WO2026029752A1

WO2026029752A1 - Methods for reduction of pet contamination in post-consumer resins

Info

Publication number: WO2026029752A1
Application number: PCT/US2024/040038
Authority: WO
Inventors: Eric D. Day
Original assignee: Equistar Chemicals LP
Current assignee: Equistar Chemicals LP
Priority date: 2024-07-29
Filing date: 2024-07-29
Publication date: 2026-02-05
Anticipated expiration: 2027-01-29

Abstract

The present disclosure relates to methods for reduction of PET contamination in post-consumer resins. In at least one embodiment, a method of making a pelletized polymeric resin includes blending, in a vessel, a reactive solvent with a post-consumer resin (PCR) to form a blend, the PCR comprising a condensation polymer and at least one of a polyethylene or a polypropylene, and the vessel selected from the group consisting of a reaction vessel, an extruder, a pelletizer, and combinations thereof. The method includes applying heat to the vessel. The method includes extruding the blend via the extruder to form a polymeric resin extrudate. The method includes pelletizing the polymeric resin extrudate via the pelletizer to form a pelletized polymeric resin. The method includes removing volatiles from the vessel, wherein the volatiles comprise a reaction product of the reactive solvent and the condensation polymer.

Description

METHODS FOR REDUCTION OF PET CONTAMINATION IN POST-CONSUMER RESINS

Field of the Invention

[0001] The present disclosure relates to methods for reduction of PET contamination in postconsumer resins.

Background of the Invention

[0002] Polymers, especially synthetic plastics, are ubiquitous in daily life due to their relatively low production costs and good balance of material properties. Synthetic plastics are used in a wide variety of applications, such as packaging, automotive components, medical devices, and consumer goods. To meet the high demand of these applications, tens of billions of pounds of synthetic plastics are produced globally on an annual basis. The overwhelming majority of synthetic plastics are produced from increasingly scarce fossil sources, such as petroleum and natural gas. Additionally, the manufacturing of synthetic plastics from fossil sources produces CO2 as a by-product.

[0003] The ubiquitous use of synthetic plastics has consequently resulted in millions of tons of plastic waste being generated every year. While the majonty of plastic waste is landfilled via municipal solid waste programs, a significant portion of plastic waste is found in the environment as litter, which, at the very least, is unsightly. Plastic waste is often washed into river systems and ultimately out to sea.

[0004] Plastics recycling has emerged as one solution to mitigate the issues associated with the wide-spread usage of plastics. Recovering and re-using plastics diverts waste from landfills and reduces the demand for virgin plastics made from fossil-based resources, which consequently reduces greenhouse gas emissions. In developed regions, such as the United States and the European Union, rates of plastics recycling are increasing due to greater awareness by consumers, businesses, and industrial manufacturing operations. The majority of recycled materials, including plastics, are mixed into a single stream which is collected and processed by a material recovery facility (MRF). At the MRF, materials are sorted, washed, and packaged for resale. Plastics can be sorted into individual materials, such as high-density polyethylene (HDPE) or polyethylene terephthalate) (PET), or mixed streams of other common plastics, such as polypropylene (PP), low-density polyethylene (LDPE), poly(vinyl chloride) (PVC), polystyrene (PS), polycarbonate (PC), and polyamides (PA). The single or mixed streams can then be further sorted, washed, and reprocessed into a pellet that is suitable for re-use in plastics processing, for example blow and injection molding. [0005] Typically, it can be difficult to sort different polymers from one another. For example, sorted polyethylene and sorted polypropylene typically has up to 5 wt. % of “condensation polymer” content, such as polyethylene terephthalate) content (also referred to as “PET contamination” in the sorted PE/PP) or polyamide content (also referred to as “PA contamination”). The PET content is not removed from the sorted PE/PP before pelletization of the sorted PE/PP, which otherwise leads to gel formation during pelletization. In addition, PET under such pelletization conditions can lead to degradation of the PET into benzene.

[0006] Depolymerization of sorted PET (without PE/PP) into its monomers has been attempted (See PCT Publication No. WO 2022/216681), but involves use of metal catalysts in meltprocessing processes to form amorphous PET before subsequent depolymerization processes. Such metal catalysts can remain in recycled materials thereof.

[0007] Mechanical recycling, also known as secondary recycling, is the process of converting recycled plastic waste into a re-usable form for subsequent manufacturing. A more detailed review of mechanical recycling and other plastics recovery processes are described in S. M. Al-Salem, P. Lettieri, J. Baeyens, “Recycling and recovery routes of plastic solid waste (PSW): A review”, Waste Management, Volume 29, Issue 10, October 2009, Pages 2625-2643, ISSN 0956- 053X. While advances in mechanical recycling technology have improved the quality of recycled polymers to some degree, there are fundamental limitations of mechanical decontamination approaches, such as the physical entrapment of contaminants within a polymer matrix. Thus, even with the improvements in mechanical recycling technology, the contamination in currently available recycled plastic waste prevents broader usage of recycled resins by the plastics industry. [0008] Accordingly, a need still exists for methods of removing PET contamination (and/or PA contamination) from reclaimed post-consumer PE (and/or PP) resins.

Summary of the Invention

[0009] The present disclosure relates to methods for reduction of PET contamination in postconsumer resins.

[0010] In at least one embodiment, a method of making a pelletized polymeric resin includes blending, in a vessel, a reactive solvent with a post-consumer resin (PCR) to form a blend, the PCR comprising a condensation polymer and at least one of a polyethylene or a polypropylene, and the vessel selected from the group consisting of a reaction vessel, an extruder, a pelletizer, and combinations thereof. The method includes applying heat to the vessel. The method includes extruding the blend via the extruder to form a polymeric resin extrudate. The method includes pelletizing the polymeric resin extrudate via the pelletizer to form a pelletized polymeric resin. The method includes removing volatiles from the vessel, wherein the volatiles comprise a reaction product of the reactive solvent and the condensation polymer.

[0011] In at least one embodiment, a method of making a pelletized polymeric resin includes blending, in a vessel, a reactive solvent with a post-consumer resin (PCR) to form a blend, the PCR comprising a polyethylene terephthalate (PET) and at least one of a polyethylene or a polypropylene, the reactive solvent selected from the group consisting of water, a mono-alcohol, and combinations thereof, and the vessel selected from the group consisting of a reaction vessel, an extruder, a pelletizer, and combinations thereof. The method includes applying heat to the vessel to provide a temperature to an interior volume of the vessel of about 80 °C to about 160 °C to the vessel. The method includes extruding the blend via the extruder to form a polymeric resin extrudate. The method includes pelletizing the polymeric resin extrudate via the pelletizer to form a pelletized polymeric resin. The method includes removing volatiles from the vessel by applying vacuum to the vessel, wherein the volatiles comprise a reaction product of the reactive solvent and the PET.

Detailed Description of the Invention

[0012] The present disclosure relates to methods for reduction of PET contamination in postconsumer resins. The inventor has discovered that condensation polymer content (e.g., PET contamination and/or PA contamination) in PE and PE PCRs can be reacted to produce low molecular weight components (e.g., monomeric units, dimeric units, trimeric units, tetrameric units) that can be devolatilized, conveniently, in a dedicated reaction vessel or during an extrusion process or pelletization process. For example, a dimeric unit has one terephthalate unit and one ethylene unit. As another example, a tetrameric unit can have two terephthalate units and two ethylene units.

