes, such as ultrafiltration, nanofiltration, and reverse osmosis. These membranes have different pore sizes and can selectively remove contaminants based on their size and molecular weight. The characteristics of recycled polymers that can be improved with advanced filtering technology include: • Contaminant Removal: Advanced filtering technology can remove various contaminants from the polymer melt, such as residual monomers, oligomers, pigments, additives, and particulate matter. The removal of these contaminants can improve the color, clarity, and purity of the recycled polymer.

• Molecular Weight Distribution: The molecular weight distribution (MWD) of the polymer can be improved with advanced filtering technology. The removal of high molecular weight species from the polymer melt can result in a narrower MWD, which can improve the processability, mechanical properties, and stability of the recycled polymer.

• Rheological Properties: Advanced filtering technology can also improve the rheological properties of the recycled polymer, such as melt flow rate, viscosity, and elasticity. The removal of contaminants and high molecular weight species can result in a more consistent and predictable rheological behavior of the recycled polymer.

The numerical levels of improvement in these characteristics depend on the specific application and the quality of the recycled polymer before filtration. In general, advanced filtering technology can achieve significant improvements in the quality of recycled polymers, such as reducing the level of contaminants by more than 90%, improving the MWD by up to 50%, and increasing the melt flow rate by up to 30%. One skilled in the art would be familiar with the required and the possible numerical levels of improvement depending on the specific equipment and polymers in specific application.

[0032] As used herein, “compounding conditions” means temperature, pressure, and shear force conditions implemented in an melt mixing apparatus to provide intimate mixing of two or more polymers and optionally additives to produce a substantially homogeneous polymer product. The compounding conditions will be such that the specific energy from the compounder from shear and/or added heat are sufficient to melt the polymer components and homogenize them.

[0033] As used herein, “extruder” means a single screw mixing extruder.

[0034] As used herein, “HDPE” means ethylene homopolymers and ethylene copolymers produced in a suspension, solution, slurry, or gas phase polymerization process and having a density in the range of 0.940 g/cm³ to 0.970 g/cm³.

[0035] As used herein, “LDPE” means ethylene homopolymers and/or ethylene copolymers produced in a high pressure free radical polymerization and having a density in the range of 0.910 g/cm³ to 0.940 g/cm³.

[0036] As used herein, “LLDPE” means ethylene copolymers produced in a suspension, solution, slurry, or gas phase polymerization process and having a density in the range of 0.910 g/cm³ to 0.940 g/cm³. [0037] As used herein, “MDPE” means ethylene copolymers produced in a suspension, solution, slurry, or gas phase polymerization process and having a density in the range of 0.925 g/cm³ to 0.940 g/cm³.

[0038] As used herein, “melt mixing apparatus” means an extruder, a continuous mixer, or any other device suitable for producing temperature, pressure, and shear force conditions to melt and homogenize a polymer or mixture of polymers and optionally any optional additives.

[0039] As used herein, “miscibility” means the degree to which two polymers will mix to form a homogeneous polymer blends. Miscibility is the capability of a mixture to form a single phase over certain ranges of temperature, pressure, and composition. Whether or not a single phase exists depends on the chemical structure, molar mass distribution, and molecular architecture of the components present. A single phase in a mixture may be confirmed by light scattering, x-ray scattering, and/or neutron scattering. For a two-component mixture, a necessary and sufficient condition for stable or metastable equilibrium of a homogeneous, single-phase is: d²AmixG~

> 0

50²

T.P wherein AmixG is the Gibbs energy of mixing per unit volume, and O the composition, where is usually taken as the volume fraction of one of the component substances. The system is unstable if the above second derivative is negative. The borderline (spinodal) between (meta)stable and unstable states is defined by the above second derivative equaling zero. Further discussion of miscibility can be found in J.M.G. Cowie, ‘Miscibility’, Encyclopedia of Polymer Science and Engineering, 2nd Ed., J.I. Kroschwitz, ed., Wiley Interscience, New York, 1985, Supplement, p. 455-480, and Work, W. J., Horie, K., Hess, M.» & UK, R. S. (2004), Definitions of Terms Related to Polymer Blends, Composites and Multiphase Polymeric Materials, Pure and Applied Chemistry? 6/11, the substance of which is fully incorporated herein by reference.

[0040] As used herein, “melt pump” refers to a machine that is used to control the flow of molten polymer from an extruder. A melt pump is typically used in applications where precise control over the flow rate and pressure is required. Melt pumps are especially useful in extrusion processes where the flow rate and pressure of the polymer melt need to be maintained to produce consistent products. They are also used to increase the output rate of the extruder.

[0041] As used herein, “polymer recyclate” means post-consumer recycled (“PCR”) polymers and/or post-industrial recycled (“PIR”) polymers. Polymer recyclate is derived from an end product that has completed its life cycle as a consumer item and would otherwise be disposed of as waste (e.g., a polyethylene water bottle) or from plastic scrap that is generated as waste from an industrial process. Post-consumer polymers include polymers that have been collected in commercial and residential recycling programs.

[0042] As used herein, “polyolefin” in some embodiments is a type of polymer with the general formula (CH2CHR)n where R is an alkyl group, including, but not limited to LDPE, LLDPE, MDPE, HDPE, and PP. Polyolefins are nonpolar polymers.

[0043] As used herein, “processability,” refers to how well a polymer composition can be formed into a cast of blown film of commercial quality or molded by injection or compression molding into a molded article of commercial quality at commercially acceptable rates using the equipment and conditions.

[0044] As used herein, “recy elate blend” means a blend of a polymer recy elate and or a filtered polymer recyclate a virgin polymer.

