Automatic extruder for processing recycled polymers with ultrasound and temperature control system

Melt viscosity is one of the main factors affecting product quality in extrusion processes particularly with regard to recycled polymers. However, due to wide variability in the physical properties of recycled feedstock, it is difficult to maintain the melt viscosity during extrusion of polymer blends and obtain good quality product without generating scrap. This research investigates the application of ultrasound and temperature control in an automatic extruder controller, which has ability to maintain constant melt viscosity from variable recycled polymer feedstock during extrusion processing. An ultrasonic modulation system has been developed and fitted to the extruder prior to the die to convey ultrasonic energy from a high power ultrasonic generator to the polymer melt. Two separate control loops have been developed to run simultaneously in one controller: the first loop controls the ultrasonic energy or temperature to maintain constant die pressure, the second loop is used to control extruder screw speed to maintain constant throughput at the extruder die. Time response and energy consumption of the control methods in real-time experiments are also investigated and reported this paper.

Viscosity Control for Extrusion Processes Using Recycled Polymers

The aim of this paper is to develop a new extruder control system for recycled materials which has ability to automatically maintain constant a polymer melt viscosity of mixed recycled polymers during extrusion, regardless of variations in the Melt Flow Index (MFI) of recycled mixed grade high density polyethylene (HDPE) feedstock. A closed-loop controller is developed to automatically regulate screw speed and barrel temperature profile to achieve constant viscosity and enable consistent processing of variable grade recycled HDPE materials. The experimental results of real time viscosity measurement and control using a 38mm single screw extruder with different recycled HDPEs with widely different MFIs are reported in this work

Production and evaluation of recycled polymers from açaí fibers

The possibility of recycling and the favorable mechanical properties of the products have encouraged the study and production of thermoplastic composites from natural fibrous waste. Açaí (cabbage palm) fiber, which is removed from the seed, has been slightly investigated, as compared to what is already known about the fruit pulp. In this study, the influence of açaí fiber as an element of reinforcement in recycled everyday usage thermoplastics using simple, low cost methodology was evaluated. Recycled matrixes of high impact polystyrene and polypropylene were molded by hot compression from which the fiber composites were obtained. The FTIR technique showed that the process was efficient in preventing degradation of the açaí fibers. The influence of the fiber on the mechanical behavior of the recycled matrixes was investigated by microscopic images of compression and impact tests. The results showed better impact performance for the fiber combined with the polymeric matrixes.

Real time measurement and control of viscosity for extrusion processes using recycled materials

The aim of this paper is to develop a new generation of extruder control system for recycled materials which has ability to automatically maintain constant a polymer melt viscosity of mixed recycled polymers during extrusion, regardless of variations in the Melt Flow Index (MFI) of recycled mixed grade high density polyethylene (HDPE) feedstock. The variations in MFI are due to differences in the source of the recycled material used. The work describes how melt viscosity for specific extruder/die system is calculated in real time using the rheological properties of the materials, the pressure drop through the extruder die and the actual throughput measurements using a gravimetric loss-in-weight hopper feeder. A closed-loop controller is also developed to automatically regulate screw speed and barrel temperature profile to achieve constant viscosity and enable consistent processing of variable grade recycled HDPE materials. Such a system will improve processability of mixed MFI polymers may also reduce the risk of polymer melt degradation, reduce producing large volumes of scrap/waste and lead to improvement in product quality. The experimental results of real time viscosity measurement and control using a 38 mm single screw extruder with different recycled HDPEs with widely different MFIs are reported in this work.

Multielemental evaluation of garbage bags by EDXRF

Conselho Nacional de Desenvolvimento Científico e Tecnológico (CNPq)