[0013] Such reaction of PET contamination (and/or PA contamination) in the presence of generally unreactive PE and/or PP polymers can be performed using water or an alcohol with heat. Without being bound by theory, it is believed that the presence of generally unreactive PE and/or PP polymers in combination with water and/or alcohol provides a dilution effect and renders use of added catalyst (such as a metal catalyst) merely optional. In some embodiments, added catalyst is not used. Also, conventional melt-processing (e.g., of the PET) before depolymerization is merely optional. In some embodiments, melt-processing is not performed before depolymerization.

[0014] After devolatilization of low molecular weight components (e.g., monomeric units, dimeric units, trimeric units, tetrameric units), substantially pure PE and/or PP PCR can be realized that is “virgin-like” for subsequent pelletization (and/or extrusion if not done so already), providing reduced or eliminated gelation of PE and/or PP PCR during pelletization and avoiding degradation of PET into benzene during pelletization of the PE and/or PP PCR.

[0015] As used herein, the term “post-consumer resin” (PCR) refers to a polymeric material that is produced after the end consumer has used the material and has disposed of the material in a waste stream.

[0016] As used herein, the term “virgin” or “virgin-like” means essentially contaminant-free, pigment-free, odor-free, homogenous, and similar in properties to virgin polymer.

Depolymerization Conditions

[0017] Depolymerization can be performed by including a reactive solvent (such as water and/or an alcohol) and PP and/or PE PCR in a dedicated reaction vessel, an extruder, and/or a pelletizer. PP and/or PE PCR has one or more condensation polymers as contaminants. The reaction vessel, extruder, and/or pelletizer can be heated (e.g., about 80 °C to about 160 °C) to promote depolymerization. For example, the reaction vessel, extruder, and/or pelletizer can be heated below the melting point of the PE and/or PP polymer(s) of the PCR. Then, during depolymerization and/or upon cooling of the reaction vessel, extruder, and/or pelletizer, vacuum and/or air flow can be applied and depolymerized product(s) (such as dimeric units, trimeric units, and/or tetrameric units) of the condensation polymer(s) can be removed from the vessel, extruder, and/or pelletizer. In some embodiments, depolymerized product(s) are removed through a vacuum port of an extruder. In some embodiments, vacuum is applied such that a pressure within the vessel, extruder, and/or pelletizer is about 0.005 atmosphere (atm) to about 1 atm, such as about 0.8 atm. In embodiments where vacuum is applied during depolymerization, the heat applied to the vessel, extruder, and/or pelletizer can be a lower temperature than those recited above, such as about 30 °C to about 80 °C.

[0018] In some embodiments, a large excess (e.g., 2, 3, 4, 5, 6, 7, 8, 9, or 10 times excess by weight) of reactive solvent to condensation polymer content (e.g., PET) can be used which helps to disperse the PCR and expose the condensation polymer content to the reactive solvent.

[0019] In some embodiments, the depolymerization is not pH dependent. In other embodiments, the depolymerization can be acid catalyzed or base catalyzed, preferably base catalyzed.

[0020] In general, depolymerization can include heating the PE and/or PP PCR in the reaction vessel, extruder, and/or pelletizer to a temperature in a range of, for example, about 30°C to about 160°C. In some embodiments, any reaction vessel typically used for batch, semi-batch, or continuous reactions may be used. Temperatures from at least 30°C, 60°C, 120°C, or 150°C and/or up to 50°C, 75°C, 100°C, 150°C, 160°C°C are particularly suitable for depolymerizing polyester condensation polymers such as PET (or polyethylene terephthalate glycol-modified (PETG)). While depolymerization is often performed at elevated temperatures (e.g., above 100°C), including catalysts such as sodium amide, sodium hydroxide, etc. can enable depolymerization to proceed at lower temperatures, such as temperatures as low as ambient (room) temperature. The depolymerization reaction is suitably performed for a sufficient time (residence time) to substantially depolymerize the condensation polymer into low molecular weight components, for example, at least 0.01 , 0.1 , 0.5, 1 , 2, 3, or 4 hr and/or up to 2, 4, 6, 8, 10, 12, 18, or 24 hr. Suitably, the product mixture contains 2, 1, 0.5, 0.2, 0.1, 0.05, 0.02, or 0.01 wt.% or less of the condensation polymer relative to the initial PE/PP PCR, for example corresponding to a conversion of at least 80, 90, 95, 98, or 99 wt.% and/or up to 95, 98, 99, or 100 wt.% of the condensation polymer.

[0021] In some embodiments, the condensation polymer includes at least one of polyethylene terephthalate (PET) and polyethylene terephthalate gly col-modified (PETG); the reactive solvent comprises methanol.

Condensation Polymers

[0022] Condensation polymers according to the present disclosure can include polyesters, polyamides, or combinations thereof. The condensation polymers are generally thermoplastic polymers such as thermoplastic polyesters and polyamides. The PE and/or PP PCR can include a single condensation polymer, or it can include two or more different condensation polymers. For example, initial PCR can include two or more polyesters, two or more polyamides, at least one polyester and at least one polyamide, etc. Examples of suitable polyamides include nylon 6,6, nylon 6, nylon 6,10, etc. Examples of other suitable thermoplastic polymers that can be depolymerized according to the present disclosure include polycarbonates, polyanhydrides, polyimides, polybenzimidazoles, polyquinoxlines, aromatic ladder polymers, phenolformaldehyde polymers, urea-formaldehyde polymers, melamine- formaldehyde polymers, polyacetals, polyethersulfones, polyethers, polyphenylene oxides, polyarylenes, and thermoplastic polyurethanes.

[0023] The condensation polymer can include at least one polyester, such as polyethylene terephthalate (PET), polyethylene terephthalate gly col-modified (PETG; including ty pi cal ly about 5-50 mol.% or 15-30 mol.% cyclohexane dimethanol comonomer with 50-95 mol.% or 70-85 mol.% ethylene glycol comonomer), polytrimethylene terephthalate (PTT), polybutylene terephthalate (PBT), polyethylene isosorbide terephthalate (PEIT), polylactic acid (PLA), polyhydroxy alkanoate (PHA), polybutylene succinate (PBS), polybutylene succinate adipate (PBSA), polybutylene adipate terephthalate (PBAT), polyethylene furanoate (PEF), polycaprolactone (PCL), polyethylene adipate) (PEA), polybutylene succinate terephthalate (PBST), polyethylene succinate (PES), polyfbutylene succinate/terephthalate/isophthalate)-co- (lactate) (PBSTIL), liquid crystalline polyesters, or combinations thereof.