[0045] As used herein, “twin screw extruder” means and extruder that uses two screws to mix, melt, and extrude polymers. They are commonly used in compounding, blending, and reactive processing applications. Twin screw extruders offer many advantages over other machines, including the ability to handle a wide range of materials, high mixing efficiency, and precise control over the processing conditions. They are also useful for processing materials with high viscosity, high filler loading, and high levels of shear-sensitive additives. In some cases, a twin screw extruder can eliminate the need for a melt pump in polymer processing.

[0046] As used herein, “virgin polymer” means pre-consumer polymers. Pre-consumer polymers are obtained directly or indirectly from petrochemical feedstocks fed to a polymerization apparatus. Pre-consumer polyolefins can be subjected to post polymerization processes such as, but not limited to, extrusion, pelletization, visbreaking, and/or other processing completed before the product reaches the end-use consumer.

[0047] As used herein, “wt%” means weight percent.

[0048] It is noted that in this disclosure and particularly in the claims and/or paragraphs, terms such as “comprises”, “comprised”, “comprising” and the like can have the meaning attributed to it in U.S. patent law; e.g., they can mean “includes”, “included”, “including”, and the like; and that terms such as “consisting essentially of’ and “consists essentially of’ have the meaning ascribed to them in U. S . patent law, e.g., they allow for elements not explicitly recited, but exclude elements that are found in the prior art or that affect a basic or novel characteristic of the disclosure.

Process

[0049] In a first group of process embodiments, a process comprises adding a virgin polymer to a first melt mixing apparatus to produce a virgin polymer melt. The process further comprises adding a polymer recyclate to a second melt mixing apparatus to produce a polymer recyclate melt and processing the polymer recyclate melt through a first melt filtration apparatus to produce a filtered polymer recy elate melt. The virgin polymer melt and the filtered polymer recy elate melt are co-fed to a melt pump to produce a recy elate blend melt. The recy elate blend melt is processed through a second melt filtration apparatus to produce a filtered recyclate blend product.

[0050] In some embodiments, the first melt filtration apparatus comprises advanced filtration technology.

[0051] In a second group of process embodiments, a process comprises adding a virgin polymer to a first melt mixing apparatus. The process further comprises adding a polymer recyclate to a second melt mixing apparatus to produce a polymer recyclate melt and processing the polymer recyclate melt through a first melt filtration apparatus to produce a filtered polymer recyclate melt. The filtered polymer recyclate melt is fed to the first melt mixing apparatus. A recyclate blend melt is withdrawn from the first melt mixing apparatus and fed to a melt pump and then processed through a second melt filtration apparatus. A filtered recyclate blend product is withdrawn from the second melt filtration apparatus.

[0052] In some embodiments, the first melt filtration apparatus comprises advanced filtration technology.

[0053] In a third group of process embodiments, a process comprises adding a virgin polymer to a first melt mixing apparatus. The process further comprises adding a polymer recyclate to a second melt mixing apparatus to produce a polymer recyclate melt and processing the polymer recyclate melt through a first melt filtration apparatus to produce a filtered polymer recyclate melt. The filtered polymer recyclate melt is fed to the first melt mixing apparatus. A recyclate blend melt is withdrawn from the first melt mixing apparatus and then processed through a second melt filtration apparatus. A filtered recyclate blend product is withdrawn from the second melt filtration apparatus.

[0054] In some embodiments, the first melt mixing apparatus comprises a twin screw extruder. [0055] In some embodiments, the first melt filtration apparatus comprises advanced filtration technology.

[0056] In a fourth group of process embodiments, a process comprises adding a virgin polymer and a polymer recyclate to a first melt mixing apparatus to produce a recyclate blend melt. The recyclate blend melt is processed through a melt filtration apparatus, and a filtered recyclate blend product is withdrawn from the melt filtration apparatus.

[0057] In some embodiments, the first melt mixing apparatus comprises a twin screw extruder. [0058] In some embodiments, the first melt filtration apparatus comprises advanced filtration technology. [0059] In any of the foregoing embodiments of the process, the ratio of the virgin polymer to the polymer recyclate added to the process is in the range of from 20: 1 to 1 :2.5, from 10: 1 to 1: 1.5, from 6:1 to 1: 1, or from 4: 1 to 1.5:1.

[0060] In any of the foregoing embodiments of the process, the virgin polymer and/or the polymer recyclate comprise: a) an ethylene homopolymer; b) a copolymer of units derived from ethylene and units derived from one or more of Cs- C20 alpha-olefins or mixtures thereof; c) a copolymer of units derived from ethylene and units derived from one or more of alpha mono-olefins comprising polar groups; or combinations thereof. d) a propylene homopolymer; e) a copolymer of units derived from propylene and units derived one or more of ethylene and C4-C20 alpha-olefins or mixtures thereof; f) a copolymer of units derived from propylene and units derived from one or more of alpha mono-olefins comprising polar groups; or combinations thereof; or g) a combination thereof.

[0061] In any of the foregoing embodiments of the process, the virgin polymer is miscible with the polymer recyclate.

Retrofitting

[0062] Methods are disclosed for retrofitting existing polymer production facilities to implement the processes for blending a virgin polymers with polymer recyclates, as disclosed herein. The methods for retrofitting a polymer production facility to add a processing capacity for polymer recyclate. The polymer production facility comprises a virgin polymer feed apparatus fluidly connected to an inlet to first melt mixing apparatus, the first melt mixing apparatus having an outlet fluidly connected to an inlet to a first melt pump, the melt pump having an outlet fluidly connected to an inlet to a melt filtration apparatus, the melt filtration apparatus having an outlet adapted for withdrawal of a polymer product. The polymer production facility has a first throughput rate.