Componentes poliméricos de alto desempenho para a indústria automóvel

Atualmente, a utilização e as diversas aplicações de materiais poliméricos seguem tendências crescentes, pelo que se torna necessário aprofundar a compreensão do seu comportamento e funcionalidades. Neste contexto, na presente dissertação analisa-se a fabricação e características de rolamentos poliméricos para a suspensão automóvel. Estes rolamentos visam a substituição dos clássicos rolamentos metálicos. Esta substituição tem por objetivos garantir a melhoria do funcionamento dos rolamentos, bem como o seu usufruto, contribuindo para um maior conforto e segurança dos passageiros e para uma redução do peso do veículo, com consequente diminuição do consumo do combustível e melhoria da eficiência. Sendo o poliacetal (POM) e a poliamida (PA) considerados polímeros de alto desempenho, estes polímeros reúnem boas características para aplicação na fabricação de dispositivos com funcionalidades exigentes como é o caso dos rolamentos. O presente trabalho aborda o estudo de algumas das suas propriedades, de modo a obter informações relevantes quanto à respetiva aplicação em rolamentos de suspensão, tendo como foco principal a análise da matéria-prima utilizada. Deste modo, alteraram-se as formulações variando-se os teores de material virgem e reciclado, estudou-se o ser comportamento mecânico, reológico e térmico: fizeram-se análises reológicas através do estudo do MFI a fim de se obterem informações complementares ao estudo mecânico, realizaram-se análises térmicas para avaliar a possibilidade de degradação térmica do material e, no caso da PA66-30GF, recorreu-se à microscopia eletrónica de varrimento para se estudar os aspetos microestruturais deste compósito reforçado com fibra de vidro. Adicionalmente, procedeu-se à análise da rugosidade superficial dos componentes dos rolamentos e quantificou-se o torque dos mesmos. A partir dos estudos anteriores, foi possível concluir que o POM apresenta um comportamento mecânico estável mesmo utilizando uma formulação com 100% de material reciclado. Este comportamento não se verificou na PA6630GF, dado que as suas propriedades mecânicas são afetadas de forma significativa pelo teor de reciclado na formulação. Com o estudo do torque determinou-se o valor limite do momento de torsão do rolamento que garante o seu bom funcionamento e eficácia.

Evaluación de las propiedades mecánicas de materiales compuestos elaborados a partir de cenizas volantes y polímeros reciclados

En el presente artículo se evalúan las propiedades mecánicas de los materiales compuestos basados en cenizas volantes de carbón de la central termoeléctrica de Termozipa combinadas con los película extensible (Stretch film), polietilenos de baja densidad lineal de pos-consumo y polímero termoplástico parcialmente cristalino pos- industrial. Se obtuvieron mezclas variando el contenido de cenizas volantes de 0 a 50 % en peso en cada uno de los tres materiales poliméricos, dentro de una máquina mezcladora tipo Brabender. Las propiedades mecánicas evaluadas fueron: resistencia a la tracción, dureza Shore D, y absorción de energía. Los resultados obtenidos indican que en todos los casos a medida que se agrega ceniza volante las propiedades mecánicas aumentan.

Polyester derived from recycled poly(ethylene terephthalate) waste for regenerative medicine

Despite advances in regenerative medicine, the cost of such therapies is beyond the reach of many patients globally in part due to the use of expensive biomedical polymers. Large volumes of poly(ethylene terephthalate) (PET) in municipal waste is a potential source of low cost polymers. A novel polyester was prepared by a catalyst-free, melt polycondensation reaction of bis(hydroxyethylene) terephthalate derived from PET post-consumer waste with other multi-functional monomers from renewable sources such as citric acid, sebacic acid and D-mannitol. The mechanical properties and degradation rate of the polyester can be tuned by varying the composition and the post-polymerization time. The polyester was found to be elastomeric, showed excellent cytocompatibility in vitro and elicited minimal immune response in vivo. Three-dimensional porous scaffolds facilitated osteogenic differentiation and mineralization. This class of polyester derived from low cost, recycled waste and renewable sources is a promising candidate for use in regenerative medicine.

Recycled carbon fiber filled polyethylene composites

Composites of recycled carbon fiber (CF) with up to 30 wt % loading with polyethylene (PE) were prepared via melt compounding. The morphology of the composites and the degree of dispersion of the CF in the PE matrix was examined using scanning electron microscopy, and revealed the CF to be highly dispersed at all loadings and strong interfacial adhesion to exist between the CF and PE. Raman and FTIR spectroscopy were used to characterize the surface chemistry and potential bonding sites of recycled CF. Both the Young's modulus and ultimate tensile stress increased with increasing CF loading, but the percentage stress at break was unchanged up to 5 wt % loading, then decreased with further successive addition of CF. The effect of CF on the elastic modulus of PE was examined using the Halpin-Tsai and modified Cox models, the former giving a better fit with the values determined experimentally. The electrical conductivity of the PE matrix was enhanced by about 11 orders of magnitude on addition of recycled CF with a percolation threshold of 7 and 15 wt % for 500-mu m and 3-mm thick samples. (c) 2007 Wiley Periodicals, Inc.