[0024] The condensation polymer can include, for instance, a blend of polyethylene terephthalate (PET) and polyethylene terephthalate glycol-modified (PETG). More generally, the condensation polymer can include a blend of condensation polymers, for example PET in combination with one or more copolyesters, such as PETG, isophthalate-modified copolyesters, sebacic acid-modified copolyesters, diethyleneglycol-modified copolyesters, triethyleneglycol modified-copolyesters, cyclohexanedimethanol modified-copolyesters, and/or polybutylene terephthalate. Such modified copolyesters generally have at least one of the TPA or ethylene glycol units in PET at least partially replaced with modifying units (e.g., at least some terephthalic units replaced with isophthalic units, at least some ethylene glycol units replaced with diethyleneglycol units). Modified copolyesters may include, for example, 2- 50 mol.%, 5-50 mol.%, 10-40 mol.%, 10-20 mol.%, 20-30 mol.%, or 15-30 mol.% of one or more modifying units. The copolyesters can have a low melting point or include an amorphous aromatic copolyester (such as one based on terephthalate/isophthalate copolymer with ethylene glycol or a copolyester made from a combination of terephthalic acid, ethylene glycol, and cyclohexyldimethanol). The condensation polymer content can include 5-95 wt.% (e.g., at least 5, 10, 15, 20, 30, 40, 50, 60, 70, or 80 wt.% and/or up to 20, 30, 40, 50, 60, 70, 80, 90, or 95 wt.%) of PET, PETG, or other copolyesters relative to the total amount of condensation polymer content of the PCR. The method can be performed on combinations of polyesters or other condensation polymers in multilayer materials, for example laminated polyester structures (e.g., where different layers can have different polyester components or compositions). [0025] The condensation polymer content can further include 0.01-10 wt.% (e.g., at least 0.01, 0.1, 1, 2, 3, or 5 wt. % and/or up to 2, 3, 4, 6, 8, or 10 wt. %) of polylactic acid (PLA) (i.e., in addition to PET and PETG or other copolyester(s)) relative to the total amount of condensation polymers in the initial melt-processed mixture.

Reactive Solvents

[0026] In some embodiments, the reactive solvent can include one or more of water, mono alcohols (e.g., methanol, ethanol), diols, mono-amines, diamines, or combinations thereof. In addition to mono-alcohols, diols or polyols such as ethylene glycol, glycerols, and those mentioned above as monomer additives can be used. Suitable amino compounds can include mono-amines, diamines and poly amines (e.g., as mentioned above as monomer additives), ammonia, and alcoholic amines (e.g., an ammo alkanol). The reactive solvent can be provided to the PCR such that the reactive solvent is present in a relative amount of at least 2, 5, 7, 10, 12, 15, or 20 and/or up to 6, 8, 10, 15, 20, 30, 40, or 50, on a w/w or v/v basis, relative to the condensation polymer content. Non-reactive solvents such as organic non-alcohol or non-amine solvents (e.g., non- protic or aprotic solvents such as tetrahydrofuran, chloroform, etc.) can also be provided to the reaction vessel, extruder, and/or pelletizer to speed up the depolymerization by enhancing the swelling the of the amorphous polymer (e.g., PET/G). Non-reactive solvents can increase the rate of depolymerization (e.g., via polymer swelling). When included, the non-reactive solvent can similarly be included in a relative amount of at least 2, 5, 7, 10, 12, 15, or 20 and/or up to 6, 8, 10, 15, 20, 30, 40, or 50, on a w/w or v/v basis, relative to the amount of total PCR.

[0027] In some embodiments when the condensation polymer includes a polyester, the reactive solvent can include water (e.g., for depolymerization via hydrolysis). For example, if the original condensation polymer is PET, then the corresponding dimeric units, trimeric units, tetrameric units, etc. formed by depolymerization via hydrolysis include terephthalic acid (TP A) units and ethylene glycol (EG) units.

[0028] In some embodiments when the condensation polymer, the reactive solvent can include methanol (e.g., for depolymerization via methanolysis; or mono-alcohol more generally), and the dimeric units, trimeric units, tetrameric units, etc. in the product mixture can include diester units and diol units formed from the repeat units of the polyester. For example, if the original condensation polymer is PET, then the corresponding dimeric units, trimeric units, tetrameric units, etc. formed by depolymerization via methanolysis include dimethyl terephthalate (DMT) units and ethylene glycol (EG) units. Analogous ethyl or other alkyl esters can be formed when using mono-alcohols other than methanol, such as ethanol, etc.

[0029] In some embodiments when the condensation polymer includes a polyester, the reactive solvent can include ethylene glycol (e.g., for depolymerization via glycolysis; or diol more generally) and the dimeric units, trimeric units, tetrameric units, etc. in the product mixture can include diester units formed from the repeat units of the polyester. For example, if the original condensation polymer is PET, then the corresponding dimeric units, trimeric units, tetrameric units, etc. formed by depolymerization via glycolysis include bis(hydroxymethyl)terephthalate (BHET) units.

[0030] In some embodiments when the condensation polymer includes a polyamide, the reactive solvent can include water (e.g., for depolymerization via hydrolysis), and the dimeric units, trimeric units, tetrameric units, etc. in the product mixture can include diacid units and diamines units formed from the repeat units of the polyamide.

[0031] In some embodiments when the condensation polymer includes a polyamide, the reactive solvent can include methanol, (e.g., for depolymerization via methanolysis), and the dimeric units, trimeric units, tetrameric units, etc. in the product mixture can include diester units and diamine units formed from the repeat units of the polyamide.

[0032] In some embodiments when the condensation polymer includes a polyamide, the reactive solvent can include ethylene glycol (e.g., for depolymerization via glycolysis), and the dimeric units, trimeric units, tetrameric units, etc. in the product mixture include diester units and diamine units formed from the repeat units of the polyamide.

[0033] Suitably, the PCR is free or substantially free of reactive solvents (i.e., before such reactive solvents are added to the PCR for depolymerization). For example, the initial PCR typically contains not more than 2, 1, 0.5, 0.2, or 0.1 wt. % of such reactive solvents (e.g. water, methanol, or other mono alcohols). However, the PCR can include, for example, 0.0001 wt.% to 1 vrt.% water to promote transesterification. Small amounts of water can be due to naturally present or ambient moisture (e.g., no added water) or, alternatively, some amount of added water. For example, the initial PCR can include at least 0.0001, 0.001, 0.01, 0.1, or 0.2 wt. % and/or up to 0.1, 0.2, 0.4, 0.6, 0.8, or 1 wt. % water relative to the melt-processed mixture as a whole or the condensation polymer portion thereof. When some water is present in the melt-processed mixture, the mixture is suitably free or substantially free of other reactive solvents in general and/or free or substantially free of added water (i.e., non-ambient or non-environmental water).

Surfactants

[0034] A surfactant can also be provided to the reaction vessel, extruder, and/or pelletizer. A surfactant can lower the surface energy of the depolymerization reaction medium to improve polymer wetting and depolymerization efficiency. The surfactant suitably can be included in an amount of 0.1- 10 wt.% or 0.5-4 wt.% based on the weight of the PCR. The surfactant is not particularly limited, for example including anionic, cationic, zwitterionic, and non-ionic surfactants. Examples of suitable anionic surfactants include sodium dodecyl sulfate (SDS) and sodium lauryl sulfate (SLS).