[0063] In a first group of method embodiments, a method for retrofitting existing polymer production facilities comprises adding a polymer recyclate feed system. The polymer recyclate feed system comprises a recyclate feed apparatus fluidly connected to an inlet to a second melt mixing apparatus. The second melt mixing apparatus has an outlet fluidly connected to a second melt filtration apparatus. The second melt filtration apparatus has an outlet. The polymer recyclate feed system has a second throughput rate. In some embodiments, the first melt filtration apparatus comprises advanced filtration technology. [0064] The method for retrofitting existing polymer production facilities further comprises replacing the first melt pump and the first melt filtration apparatus with a recy elate blend system. The recy elate blend system comprises a second melt pump having an inlet fluidly connected to the outlet from the first melt pump and the outlet from the second melt filtration apparatus and an outlet fluidly connected to an inlet to a third melt filtration apparatus. The third melt filtration apparatus has an outlet adapted for withdrawal of a recyclate blend product. The recy elate blend system has a third throughput rate, wherein the third throughput rate is the sum of the first throughput rate and the second throughput rate.

[0065] In some embodiments, the first melt filtration apparatus comprises advanced filtration technology.

[0066] In a second group of method embodiments, a method for retrofitting existing polymer production facilities comprises adding a polymer recyclate feed system. The polymer recyclate feed system comprises a recyclate feed apparatus fluidly connected to an inlet to a second melt mixing apparatus. The second melt mixing apparatus has an outlet fluidly connected to a second melt filtration apparatus. The second melt filtration apparatus has an outlet. The polymer recyclate feed system has a second throughput rate.

[0067] The method for retrofitting existing polymer production facilities further comprises fluidly connecting the outlet of the second melt filtration apparatus to a second inlet to the first melt mixing apparatus.

[0068] The method for retrofitting existing polymer production facilities further comprises adding a control system, wherein the control system provides for maintaining the sum of a virgin polymer feed rate and a polymer recyclate feed rate being less than or equal to the first throughput rate.

[0069] In some embodiments, the first melt filtration apparatus comprises advanced filtration technology.

[0070] In a third group of method embodiments, a method for retrofitting existing polymer production facilities comprises adding a polymer recyclate feed system. The polymer recyclate feed system comprises a recyclate feed apparatus fluidly connected to an inlet to a second melt mixing apparatus. The second melt mixing apparatus has an outlet fluidly connected to a second melt filtration apparatus. The second melt filtration apparatus has an outlet. The polymer recyclate feed system has a second throughput rate.

[0071] The method for retrofitting existing polymer production facilities further comprises replacing the first melt mixing apparatus, the first melt pump, and the first melt filtration apparatus with a recyclate blend system. The recyclate blend system comprises a second melt mixing apparatus. The second melt mixing apparatus has one or more inlets fluidly connected to the virgin polymer feed apparatus and the outlet from the second melt filtration apparatus. The second melt mixing apparatus has an outlet fluidly connected to a second melt filtration apparatus. The second melt filtration apparatus has an outlet adapted for withdrawal of a recyclate blend product. The recyclate blend system has a third throughput rate, wherein the third throughput rate is the sum of the first throughput rate and the second throughput rate.

[0072] In some embodiments, the first melt mixing apparatus comprises a twin screw extruder. [0073] In some embodiments, the first melt filtration apparatus comprises advanced filtration technology.

[0074] In a fourth group of method embodiments, a method for retrofitting existing polymer production facilities comprises converting the virgin polymer feed apparatus to a recyclate blend feed apparatus by (1) adapting the virgin polymer feed apparatus to accept the virgin polymer feed and a polymer recyclate feed and (2) increasing the throughput rate of the virgin polymer feed apparatus to accept a second throughput rate of the polymer recyclate in addition to the first throughput rate of the virgin polymer.

[0075] The method for retrofitting existing polymer production facilities further comprises replacing the first melt mixing apparatus, the first melt pump, and the first melt filtration apparatus with a recyclate blend system. The recyclate blend system comprises a second melt mixing apparatus and a second melt filtration system. The second melt mixing apparatus has an inlet fluidly connected to the recyclate blend feed apparatus and an outlet fluidly connected to a second melt filtration apparatus. The second melt filtration apparatus has an outlet adapted for withdrawal of a recyclate blend product. The recyclate blend system has a third throughput rate, wherein the third throughput rate is the sum of the first throughput rate and the second throughput rate.

[0076] In some embodiments, the first melt mixing apparatus comprises a twin screw extruder. [0077] In some embodiments, the first melt filtration apparatus comprises advanced filtration technology.

[0078] In any of the first, second, third, or fourth groups of embodiments of the method for retrofitting existing polymer production facilities, in addition to the above limitations in any of the foregoing embodiments of the method for retrofitting existing polymer production facilities, the method is further characterized by one or more of the following: a) the ratio of the virgin polymer to the polymer recyclate added to the process is in the range of from 20:1 to 1:2.5, from 10:1 to 1: 1.5, from 6: 1 to 1 : 1, or from 4: 1 to 1.5: 1; b) the virgin polymer comprises:

(i) an ethylene homopolymer;

(ii) a copolymer of units derived from ethylene and units derived from one or more of C3-C20 alpha-olefins or mixtures thereof; (in) a copolymer of units derived from ethylene and units derived from one or more of alpha mono-olefins comprising polar groups; or combinations thereof

(iv) a propylene homopolymer;

(v) a copolymer of units derived from propylene and units derived one or more of ethylene and C4-C20 alpha-olefins or mixtures thereof;

(vi) a copoly mer of units derived from propylene and units derived from one or more of alpha mono-olefins comprising polar groups; or combinations thereof; or

(vii) a combination thereof; c) the polymer recyclate comprises:

(i) an ethylene homopolymer;

(ii) a copolymer of units derived from ethylene and units derived from one or more of C3-C20 alpha-olefins or mixtures thereof;

(iii) a copolymer of units derived from ethylene and units derived from one or more of alpha mono-olefins comprising polar groups; or combinations thereof.