Mix design process of polyester polymer mortars modified with recycled GFRP waste materials

In this study, the effect of incorporation of recycled glass fibre reinforced plastics (GFRP) waste materials, obtained by means of shredding and milling processes, on mechanical behaviour of polyester polymer mortars (PM) was assessed. For this purpose, different contents of GFRP recyclates, between 4% up to 12% in weight, were incorporated into polyester PM materials as sand aggregates and filler replacements. The effect of the addition of a silane coupling agent to resin binder was also evaluated. Applied waste material was proceeding from the shredding of the leftovers resultant from the cutting and assembly processes of GFRP pultrusion profiles. Currently, these leftovers as well as non-conform products and scrap resulting from pultrusion manufacturing process are landfilled, with additional costs to producers and suppliers. Hence, besides the evident environmental benefits, a viable and feasible solution for these wastes would also conduct to significant economic advantages. Design of experiments and data treatment were accomplish by means of full factorial design approach and analysis of variance ANOVA. Experimental results were promising toward the recyclability of GFRP waste materials as partial replacement of aggregates and reinforcement for PM materials, with significant improvements on mechanical properties of resultant mortars with regards to waste-free formulations.

Synthesis and characterization of cellulose acetate produced from recycled newspaper

In this work, the viability of recycling newspaper for producing cellulose acetate was tested. Newspaper recycling is extremely important not only for the environment preservation, but also from the economical point of view of aggregating value to this residue. Cellulose acetate was produced from a homogeneous acetylation, and then characterized by FTIR, DSC and TGA. Acetylation times were 48 h for as received newspaper (CA48) and 24 h for delignified newspaper (CA24), resulting in cellulose diacetate (DS = 1.98 +/- 0.22) for CA48 and cellulose triacetate (DS = 2.79 +/- 0.02) for CA24, respectively. Membranes of these materials were produced and characterized according to the previously mentioned techniques and by measurements of water vapor flux, which were compared to membranes of nanofiltration SG from Osmonix (R). Results showed that independently of a purification step, it is possible to produce cellulose acetate membranes through the chemical recycling of newspaper and that membrane CA24 presents thermal stability comparable to membranes produced of commercial cellulose acetate. (C) 2007 Elsevier Ltd. All rights reserved.

Comparison of polymers and ceramics in new and discarded electrical insulators: reuse and recycling possibilities

The expansion and maintenance of electricity distribution networks generates large amounts of waste, much of it in the form of discarded insulators that are not reused or recycled. This paper describes the results of tests on used and new ceramic and polymeric insulators to verify if their exposure to weathering justifies their replacement. In new and used ceramic insulators, properties such as contact angle, relative density, porosimetry, dilatometry and X-ray diffraction patterns showed no differences or the differences that were found could not be related to their use. The discarded ceramic material showed high thermal stability, an interesting characteristic for application as chamotte. It can also be reused to replace gravel used in substations. In polymeric insulators, thermogravimetry, differential scanning calorimetry and relative density test results suggest degradation of used material compared to new. This would justify their replacement and discard as waste, but they show little recycling potential.

Physical and mechanical characterization of a recycled polypropylene and wood flour without additives

Recycled polymer matrix composites reinforced with wood flour can be a viable alternative for the replacement of wood and virgin polymers in materials used in floors, door frames, windows and external cladding. The objective of this research was to determine some physical and mechanical parameters of composite made with Pinus taeda and elliottii wood flour (WF) and recycled polypropylene (PP), without the use of compatibilizers or additives. The composites were separated into four traits, namely 100% PP, 90% PP with 10%, WF 80% PP with 20% WF and 70 % PP with 30% WF. The characterization of the composite followed the standards ASTM D-638-10, ASTM D256-00, ASTM D570 -98, ASTM D1238 -10 and ASTM G 155-05, it was also employed the surface analysis by scanning electron microscopy. The dimensional stability tests showed satisfactory results. Even the composite with a higher percentage of wood flour (30%) had a flow index of 10 MFI, considered compatible with that observed for PP (polypropylene) virgin by standard ASTM D 1238-10. The inclusion of wood flour (FM) afforded composites with good mechanical characteristics which can be applied in manufacture of different materials, specifically employed outdoors.

Plasma Treatment to Improve the Surface Properties of Recycled Post-Consumer PVC

Fundação de Amparo à Pesquisa do Estado de São Paulo (FAPESP)

Thermal and mechanical properties of recycled poly(Lactic acid)

Biodegradable polymers have experienced increased attention in recent years because of their wide range of applications in biomedical, packaging and agriculture fields. PLA, poly(lactic acid), is a linear aliphatic biodegradable thermoplastic polyester, with good mechanical properties, thermal stability, processability and low environmental impact, widely used as an alternative to conventional polymers. PLA products can be recycled after use either by remelting and reprocessing the material, or by hydrolysis to basic lactic acid [1]. The object of this communication is the study of the possible variation in physical properties induced by sub sequent reprocessing cycles of PLA.