Swelling Treatment

[0035] Methods can further include swelling the PCR with at least one of a gaseous swelling and a non-protic solvent swelling agent (e.g., to enhance depolymerization). High-pressure gases such as carbon dioxide and oxygen can swell condensation polymers (e.g., PET, PETG, and other polyesters), making the PCR more accessible during depolymerization. For example, prior to depolymerization, the PCR can be exposed to carbon dioxide and/or oxygen at high pressures, for example in a pressurized vessel (e.g., which could be the reaction vessel for depolymerization, but without added reaction solvent/reaction medium). The pressure is then released, the swelled PCR is then added to or otherwise combined with the reactive solvent, and depolymerization can then be performed. As described above, non-protic or aprotic solvents such as tetrahydrofuran, chloroform, etc. can be added to the reaction vessel as an additional or alternative means to swell the PCR to enhance depolymerization.

Auxiliary Catalysts

[0036] The reaction medium can further include at least one of polystyrene (PS) sulfonic acid beads and a hydroxylated pyridine. The PS sulfonic acid beads can be included as a solid acid external catalyst that can be easily recovered and re-used after deopolymerization. The hydroxylated pyridine can serve as a bifunctional catalyst.

Post-Consumer Resins

[0037] Post-consumer resins used as feed material in processes of the present disclosure may be sourced from post-consumer, post-industrial, post-commercial, and/or other special waste streams. For example, post-consumer resins can be waste polymers that can be derived from curbside recycle streams where end-consumers place used polymers from packages and products into a designated bin for collection by a waste hauler or recycler. Post-consumer waste polymers can also be derived from in-store "take-back" programs where the consumer brings waste polymers into a store and places the waste polymers in a designated collection bin. An example of post-industrial waste polymers can be waste polymers produced during the manufacture or shipment of a good or product that are collected as unusable material by the manufacturer (i.e. trim scraps, out of specification material, start up scrap). An example of waste polymers from a special waste stream can be waste polymers derived from the recycling of electronic waste, also known as "e-waste." Another example of waste polymers from a special waste stream can be waste polymers derived from the recycling of automobiles. Another example of waste polymers from a special waste stream can be waste polymers derived from the recycling of used carpeting and textiles.

[0038] Post-consumer resins of the present disclosure may be a homogenous composition of an individual polymer or a mixture of several different polymer compositions. Non-limiting examples of post-consumer resins include homopolymers and copolymers of polyolefins, such as polyethylene and isotactic polypropylene, polyesters, such as polyethylene terephthalate), vinyl polymers, such as poly(vinyl chloride), styrenic polymers, such as polystyrene, polyamides, such as poly(hexamethylene adapamide), polycarbonates, such as poly(bisphenol-A carbonate), polyacrylates, such as poly(methyl methacrylate), polysiloxanes, such as poly(dimethylsiloxane), thermoplastic elastomers, such as styrene-butadiene block copolymers and ethylene-propylene rubber, and other dissolvable polymers.

[0039] Post-consumer resins may also contain various pigments, dyes, process aides, stabilizing additives, fillers, and other performance additives that were added to the polymer during polymerization or conversion of the original polymer to the final form of an article. Non-limiting examples of pigments are organic pigments, such as copper phthalocyanine, inorganic pigments, such as titanium dioxide, and other pigments that may be apparent to those having ordinary skill in the art. A non-limiting example of an organic dye is Basic Yellow 51. Non-limiting examples of process aides are antistatic agents, such as glycerol monostearate and slip-promoting agents, such as erucamide. A non-limiting example of a stabilizing additive is octadecyl-3-(3,5-di- tert.butyl-4-hydroxyphenyl)-propionate. Non-limiting examples of fillers are calcium carbonate, talc, and glass fibers.

[0040] In some embodiments, resins of the current disclosure include one or more polymeric components, where at least one component includes a polymer having at least one ethylene monomeric unit. In some embodiments, polymeric components of the present disclosure include copolymer compositions, namely polymers derived from two or more structurally distinct monomers. In some embodiments, a resin is a polymeric resin, wherein a polymeric resin includes a blend of two or more polymer components. More specifically, resins of the present disclosure can include a polymeric resin comprising two or more polymeric components. Resins of the present disclosure can be useful as manufacturing materials, as a result of chemical resistance and environmental stress crack growth resistance (ESCR).

[0041] In at least one embodiment, a polymeric resin for use in the production of blow molded products includes a blend of a first polymeric component and a second polymeric component. In some embodiments, the first polymeric component is a high density polyethylene (HDPE) base resin. Such materials and products produced from the polymeric resin exhibit sufficient physical properties, mechanical properties, chemical resistant properties, impact strength, hardness, and environmental stress crack resistance (ESCR) suitable for commercial products and uses.

Virgin HDPE Base Resin

[0042] In some embodiments, the HDPE base resin has a density (as determined by ASTM1505) of about 0.940 g/cm³ to about 0.975 g/cm³, such as about 0.940 g/cm³ to about 0.960 g/cm³, such as about 0.940 g/cm³ to about 0.955 g/cm³, such as about 0.953 g/cm³.

[0043] In some embodiments, the HDPE base resin has a high load melt index (HLMI) (as determined by ASTM D-1238, 190°C with a 21.6 kg load) of about 2 g/10 min to about 10 g/10 min, such as about 4 g/10 min to about 8 g/10 min, such as about 5.5 g/10 min to about 7.5 g/10 min.

[0044] In some embodiments, the HDPE base resin includes a weight average molecular weight (Mw), as determined by gel permeation chromatography (GPC), of about 180,000 g/mol to about 400,000 g/mol, such as about 215,000 g/mol to about 375,000 g/mol, such as about 275,000 g/mol to about 375,000 g/mol.

[0045] In some embodiments, the HDPE base resin has an ESCR (as determined by ISO 16770; 3.5 MPa, 2% Arkopal N100, 80 °C) of about 10 hrs to about 125 hrs, such as about 15 hrs to about 100 hrs, such as about 25 hrs to about 75 hrs, such as about 35 hrs to about 65 hrs.

[0046] In some embodiments, the HDPE base resin can include any suitable commercially available resin, such as Hostalen ACP 5231 D, Hostalen ACP 5331 A, Lupolen 4261 AG Q 469, Hyperzone HY 4008, Hyperzone HY55430, and combinations thereof. In at least one embodiment, the HDPE base resin is sourced from LyondellBasell Industries N.V.

Post-Consumer Resin (PCR) Properties

[0047] The PCR can be sourced from any appropriate plastic waste streams, such as polyethylene PCR sourced from recycled intermediate bulk containers (IBC), drums, and/or pipes. In additional or alternative embodiments, the PCR can further be sourced from suitable resins used in small blow molding applications. Without being bound by theory, blending the HDPE base resin with the PCR allows an operator to tune the rheological properties of the polymeric resin, so as to produce a resin suitable for use in general purpose large blow molding applications. However, because condensation polymer content of post-consumer resins of the present disclosure can be depolymerized and removed, added virgin resin (such as an HDPE) can be reduced or eliminated. Examples of such applications can include, but are not limited to, outdoor recreational equipment (e.g., kayaks and playground equipment).