(iv) a propylene homopolymer;

(vii) a combination thereof; d) the virgin polymer is miscible with the polymer recyclate.

Certain Embodiments

[0079] In a first group of process embodiments, a process comprises adding a virgin polymer to a first melt mixing apparatus to produce a virgin polymer melt. The process further comprises adding a polymer recyclate to a second melt mixing apparatus to produce a polymer recyclate melt and processing the polymer recyclate melt through a first melt filtration apparatus to produce a filtered polymer recyclate melt. The virgin polymer melt and the filtered polymer recyclate melt are co-fed to a melt pump to produce a recyclate blend melt. The recyclate blend melt is processed through a second melt filtration apparatus to produce a filtered recyclate blend product. In some embodiments, the first melt filtration apparatus comprises advanced filtration technology.

[0080] In a second group of process embodiments, a process comprises adding a virgin polymer to a first melt mixing apparatus. The process further composes adding a polymer recyclate to a second melt mixing apparatus to produce a polymer recyclate melt and processing the polymer recyclate melt through a first melt filtration apparatus to produce a filtered polymer recyclate melt. The filtered polymer recyclate melt is fed to the first melt mixing apparatus. A recyclate blend melt is withdrawn from the first melt mixing apparatus and fed to a melt pump and then processed through a second melt filtration apparatus. A filtered recyclate blend product is withdrawn from the second melt filtration apparatus. In some embodiments, the first melt filtration apparatus comprises advanced filtration technology.

[0081] In a third group of process embodiments, a process comprises adding a virgin polymer to a first melt mixing apparatus. The process further comprises adding a polymer recyclate to a second melt mixing apparatus to produce a polymer recyclate melt and processing the polymer recyclate melt through a first melt filtration apparatus to produce a filtered polymer recyclate melt. The filtered polymer recyclate melt is fed to the first melt mixing apparatus. A recyclate blend melt is withdrawn from the first melt mixing apparatus and then processed through a second melt filtration apparatus. A filtered recyclate blend product is withdrawn from the second melt filtration apparatus. In some embodiments, the first melt mixing apparatus comprises a twin screw extruder. In some embodiments, the first melt filtration apparatus comprises advanced filtration technology. [0082] In a fourth group of process embodiments, a process comprises adding a virgin polymer and a polymer recyclate to a melt mixing apparatus to produce a recyclate blend melt. The recyclate blend melt is processed through a melt filtration apparatus, and a filtered recyclate blend product is withdrawn from the melt filtration apparatus. In some embodiments, the melt mixing apparatus comprises a twin screw extruder. In some embodiments, the melt filtration apparatus comprises advanced filtration technology.

[0083] In any of the first, second, third, or fourth groups of embodiments of the process, in addition to the above limitations in any of the foregoing embodiments of the process, the method is further characterized by one or more of the following: a) the ratio of the virgin polymer to the polymer recyclate added to the process is in the range of from 20:1 to 1:2.5, from 10:1 to 1: 1.5, from 6: 1 to 1 : 1, or from 4: 1 to 1.5: 1; b) the virgin polymer and/or the polymer recyclate comprise:

(i) an ethylene homopolymer;

(iv) a propylene homopolymer;

(vi) a copolymer of units derived from propylene and units derived from one or more of alpha mono-olefins comprising polar groups; or combinations thereof; or (vn) a combination thereof; c) the virgin polymer is miscible with the polymer recyclate.

[0084] Methods are disclosed for retrofitting existing polymer production facilities to implement the processes for blending a virgin polymers with polymer recyclates, as disclosed herein. The methods for retrofitting a polymer production facility to add a processing capacity for polymer recyclate. The polymer production facility comprises a virgin polymer feed apparatus fluidly connected to an inlet to first melt mixing apparatus, the first melt mixing apparatus having an outlet fluidly connected to an inlet to a first melt pump, the melt pump having an outlet fluidly connected to an inlet to a melt filtration apparatus, the melt filtration apparatus having an outlet adapted for withdrawal of a polymer product. The polymer production facility has a first throughput rate.

[0085] In a first group of method embodiments, a method for retrofitting existing polymer production facilities comprises adding a polymer recyclate feed system. The polymer recyclate feed system comprises a recyclate feed apparatus fluidly connected to an inlet to a second melt mixing apparatus. The second melt mixing apparatus has an outlet fluidly connected to a second melt filtration apparatus. The second melt filtration apparatus has an outlet. The polymer recyclate feed system has a second throughput rate.

[0086] The method for retrofitting existing polymer production facilities further comprises replacing the first melt pump and the first melt filtration apparatus with a recyclate blend system. The recyclate blend system comprises a second melt pump having an inlet fluidly connected to the outlet from the first melt pump and the outlet from the second melt filtration apparatus and an outlet fluidly connected to an inlet to a third melt filtration apparatus. The third melt filtration apparatus has an outlet adapted for withdrawal of a recyclate blend product. The recyclate blend system has a third throughput rate, wherein the third throughput rate is the sum of the first throughput rate and the second throughput rate.

[0087] In some embodiments, the first melt filtration apparatus comprises advanced filtration technology.

[0088] In a second group of method embodiments, a method for retrofitting existing polymer production facilities comprises adding a polymer recyclate feed system. The polymer recyclate feed system comprises a recyclate feed apparatus fluidly connected to an inlet to a second melt mixing apparatus. The second melt mixing apparatus has an outlet fluidly connected to a second melt filtration apparatus. The second melt filtration apparatus has an outlet. The polymer recyclate feed system has a second throughput rate. [0089] The method for retrofitting existing polymer production facilities further comprises fluidly connecting the outlet of the second melt filtration apparatus to a second inlet to the first melt mixing apparatus.

[0090] The method for retrofitting existing polymer production facilities further comprises adding a control system, wherein the control system provides for maintaining the sum of a virgin polymer feed rate and a polymer recy elate feed rate being less than or equal to the first throughput rate.

[0091] In some embodiments, the first melt filtration apparatus comprises advanced filtration technology.

[0092] In a third group of method embodiments, a method for retrofitting existing polymer production facilities comprises adding a polymer recyclate feed system. The polymer recyclate feed system comprises a recyclate feed apparatus fluidly connected to an inlet to a second melt mixing apparatus. The second melt mixing apparatus has an outlet fluidly connected to a second melt filtration apparatus. The second melt filtration apparatus has an outlet. The polymer recyclate feed system has a second throughput rate.

[0093] The method for retrofitting existing polymer production facilities further comprises replacing the first melt mixing apparatus, the first melt pump, and the first melt filtration apparatus with a recyclate blend system. The recyclate blend system comprises a third melt mixing apparatus. The third melt mixing apparatus has one or more inlets fluidly connected to the virgin polymer feed apparatus and the outlet from the second melt filtration apparatus. The third melt mixing apparatus has an outlet fluidly connected to a second melt filtration apparatus. The second melt filtration apparatus has an outlet adapted for withdrawal of a recyclate blend product. The recyclate blend system has a third throughput rate, wherein the third throughput rate is the sum of the first throughput rate and the second throughput rate.

[0094] In some embodiments, the third melt mixing apparatus comprises a twin screw extruder.

[0095] In some embodiments, the first melt filtration apparatus comprises advanced filtration technology.

[0096] In a fourth group of method embodiments, a method for retrofitting existing polymer production facilities comprises converting the virgin polymer feed apparatus to a recyclate blend feed apparatus by (1) adapting the virgin polymer feed apparatus to accept the virgin polymer feed and a polymer recyclate feed and (2) increasing the throughput rate of the virgin polymer feed apparatus to accept a second throughput rate of the polymer recyclate in addition to the first throughput rate of the virgin polymer. [0097] The method for retrofitting existing polymer production facilities further comprises replacing the first melt mixing apparatus, the first melt pump, and the first melt filtration apparatus with a recyclate blend system. The recyclate blend system comprises a second melt mixing apparatus and a second melt filtration system. The second melt mixing apparatus has an inlet fluidly connected to the recyclate blend feed apparatus and an outlet fluidly connected to a second melt filtration apparatus. The second melt filtration apparatus has an outlet adapted for withdrawal of a recyclate blend product. The recyclate blend system has a third throughput rate, wherein the third throughput rate is the sum of the first throughput rate and the second throughput rate.

[0098] In some embodiments, the second melt mixing apparatus comprises a twin screw extruder.

[0099] In some embodiments, the second melt filtration apparatus comprises advanced filtration technology.

[0100] In any of the first, second, third, or fourth groups of embodiments of the method for retrofitting existing polymer production facilities, in addition to the above limitations in any of the foregoing embodiments of the method for retrofitting existing polymer production facilities, the method is further characterized by one or more of the following: a) the ratio of the virgin polymer to the polymer recyclate added to the process is in the range of from 20:1 to 1:2.5, from 10:1 to 1: 1.5, from 6: 1 to 1 : 1, or from 4: 1 to 1.5: 1; b) the virgin polymer and/or the polymer recyclate comprise:

(i) an ethylene homopolymer;

(111) a copolymer of units derived from ethylene and units derived from one or more of alpha mono-olefins comprising polar groups; or combinations thereof.

(iv) a propylene homopolymer;

(vii) a combination thereof; c) the virgin polymer is miscible with the polymer recyclate.

EXAMPLES

[0101] The following examples are included to demonstrate preferred embodiments of the invention. It should be appreciated by those of skill in the art that the techniques disclosed in the examples which follow represent techniques discovered by the inventor to function well in the practice of the invention, and thus can be considered to constitute preferred modes for its practice. However, those of skill in the art should, in light of the present disclosure, appreciate that many changes can be made in the specific embodiments which are disclosed and still obtain a like or similar result without departing from the spirit and scope of the invention.

Example 1

[0102] An embodiment of a conventional polymer processing system 100 is shown in FIG. 1. Virgin polymer is fed to extruder 120 from feed hopper 110. The virgin polymer is heated to above its melting temperature and optionally mixed with additives in extruder 120. Melt pump 130 receives virgin polymer melt from extruder 120. The discharge from melt pump 130 is processed through melt filtration apparatus 140 from which a filtered virgin polymer melt is withdrawn and sent to railcar 150 for shipping.

Example 2

[0103] An embodiment of polymer processing system 200 as disclosed herein is shown in FIG. 2. Virgin polymer is fed to extruder 220 from feed hopper 210. The virgin polymer is heated to above its melting temperature and optionally mixed with additives in extruder 120. Polymer recy elate is fed to extruder 222 from feed hopper 212. The polymer recy elate is heated to above its melting temperature and optionally mixed with additives in extruder 222. A polymer recyclate melt is withdrawn from extruder 222 and processed through a melt filtration apparatus 224 comprising advanced filtration technology to produce a filtered polymer recyclate melt. The virgin polymer melt and the filtered polymer recyclate melt are co-fed to melt pump 230, which is sized to accommodate the combined output of virgin polymer extruder 220 and polymer recyclate extruder 222. A recyclate blend, comprising the combination of the virgin polymer melt and the filtered polymer recyclate melt is withdrawn from melt pump 230 and then processed through melt filtration apparatus 240, from which a filtered virgin polymer melt is withdrawn and sent to railcar 250 for shipping.