[0048] In some embodiments, the PCR (e.g., before a depolymerization process) has a density (as determined by ASTM1505) of about 0.910 g/cm³ to about 0.970 g/cm³, such as about 0.920 g/cm³ to about 0.955 g/cm³, such as about 0.935 g/cm³ to about 0.945 g/cm³, such as about 0.941 g/cm³. In at least one embodiment, the PCR has a melt index (as determined by ASTM D-1238, 190°C with a 2.16 kg load) of about 0.3 g/10 min to about 10 g/10 min, such as about 0.3 g/10 min to about 10 g/10 min, such as about 0.3 g/10 min to about 5 g/10 min such as about 0.3 g/10 min to about 2 g/10 min.

[0049] In some embodiments, the PCR (e.g., before a depolymerization process) has a high load melt index (as determined by ASTM D-1238, 190°C with a 21.6 kg load) of about 10 g/10 min to about 60 g/10 min, such as about 10 g/10 min to about 50 g/10 min, such as about 10 g/10 min to about 40 g/10 min.

[0050] In one or more embodiments, the PCR (e.g., before a depolymerization process) is selected from an ultra-high molecular weight polyethylene (UHMWPE), ultra-low molecular weight polyethylene (ULMWPE), high molecular weight polyethylene (HMWPE), high density polyethylene (HDPE), medium density polyethylene (MDPE), linear low density polyethylene (LLDPE), low density polyethylene (LDPE), very-low density polyethylene (VLDPE), and combinations thereof. In some embodiments, the PCR is a copolymer of polyethylene of any one or more selected from the group previously described.

[0051] In at least one embodiment, the PCR (e.g., before a depolymerization process) is HDPE homopolymer and/or a copolymer thereof. In some embodiments, the HDPE PCR homopolymer includes a weight average molecular weight (Mw), as determined by GPC, of about 180,000 g/mol to about 400,000 g/mol, such as about 200,000 g/mol to about 360,000 g/mol, such as about 225,000 g/mol to about 350,000 g/mol.

[0052] In some embodiments, the HDPE PCR (e g., before a depolymerization process) has a density of about 0.925 g/cm³ to about 0.965 g/cm³, such as about 0.935 g/cm³ to about 0.955 g/cm³, such as about 0.945 g/cm³ to about 0.955 g/cm³. In at least one embodiment, the HDPE PCR homopolymer has a melt index (as determined by ASTM D-1238, 190°C with a 2.16 kg load) of about 1 g/10 min to about 60 g/10 min, such as about 10 g/10 min to about 50 g/10 min, such as about 20 g/10 min to about 40 g/10 min such as about 25 g/10 min to about 35 g/10 min.

[0053] In some embodiments, the PCR (e.g., before a depolymerization process) is a HDPE PCR comprising any one or more comonomers selected from propylene, 1 -butene, 1 -hexene, 1 -octene, 4-methyl-l-pentene, and any combination thereof. In some embodiments, the HDPE copolymer PCR includes about 90. 1 mol % to about 99.9 mol % of ethylene units, such as about 91 mol % to 99 mol %, such as about 92 mol % to 98 mol %, such as about 93 mol % to 97 mol %, such as about 94 mol % to 96 mol %. In at least one embodiment, the HDPE copolymer or homopolymer PCR is sourced from post-consumer waste products, such as products formed from HDPE copolymer resins typically used for small blow molding applications.

[0054] In some embodiments, the HDPE copolymer PCR (e.g., before a depolymerization process) includes a backbone architecture of at least one of a random copolymer, a block copolymer, an alternating copolymer, or a gradient copolymer. In one or more embodiments, the HDPE copolymer PCR is a random copolymer. In one or more embodiments, the HDPE copolymer PCR includes a molar ratio of ethylene units to any one or more comonomer units of about 60:40 to about 99: 1, such as about 70:30 to about 90: 10, such as about 75:25 to about 85:15.

[0055] In some embodiments, the HDPE copolymer PCR (e.g., before a depolymerization process) includes a weight average molecular weight (Mw), as determined by GPC, of about 200,000 g/mol to about 400,000 g/mol, such as about 225,000 g/mol to about 375,000 g/mol, such as about 250,000 g/mol to about 375,000 g/mol. [0056] In some embodiments, the HDPE copolymer PCR (e.g., before a depolymerization process) has an ESCR (as determined by ASTM DI 693; 100% Igepal®, Cond B) of about 10 hrs to about 50 hrs, such as about 20 hrs to about 40 hrs, such as about 25 hrs to about 35 hrs.

[0057] In at least one embodiment, the PCR (e.g., before a depolymerization process) includes at least one of HDPE homopolymer PCR sourced from one or more intermediate bulk containers and/or HDPE copolymer PCR sourced from resins used in small blow molding applications. In some embodiments, the PCR includes both HDPE PCR and HDPE copolymer PCR at a weight ratio of about 50:50 to about 99:1, such as 60:40 to about 90: 10, such as 70:30 to about 80:20, such as 75:25 to about 85: 15.

[0058] In some embodiments, the PCR (e.g., before a depolymerization process) includes one or more polymers selected from the group consisting of low density polyethylene (LDPE), medium density polyethylene (MDPE), polypropylene, polyester, acrylic resin, polyvinyl alcohol, polyvinyl chloride, polyvinyl acetate, polyvinyl ether, ethylene-vinyl acetate copolymers (EVA), ethylenevinyl alcohol copolymers (EV OH), ethylene-acrylic acid copolymers, any one or more nylons, and the like, and mixtures thereof. In at least one embodiment, such one or more polymers includes less than 15 wt. % of the PCR, such as about 0.01 wt. % to about 15 wt. %, such as about 0.01 wt. % to about 10 wt. %, such as about 0.01 wt. % to about 5 wt. %, such as about 0.01 wt. % to about 2.5 wt. %, such as about 0.01 wt. % to about 1 wt. %.

[0059] In some embodiments, the PCR (e.g., before a depolymerization process) further includes one or more compatiblizers, such as grafted copolymers of maleic anhydride with HDPE, LLDPE, and/or LDPE. In at least one embodiment, the one or more compatibilizers includes less than 15 wt. % of the PCR, such as about 0.01 wt. % to about 15 wt. %, such as about 0.01 wt. % to about 10 wt. %, such as about 0.01 wt. % to about 5 wt. %, such as about 0.01 wt. % to about 2.5 wt. %, such as about 0.01 wt. % to about 1 wt. %.

[0060] In some embodiments, the PCR (e.g., before a depolymerization process) further includes one or more tie layer material. A tie layer is commonly used in multi-layered film applications as an adhesive applied to prevent film delamination. A tie layer material typically includes a polyolefin base resin as the predominant component and one or more grafted polyolefins. In at least one embodiment, the one or more tie layer materials includes less than 15 wt. % of the PCR, such as about 0.01 wt. % to about 15 wt. %, such as about 0.01 wt. % to about 10 wt. %, such as about 0.01 wt. % to about 5 wt. %, such as about 0.01 wt. % to about 2.5 wt. %, such as about 0.01 wt. % to about 1 wt. %.