[0104] An existing polymer production facility having polymer processing system 100 as shown in FIG. 1 could be retrofitted to form polymer processing system 200 as shown in FIG. 2 to both add a capacity for processing polymer recyclate and expand the overall production capacity of the existing polymer production facility . A polymer recyclate feed system is added to system 100. The polymer recyclate feed system comprises feed hopper 212, extruder 222, and melt filtration apparatus 224 comprising advanced filtration technology. Melt pump 130 and melt filtration apparatus 140 are replaced with larger melt pump 230 and larger melt filtration apparatus 240, respectively. The capacity of melt pump 230 and melt filtration apparatus 240 are sufficient to handle the combined outputs from extruder 220 and extruder 222, respectively. The virgin polymer feed system remains unchanged such that feed hopper 110 is the same as feed hopper 210, and extruder 110 is the same as extruder 210.

Example 3

[0105] An embodiment of polymer processing system 300 as disclosed herein is shown in FIG. 3. Virgin polymer is fed to extruder 320 from feed hopper 310. Polymer recyclate is fed to extruder 322 from feed hopper 312. The polymer recyclate is heated to above its melting temperature and optionally mixed with additives in extruder 322. A polymer recyclate melt is withdrawn from extruder 322 and processed through a melt filtration apparatus 324 comprising advanced filtration technology to produce a filtered polymer recyclate melt. The filtered polymer recyclate melt is fed to extruder 320 along with the virgin polymer. The filtered polymer recyclate melt and the virgin polymer are heated to above their melting temperatures and intimately mixed, optionally with additives, and a recyclate blend melt is withdrawn from extruder 320. The recyclate blend melt is fed to melt pump 330, which is sized to accommodate the output of extruder 320. The discharge of melt pump 330 is processed through melt filtration apparatus 340, from which a filtered virgin polymer melt is w ithdrawn and sent to railcar 350 for shipping.

[0106] An existing polymer production facility having polymer processing system 100 as shown in FIG. 1 could be retrofitted to form polymer processing system 300 as shown in FIG. 3 to add a capacity for processing polymer recyclate to the existing polymer production facility. A polymer recyclate feed system is added to system 100. The polymer recyclate feed system comprises feed hopper 312, extruder 322, and melt filtration apparatus 324 comprising advanced filtration technology. Melt pump 130 and melt filtration apparatus 140 are unchanged such that they are the same as melt pump 330 and melt filtration apparatus 340, respectively. A control system (not shown) is added to maintain the total of virgin polymer feed from feed hopper 310 and the flow of filtered polymer recyclate from melt filtration apparatus 324 are less than or equal to the capacity of extruder 320.

Example 4

[0107] An embodiment of polymer processing system 400 as disclosed herein is shown in FIG. 4. Virgin polymer is fed to extruder 420 from feed hopper 410. Polymer recyclate is fed to extruder 422 from feed hopper 412. A polymer recyclate melt is withdrawn from extruder 422 and processed through a melt filtration apparatus 424 comprising advanced filtration technology to produce a filtered polymer recyclate melt. The filtered polymer recyclate melt is fed to twin screw extruder 420 along with the virgin polymer. The filtered polymer recyclate melt and the virgin polymer are heated to above their melting temperatures and intimately mixed, optionally with additives, and a recyclate blend melt is withdrawn from extruder 420. The recyclate blend melt is processed through melt filtration apparatus 440, from which a filtered virgin polymer melt is withdrawn and sent to railcar 450 for shipping.

[0108] An existing polymer production facility having polymer processing system 100 as shown in FIG. 1 could be retrofitted to form polymer processing system 400 as shown in FIG. 4 to both add a capacity for processing polymer recy elate and expand the overall production capacity of the existing polymer production facility . A polymer recy elate feed system is added to system 100. The polymer recyclate feed system comprises feed hopper 412, extruder 422, and melt filtration apparatus 424 comprising advanced filtration technology. Extruder 120 and melt pump 130 are replaced with larger capacity twin screw extruder 420. The capacity of twin screw extruder 420 is sized to be greater than or equal to the desired flow of virgin polymer feed from feed hopper 410 and the flow of filtered polymer recyclate from melt filtration apparatus 424 are less than or equal to the capacity of extruder 420. The virgin polymer feed hopper 110 remains unchanged as is the same as feed hopper 410. Melt filtration apparatus 424 is designed to match the capacity of twin screw extruder 420.

Example 5

[0109] An embodiment of polymer processing system 500 as disclosed herein is shown in FIG. 5. Virgin polymer and polymer recyclate are fed to extruder 520 from feed hopper 510. The polymer recyclate and the virgin polymer are heated to above their melting temperatures and intimately mixed, optionally with additives, and a recyclate blend melt is withdrawn from extruder 520. The recyclate blend melt is processed through melt filtration apparatus 540, from which a filtered virgin polymer melt is withdrawn and sent to railcar 550 for shipping.

[0110] An existing polymer production facility having polymer processing system 100 as shown in FIG. 1 could be retrofitted to form polymer processing system 500 as shown in FIG. 5 to both add a capacity for processing polymer recyclate and expand the overall production capacity of the existing polymer production facility. Feed hopper 510 is sized to accommodate a desired combined feed rate of the original virgin polymer feed rate plus a desired polymer recyclate feed rate.. Extruder 120 and melt pump 130 are replaced with twin screw extruder 520, having a capacity to match the feed rate from feed hopper 510. Melt filtration apparatus 140 is replaced with melt filtration apparatus 540, compnsing advanced filtration technology and having a capacity to match twin screw extruder 520.

[OHl] For the sake of brevity, only certain ranges are explicitly disclosed herein. However, in addition to recited ranges, any lower limit may be combined with any upper limit to recite a range not explicitly recited, as well as, ranges from any lower limit may be combined with any other lower limit to recite a range not explicitly recited, in the same way, ranges from any upper limit may be combined with any other upper limit to recite a range not explicitly recited. Additionally, within a range includes every point or individual value between its end points even though not explicitly recited. Thus, every point or individual value may serve as its own lower or upper limit combined with any other point or individual value or any other lower or upper limit, to recite a range not explicitly recited.

[0112] All documents and references cited herein, including testing procedures, publications, patents, journal articles, etc., are herein fully incorporated by reference for all jurisdictions in which such incorporation is permitted and to the extent such disclosure is consistent with the description of the present invention.

[0113] Although the present invention and its advantages have been described in detail, it should be understood that various changes, substitutions and alterations can be made herein without departing from the spirit and scope of the invention as defined by the appended claims. Moreover, the scope of the present application is not intended to be limited to the particular embodiments of the processes, machines, means, methods, and/or steps described in the specification. As one of the ordinary skill in the art will readily appreciate from the disclosure of the present invention, processes, machines, means, methods, and/or steps, presently existing or later to be developed that perform substantially the same function or achieve substantially the same result as the corresponding embodiments described herein, may be utilized according to the present invention. Accordingly, the appended claims are intended to include within their scope such processes, machines, means, methods, and/or steps.

Claims

CLAIMS What is claimed is:

1. A process comprising: a) feeding a virgin polymer to a first melt mixing apparatus to produce a virgin polymer melt; b) feeding a polymer recy elate to a second melt mixing apparatus to produce a polymer recyclate melt; c) processing the polymer recyclate melt through a first melt filtration apparatus, comprising advanced filtration technology, to produce a filtered polymer recyclate melt; d) feeding the virgin polymer melt and the filtered polymer recyclate melt to a melt pump to produce a recyclate blend melt; and e) processing the recyclate blend melt through a second melt filtration apparatus; and f) withdrawing a filtered recyclate blend product from the second melt filtration apparatus.

2. The process of claim 1, wherein the ratio of the virgin polymer to the polymer recyclate added to the process is in the range of from 20: 1 to 1 :2.5.

3. The process of claim 1, wherein the ratio of the virgin polymer to the polymer recyclate added to the process is in the range of from 10: 1 to 1 : 1.5.

4. The process of claim 1, wherein the ratio of the virgin polymer to the polymer recyclate added to the process is in the range of from 6: 1 to 1 : 1.

5. The process of claim 1, wherein the ratio of the virgin polymer to the polymer recyclate added to the process is in the range of from 4: 1 to 1.5: 1.

6. The process of claim 1 , wherein the virgin polymer and/or the polymer recyclate comprises: a) an ethylene homopolymer; b) a copolymer of units derived from ethylene and units derived from one or more of C3-C20 alpha-olefins or mixtures thereof; c) a copolymer of units derived from ethylene and units derived from one or more of alpha mono-olefins comprising polar groups; or combinations thereof. d) an ethylene homopolymer; e) a copolymer of units derived from propylene and units derived one or more of ethylene and C4-C20 alpha-olefins or mixtures thereof; f) a copolymer of units derived from propylene and units denved from one or more of alpha mono-olefins comprising polar groups; or combinations thereof; or g) a combination thereof.

7. The process of claim 1, wherein the virgin polymer is miscible with the polymer recyclate.

8. A process comprising: a) feeding a virgin polymer to a first melt mixing apparatus; b) feeding a polymer recyclate to a second melt mixing apparatus to produce a polymer recyclate melt; c) processing the polymer recyclate melt through to a first melt filtration apparatus, compnsing advanced filtration technology, to produce a filtered polymer recyclate melt; d) feeding the filtered polymer recyclate melt to the first melt mixing apparatus; e) withdrawing a recyclate blend melt from the first melt mixing apparatus; f) processing the recyclate blend melt through a melt pump; f) processing an effluent from the melt pump through a second melt filtration apparatus; and g) withdrawing a filtered recyclate blend product from the second melt filtration apparatus.

9. A process comprising: a) feeding a virgin polymer to a first melt mixing apparatus; b) feeding a polymer recyclate to a second melt mixing apparatus to produce a polymer recyclate melt; c) processing the polymer recyclate melt through a first melt filtration apparatus, comprising advanced filtration technology, to produce a filtered polymer recyclate melt; d) feeding the filtered polymer recyclate melt to the first melt mixing apparatus; e) withdrawing a recyclate blend melt from the first melt mixing apparatus; f) processing the recyclate blend melt through a second melt filtration apparatus; and g) withdrawing a filtered recyclate blend product from the second melt filtration apparatus.

10. A process comprising: a) adding a virgin polymer and a polymer recyclate to a first melt mixing apparatus to produce a recyclate blend melt; b) processing the recyclate blend melt through a melt filtration apparatus, comprising advanced filtration technology; and c) withdrawing a filtered recyclate blend product from the melt filtration apparatus.

11. A method for retrofitting a polymer production facility' to add a processing capacity for polymer recyclate, wherein the polymer production facility (1) comprises a virgin polymer feed apparatus fluidly connected to an inlet to first melt mixing apparatus, the first melt mixing apparatus having an outlet fluidly connected to an inlet to a first melt pump, the melt pump having an outlet fluidly connected to an inlet to a melt filtration apparatus, the melt filtration apparatus having an outlet adapted for withdrawal of a polymer product and (2) has a first throughput rate, the method comprising: a) adding a polymer recyclate feed system:

(1) comprising a polymer recyclate feed apparatus fluidly connected to an inlet to a second melt mixing apparatus, the second melt mixing apparatus having an outlet fluidly connected to a second melt filtration apparatus, wherein the second melt filtration apparatus comprises advanced filtration technology; and

(2) having a second throughput rate; and b) replacing the first melt pump and the first melt filtration apparatus with a recyclate blend system (1) comprising a second melt pump having an inlet fluidly connected to the outlet from the first melt pump and an outlet from the second melt filtration apparatus and an outlet fluidly connected to an inlet to a third melt filtration apparatus, the third melt filtration apparatus having an outlet adapted for withdrawal of a recyclate blend product and (2) having a third throughput rate, wherein the third throughput rate is the sum of the first throughput rate and the second throughput rate.