[0061] In one or more embodiments, the compositional summation of the one or more additional polymers, one or more compatibilizers, and one or more tie layer materials of the PCR includes less than 15 wt. % of the PCR, such as about 0.01 wt. % to about 15 wt. %, such as about 0.01 wt. % to about 10 wt. %, such as about 0.01 wt. % to about 5 wt. %, such as about 0.01 wt. % to about 2.5 wt. %, such as about 0.01 wt. % to about 1 wt. %.

Post-Extrusion Polymeric Resin and Components Thereof

[0062] In one or more embodiments, the post-extrusion polymeric resin includes about 50 wt. % to about 100 wt. % of base resin (e.g., the starting PE and/or PP and not the condensation polymer), such as about 95 wt. % to about 99 wt. % base resin, alternatively about 20 wt. % to about 95 wt. % base resin. In at least one embodiment, base resin includes at least 50 wt. % of the post-extrusion polymenc resin.

[0063] In one or more embodiments, the post-extrusion polymenc resin includes a weight ratio of base resin to additional polymer (e.g., added during extrusion) of about 60:40 to about 90: 10, such as about 70:30 to about 90: 10, such as about 75:25 to about 90: 10.

[0064] In some embodiments, the post-extrusion polymeric resin can further include any one or more additives. Suitable additives include, but are not limited to UV stabilizers, flame retardants, fillers, and pigments. Additives are important in establishing the long term stability of the polymenc resin as well as the resulting material’s chemical and impact resistance.

[0065] In one or more embodiments, the post-extrusion polymeric resin further includes one or more UV stabilizers in an amount of about 1500 ppm to about 2500 ppm, such as about 1750 ppm to about 2250 ppm, such as about 2000 ppm. Suitable UV stabilizers include, but are not limited to, hindered amine light stabilizers ("HALS"). Examples of HALS include: Chimassorb 944, Chimassorb 994, Chimassorb 905, Tinuvin 770, Tinuvin 992, Tinuvin 622, Tinuvin 144, and Spinuvex A36 available from Geigy; and Cyasorb UV 3346 and Cyasorb UV 944 commercially available American Cyanamide. Particularly preferred UV stabilizers are Cytec UV 3346 and Chemasorb 944 (poly[N,N-bis(2,2,6,6-tetramethyl-4-piperidinyl)-l,6-hexanediamine-co-2,4- dichloro-6-morpholino-l,3,5-triazine).

[0066] In one or more embodiments, the post-extrusion polymeric resin further includes one or more flame retardants. Flame retardants include, for example, halogen-containing compounds, antimony oxides, or phosphorus compounds. Suitable flame retardants include, but are not limited to aluminum trihydrate, antimony oxide (Sb20s), and decabromobiphenyl oxide ("decabrome").

[0067] In one or more embodiments, the post-extrusion polymeric resin includes 0.01 wt. % to about 5 wt. % of one or more additives, such as about 0.01 wt. % to about 2.5 wt. %, such as about 0.01 wt. % to about 1 wt. %. In one or more embodiments, the polymeric resin includes about 1 wt. % or less of additives (such as flame retardant). [0068] In one or more embodiments, the one or more components blended with the base resin, the carbon nanotubes, and any additional polymers via any one or more suitable methods known to one of ordinary skill in the art. Such blending methods can include, solution processing, thermal processing, and/or mechanical processing. In some embodiments, melt screw extrusion is implemented to depolymerize condensation polymer and form the polymeric resin extrudate (postextrusion polymeric resin), which can then be further processed via pelletization (optionally with additional or alternative depolymerization) to form a pelletized polymeric resin. Melt blending is one suitable method for preparing the post-extrusion polymer blend of the present disclosure, although any suitable polymer blending techniques available to those of ordinary skill in the art may be used. Techniques for melt blending of a polymer with additives of all types are known to those of ordinary skill the art and can ty pically be used with the present disclosure. In one type of melt blending operation useful with the present disclosure, the individual components of the blend are combined in a mechanical extruder or mixer, and then heated to a temperature sufficient to form a polymer melt.

[0069] The mechanical mixer for mixing and/or depolymerizing can be a continuous or batch mixer. Examples of suitable continuous mixers include single screw extruders, intermeshing corotating twin screw extruders such as Wemer & Pfleiderer ZSK™ extruders, counter-rotating twin screw extruders such as those manufactured by Leistritz™, and reciprocating single screw kneaders such as Buss™ co-kneaders. Examples of suitable batch mixers are lateral 2-roll mixers such as Banbury™ or Boling™ mixers. The temperature of the melt, residence time of the melt within the mixer, and the mechanical design of the mixer are several well-known variables that control the amount of shear to be applied to the composition during mixing, and can be readily selected by one of ordinary skill in the art based on the disclosure of the disclosure herein.

[0070] The polymeric resins disclosed herein may be pelletized (with optional depolymerization of condensation polymer) via strand pelleting or commercial underwater pelletization. Pellets of the polymeric resin may then be easily processed into shaped articles by injection molding, profile extrusion, blow molding, and other forming processes to give products which have well balanced properties suitable for commercial applications.

[0071] In at least one embodiment, pellets of the polymeric resin are formed in a continuous process. As such, components of the polymeric resin are fed into a continuous mixer, a single screw or twin screw extruder via volumetric or gravimetric feeders. The extruder is heated to a temperature sufficient to melt the polymers, for example between 165 °C and 190 °C. The components are fed into an extruder and mixed/blended together in a molten state. The extruder speed may be from about 1 to about 100 revolutions per minute (rpm), more typically from about 10 to about 50 rpm. The gas from the extruder may be evacuated by a vacuum pump. The polymeric resin extrudate is typically cooled (e.g., in a water bath or underwater pelletizer) and pelletized to form pellets of the polymeric resin.

[0072] In at least one embodiment, pellets of the polymeric resin are formed in a batch process (with optional depolymerization of condensation polymer). As such, components of the polymeric resin are added to a mixing device, such as a Banbury mixer, and heated to a temperature sufficient to melt the polymer, such as about 100 °C to about 155 °C. The mixing speed is typically about 35 to about 75 rpm. The output from the mixer is cooled and pelletized to form pellets of the polymeric resin.

[0073] In one or more embodiments, the polymeric resin, or pellets thereof, is useful for making articles by injection molding, blow molding, rotomolding, and compression molding. In at least one embodiment, the polymeric resin can be implemented into an extrusion blow molding process to manufacture jerry cans comprising recycled PCR material.

[0074] In embodiments wherein the polymeric resin includes a PCR base resin and one or more additional polymers, the polymeric resin exhibits intermediate physical and mechanical properties in comparison the input materials. That is to say that such resulting physical and mechanical properties are tailorable via altering the feed of the polymeric components and/or additives.