12. The method of claim 11, wherein the ratio of the virgin polymer to the polymer recyclate added to the process is in the range of from 20: 1 to 1 :2.5.

13. The method of claim 11, wherein the ratio of the virgin polymer to the polymer recyclate added to the process is in the range of from 10: 1 to 1 : 1.5.

14. The method of claim 11, wherein the ratio of the virgin polymer to the polymer recyclate added to the process is in the range of from 6: 1 to 1 : 1.

15. The method of claim 11, wherein the ratio of the virgin polymer to the polymer recyclate added to the process is in the range of from 4: 1 to 1.5: 1.

16. The method of claim 11, wherein the virgin polymer and/or the polymer recyclate comprise: a) an ethylene homopolymer; b) a copolymer of units derived from ethylene and units derived from one or more of C3-C20 alpha-olefins or mixtures thereof; c) a copolymer of units derived from ethylene and units derived from one or more of alpha mono-olefins comprising polar groups; or combinations thereof d) an ethylene homopolymer; e) a copolymer of units derived from propylene and units derived one or more of ethylene and C4-C20 alpha-olefins or mixtures thereof; f) a copolymer of units derived from propylene and units derived from one or more of alpha mono-olefins comprising polar groups; or combinations thereof; or g) a combination thereof.

17. The method of claim 11, wherein the virgin polymer is miscible with the polymer recy elate.

18. A method for retrofitting a polymer production facility' to add a processing capacity for polymer recy elate, wherein the polymer production facility (1) comprises a virgin polymer feed apparatus fluidly connected to an inlet to first melt mixing apparatus, the first melt mixing apparatus having an outlet fluidly connected to an inlet to a melt pump, the melt pump having an outlet fluidly connected to an inlet to a melt filtration apparatus, the melt filtration apparatus having an outlet adapted for withdrawal of a polymer product and (2) has a first throughput rate, the method comprising: a) adding a polymer recy elate feed system:

(1) comprising a polymer recy elate feed apparatus fluidly connected to an inlet to a second melt mixing apparatus, the second melt mixing apparatus having an outlet fluidly connected to a second melt filtration apparatus, the second melt filtration apparatus comprising advanced filtration technology; and

(2) having a second throughput rate; b) fluidly connecting an outlet from the second melt filtration apparatus to a second inlet to the first melt mixing apparatus; and c) adding a control system, wherein the control system provides for maintaining the sum of a virgin polymer feed rate and a polymer recyclate feed rate being less than or equal to the first throughput rate.

19. A method for retrofitting a polymer production facility' to add a processing capacity for polymer recyclate, wherein the polymer production facility (1) comprises a virgin polymer feed apparatus fluidly connected to an inlet to first melt mixing apparatus, the first melt mixing apparatus having an outlet fluidly connected to an inlet to a melt pump, the melt pump having an outlet fluidly connected to an inlet to a melt filtration apparatus, the melt filtration apparatus having an outlet adapted for withdrawal of a polymer product and (2) has a first throughput rate, the method comprising: a) adding a polymer recy elate feed system:

(1) comprising a polymer recyclate feed apparatus fluidly connected to an inlet to a second melt mixing apparatus, the second melt mixing apparatus having an outlet fluidly connected to a second melt filtration apparatus, the second melt filtration apparatus comprising advanced filtration technology; and

(2) having a second throughput rate; and b) replacing the first melt mixing apparatus, the first melt pump, and the first melt filtration apparatus with a recyclate blend system (1) comprising a second melt mixing apparatus having (i) one or more inlets fluidly connected to the virgin polymer feed apparatus and an outlet from the second melt filtration apparatus and (ii) an outlet fluidly connected to a second melt filtration apparatus, the second melt filtration apparatus having an outlet adapted for withdrawal of a recyclate blend product and (2) having a third throughput rate, wherein the third throughput rate is the sum of the first throughput rate and the second throughput rate.

20. A method for retrofitting a polymer production facility' to add a processing capacity for polymer recyclate, wherein the polymer production facility (1) comprises a virgin polymer feed apparatus fluidly connected to an inlet to first melt mixing apparatus, the first melt mixing apparatus having an outlet fluidly connected to an inlet to a melt pump, the melt pump having an outlet fluidly connected to an inlet to a melt filtration apparatus, the melt filtration apparatus having an outlet adapted for withdrawal of a polymer product and (2) has a first throughput rate, the method comprising: a) converting the virgin polymer feed apparatus to a recyclate blend feed apparatus by (1) adapting the virgin polymer feed apparatus to accept the virgin polymer feed and a polymer recyclate feed and (2) increasing the throughput rate of the virgin polymer feed apparatus to accept a second throughput rate of the polymer recyclate in addition to the first throughput rate of the virgin polymer; and b) replacing the first melt mixing apparatus, the first melt pump, and the first melt filtration apparatus with a recyclate blend system (1) comprising a second melt mixing apparatus having (i) an inlet fluidly connected to the recyclate blend feed apparatus and (ii) an outlet fluidly connected to a second melt filtration apparatus comprising advanced filtration technology, the second melt filtration apparatus having an outlet adapted for withdrawal of a recyclate blend product and (2) having a third throughput rate, wherein the third throughput rate is the sum of the first throughput rate and the second throughput rate.