[0075] In some embodiments, the polymeric resin has a density (as determined by ASTM DI 505) of about of about 0.940 g/cm³ to about 0.975 g/cm³, such as about 0.940 g/cm³ to about 0.960 g/cm³, such as about 0.940 g/cm³ to about 0.955 g/cm³, such as about 0.948 g/cm³

[0076] In some embodiments, the polymeric resin has a melt index (as determined by ASTM D- 1238, 190°C with a 2.16 kg load) of about 0.05 g/10 min to about 1 g/10 min, such as about 0.05 g/10 min to about 0.5 g/10 min, such as about 0.05 g/10 min to about 0. 1 g/10 min.

[0077] In some embodiments, the polymeric resin has a high load melt index (as determined by ASTM D-1238, 190°C with a 21.6 kg load) of about 2 g/10 min to about 20 g/10 min, such as about 5 g/10 min to about 15 g/10 min, such as about 8.5 g/10 min to about 12.5 g/10 min, such as about 10 g/10 min.

[0078] In some embodiments, the polymeric resin has an ESCR (as determined by ASTM D1693; 100% Igepal®, Cond B) of greater than 1000 hrs.

[0079] It should be noted that an object of the present disclosure is that the polymeric resin may be implemented into extrusion blow molded articles formed from post-consumer waste products, articles such as playground equipment, outdoor recreational equipment (e.g., kayaks), and the like. Furthermore, it is an object of the present disclosure to provide hollow plastic articles whose structure has one or more layers which have PCR content, and also to provide a process for their production. Such products can be produced via blow molding or co-extrusion blow molding processes.

[0080] In at least one embodiment, hollow plastic articles can be produced via a process comprising: (1) molding a blow molded article in a blow molding and/or co-extrusion blow molding machine, whereby the blow molding cavity formed by the two mold contours is shaped in such a way that said cavity essentially matches the outer contour of the plastic hollow article to be fabricated and, in addition, it has a circumferential indentation and/or protuberance, preferably located in the middle relative to the nip-off edge, (2) separation of the indentation and/or protuberance, which yields at least two sheets, (3) optionally, prior to joining the sheets together to form a hollow article, installation of the built-in components on the inside of the sheets, and (4) joining the sheets together to form a hollow article, optionally by means of welding and/or gluing. [0081] The principle of the process for the production of plastic hollow articles includes first the conventional fabrication of a blow molded article in a regular blow molding or co-extrusion blow molding machine. The cavity formed by the two mold contours is shaped in such a way that said cavity essentially matches the outer contour of the plastic hollow article or plastic tank to be manufactured. In one or more embodiments, the above-mentioned blow molding cavity or the blowing mold used for the process additionally has a circumferential indentation and/or protuberance, preferably located in the middle relative to the nip-off edge. "Circumferential", as used herein, means that the indentation and/or protuberance preferably extends around the entire blow molded article or plastic hollow article. Therefore, the modified configuration of the contact areas of the mold, which is new in comparison to the commonly employed blowing molds, allows the creation of a hollow plastic article that has an indentation and/or protuberance (a groove or bead) extending around the container.

[0082] In the second step of the process, the described indentation and/or protuberance is separated, preferably in the perpendicular direction with respect to the above-mentioned indentation and/or protuberance. Two half shells or sheets are obtained by this separation procedure, that is to say, for instance, by cutting, grinding or punching out the indentation and/or protuberance that encircles the hollow plastic article. In some embodiments, the half shells obtained are glued and/or welded together to form a hollow article.

[0083] In at least one embodiment, it is provided that the hollow plastic articles manufactured by means of the process according to this disclosure are preferably employed as playground and outdoor recreational equipment (e.g, kayaks), pipes, automotive dunnage, truck bedliners, and the like.

EMBODIMENTS LISTING [0084] The present disclosure provides, among others, the following aspects, each of which can be considered as optionally including any alternate embodiments:

Clause 1. A method of making a pelletized polymeric resin, comprising: blending, in a vessel, a reactive solvent with a post-consumer resin (PCR) to form a blend, the PCR comprising a condensation polymer and at least one of a polyethylene or a polypropylene, and the vessel selected from the group consisting of a reaction vessel, an extruder, a pelletizer, and combinations thereof; applying heat to the vessel; extruding the blend via the extruder to form a polymeric resin extrudate; pelletizing the polymeric resin extrudate via the pelletizer to form a pelletized polymeric resin; and removing volatiles from the vessel, wherein the volatiles comprise a reaction product of the reactive solvent and the condensation polymer.

Clause 2. The method of Clause 1, wherein the reactive solvent is selected from the group consisting of water, a mono-alcohol, and combinations thereof.

Clause 3. The method of Clauses 1 or 2, wherein the condensation polymer is selected from the group consisting of a polyethylene terephthalate (PET), polyethylene terephthalate glycol- modified (PETG), and combinations thereof.

Clause 4. The method of any of Clauses 1 to 3, wherein the vessel is the extruder.

Clause 5. The method of any of Clauses 1 to 4, wherein the vessel is the pelletizer.

Clause 6. The method of any of Clauses 1 to 5, wherein the vessel is the reaction vessel.

Clause 7. The method of any of Clauses 1 to 6, wherein blending the reactive solvent with the PCR to form the blend, is performed in a combination of the reaction vessel, the extruder, or the pelletizer.

Clause 8. The method of any of Clauses 1 to 7, wherein applying heat to the vessel provides a temperature of about 80 °C to about 160 °C to an interior volume of the vessel.

Clause 9. The method of any of Clauses 1 to 8, wherein the temperature is about 80 °C to about 110 °C.

Clause 10. The method of any of Clauses 1 to 9, wherein removing volatiles from the vessel comprises applying vacuum to the vessel.

Clause 11. The method of any of Clauses 1 to 10, wherein removing volatiles from the vessel compnses applying vacuum to the vessel.

Clause 12. The method of any of Clauses 1 to 11, wherein the vessel is the extruder.

Clause 13. The method of any of Clauses 1 to 12, wherein the vessel is the pelletizer. Clause 14. The method of any of Clauses 1 to 13, wherein the vessel is the reaction vessel.

Clause 15. The method of any of Clauses 1 to 14, wherein the PCR comprises a polyethylene selected from the group consisting of ultra-high molecular weight polyethylene (UHMWPE), ultra-low molecular weight polyethylene (ULMWPE), high molecular weight polyethylene (HMWPE), high density polyethylene (HDPE), medium density polyethylene (MDPE), linear low density polyethylene (LLDPE), low density polyethylene (LDPE), very-low density polyethylene (VLDPE), and combinations thereof.

Clause 16. The method of any of Clauses 1 to 15, wherein the reaction product comprises a dimeric unit, a trimeric unit, a tetrameric unit, or combinations thereof of the condensation polymer.

Clause 17. The method of any of Clauses 1 to 16, wherein the reaction product comprises the dimeric unit, the dimeric unit comprising one terephthalate unit and one ethylene unit.

Clause 18. The method of any of Clauses 1 to 17, wherein the reaction product comprises the tetrameric unit, the tetrameric unit comprising two terephthalate units and two ethylene units.

Clause 19. A method of making a pelletized polymeric resin, comprising: blending, in a vessel, a reactive solvent with a post-consumer resin (PCR) to form a blend, the PCR comprising a polyethylene terephthalate (PET) and at least one of a polyethylene or a polypropylene, the reactive solvent selected from the group consisting of water, a mono-alcohol, and combinations thereof, and the vessel selected from the group consisting of a reaction vessel, an extruder, a pelletizer, and combinations thereof; applying heat to the vessel to provide a temperature to an interior volume of the vessel of about 80 °C to about 160 °C to the vessel; extruding the blend via the extruder to form a polymeric resin extrudate; pelletizing the polymeric resin extrudate via the pelletizer to form a pelletized polymeric resin; and removing volatiles from the vessel by applying vacuum to the vessel, wherein the volatiles comprise a reaction product of the reactive solvent and the PET.

Clause 20. The method of Clause 19, wherein applying vacuum to the vessel provides a pressure of about 0.005 atm to about 1 atm to the interior volume the vessel.

[0085] Overall, processes of the present disclosure provide reaction of condensation polymer content (e.g., PET contamination and/or PA contamination) in PE and PE PCRs into low molecular weight components (e.g., monomeric units, dimeric units, trimeric units, tetrameric units) that can be devolatilized, conveniently, in a dedicated reaction vessel or during an extrusion process or pelletization process. Such reaction of, for example, PET contamination (and/or PA contamination) in the presence of generally unreactive PE and/or PP polymers can be performed using water or an alcohol with heat. Without being bound by theory, it is believed that the presence of generally unreactive PE and/or PP polymers in combination with water and/or alcohol provides a dilution effect and renders use of added catalyst (such as a metal catalyst) merely optional for depolymerization to proceed sufficiently. After devolatilization of low molecular weight components (e.g., monomeric units, dimeric units, trimeric units, tetrameric units), substantially pure PE and/or PP PCR can be realized that is “virgin-hke” for subsequent pelletization (and/or extrusion if not done so already), providing reduced or eliminated gelation of PE and/or PP PCR during pelletization and avoiding degradation of PET into benzene during pelletization of the PE and/or PP PCR.

[0086] The phrases, unless otherwise specified, "consists essentially of' and "consisting essentially of' do not exclude the presence of other steps, elements, or materials, whether or not, specifically mentioned in this specification, so long as such steps, elements, or materials, do not affect the basic and novel characteristics of the present disclosure, additionally, they do not exclude impurities and variances normally associated with the elements and materials used.

[0087] For the sake of brevity, only certain ranges are explicitly disclosed herein. However, ranges from 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.

[0088] All documents described herein are incorporated by reference herein, including any priority documents and or testing procedures to the extent they are not inconsistent with this text. As is apparent from the foregoing general description and the specific embodiments, while forms of the present disclosure have been illustrated and described, various modifications can be made without departing from the spirit and scope of the present disclosure. Accordingly, it is not intended that the present disclosure be limited thereby. Likewise, the term “comprising” is considered synonymous with the term “including” for purposes of United States law. Likewise whenever a composition, an element or a group of elements is preceded with the transitional phrase “comprising,” it is understood that we also contemplate the same composition or group of elements with transitional phrases “consisting essentially of,” “consisting of,” “selected from the group of consisting of,” or ^;‘is” preceding the recitation of the composition, element, or elements and vice versa.

[0089] While the present disclosure has been described with respect to a number of embodiments and examples, those skilled in the art, having benefit of this disclosure, will appreciate that other embodiments can be devised which do not depart from the scope and spirit of the present disclosure.

Claims

CLAIMS What is claimed is:

1. A method of making a pelletized polymeric resin, comprising: blending, in a vessel, a reactive solvent with a post-consumer resin (PCR) to form a blend, the PCR comprising a condensation polymer and at least one of a polyethylene or a polypropylene, and the vessel selected from the group consisting of a reaction vessel, an extruder, a pelletizer, and combinations thereof; applying heat to the vessel; extruding the blend via the extruder to form a polymeric resin extrudate; pelletizing the polymeric resin extrudate via the pelletizer to form a pelletized polymeric resin; and removing volatiles from the vessel, wherein the volatiles comprise a reaction product of the reactive solvent and the condensation polymer.

2. The method of claim 1, wherein the reactive solvent is selected from the group consisting of water, a mono-alcohol, and combinations thereof.

3. The method of claim 2, wherein the condensation polymer is selected from the group consisting of a polyethylene terephthalate (PET), polyethylene terephthalate glycol-modified (PETG), and combinations thereof.

4. The method of claim 1, wherein the vessel is the extruder.

5. The method of claim 1, wherein the vessel is the pelletizer.

6. The method of claim 1, wherein the vessel is the reaction vessel.

7. The method of claim 1, wherein blending the reactive solvent with the PCR to form the blend, is performed in a combination of the reaction vessel, the extruder, or the pelletizer.

8. The method of claim 1 , wherein applying heat to the vessel provides a temperature of about 80 °C to about 160 °C to an interior volume of the vessel.

9. The method of claim 8, wherein the temperature is about 80 °C to about 110 °C.

10. The method of claim 9, wherein removing volatiles from the vessel comprises applying vacuum to the vessel.

11. The method of claim 1, wherein removing volatiles from the vessel comprises applying vacuum to the vessel.

12. The method of claim 11, wherein the vessel is the extruder.

13. The method of claim 11, wherein the vessel is the pelletizer.

14. The method of claim 11, wherein the vessel is the reaction vessel.

15. The method of claim 1, wherein the PCR comprises a polyethylene selected from the group consisting of ultra-high molecular weight polyethylene (UHMWPE), ultra-low molecular weight polyethylene (ULMWPE), high molecular weight polyethylene (HMWPE). high density polyethylene (HDPE), medium densify polyethylene (MDPE), linear low densify polyethylene (LLDPE), low densify polyethylene (LDPE), very-low densify polyethylene (VLDPE), and combinations thereof.

16. The method of claim 1, wherein the reaction product comprises a dimeric unit, a trimeric unit, a tetrameric unit, or combinations thereof of the condensation polymer.

17. The method of claim 16, wherein the reaction product comprises the dimeric unit, the dimeric unit comprising one terephthalate unit and one ethylene unit.

18. The method of claim 16, wherein the reaction product comprises the tetrameric unit, the tetrameric unit comprising two terephthalate units and two ethylene units.

19. A method of making a pelletized polymeric resin, comprising: blending, in a vessel, a reactive solvent with a post-consumer resin (PCR) to form a blend, the PCR comprising a polyethylene terephthalate (PET) and at least one of a polyethylene or a polypropylene, the reactive solvent selected from the group consisting of water, a mono-alcohol, and combinations thereof, and the vessel selected from the group consisting of a reaction vessel, an extruder, a pelletizer, and combinations thereof; applying heat to the vessel to provide a temperature to an interior volume of the vessel of about 80 °C to about 160 °C to the vessel; extruding the blend via the extruder to form a polymeric resin extrudate; pelletizing the polymeric resin extrudate via the pelletizer to form a pelletized polymeric resin; and removing volatiles from the vessel by applying vacuum to the vessel, wherein the volatiles comprise a reaction product of the reactive solvent and the PET.

20. The method of claim 19, wherein applying vacuum to the vessel provides a pressure of about 0.005 atm to about 1 atm to the interior volume the vessel.