The effect of chain extension on the thermal behaviour and crystallinity of reactive extruded recycled PET

Recycled poly(ethylene terephthalate) (R-PET) was chain extended with pyromellitic dianhydride (PMDA) in a commercial size twin-screw reactive extrusion system. Temperature-modulated differential scanning calorimetry (TMDSC) was used to evaluate the effect of the chain extension process on the thermal transitions and crystallinity of R-PET. Reactive extruded recycled PET (RER-PET) samples were tested based on different PMDA concentration and reactive extrusion residence times. The glass transition temperature (T _g) did not show a significant change as a function of PMDA addition or the extrusion residence time. Melting temperature (T _m) and crystallisation temperature (T _c) decreased with increasing PMDA concentration and with increasing extrusion residence time. RER-PET samples showed double melting peaks, it is believed that different melting mechanism is the reason behind this phenomenon. The crystallinity of RER-PET samples is lower than that of R-PET. RER-PET samples at constant PMDA concentration showed a decrease in crystallinity with increasing extrusion residence time. Results suggest that the reactive extrusion process is more dependent on PMDA concentration rather than reactive extrusion process residence time.The first author would like to acknowledge Advanced Engineering Center for Manufacturing (AECM) and Visy Industries for their financial support to this study.     

Modelling of PET Quality Parameters for a Closed-Loop Recycling System for Food Contact

Summary: A rigorous process model has been developed which describes a closed-loop recycling system for PET beverage bottles. The reaction / mass transport model is aimed at the dominant quality parameters such as intrinsic viscosity, concentration of acetaldehyde, concentration of carboxylic end-groups, and concentration of vinyl end-groups, respectively. The model covers the main process steps being preform production (injection moulding), drying, solid-state polycondensation, and melt filtration. The simulation reveals that after a single recycling loop all the relevant quality parameters achieve the specification, if certain temperatures, residence times, and surface areas for degassing are provided during the recycling process. Another simulation showed the evolution of quality parameters in PET being subjected to an “infinite” number of recycling loops in a closed system. In this case, the concentration of acetaldehyde and vinyl end-groups decreases with the number of recycling loops, which is a desired effect. On the other hand, the concentration of carboxylic end-groups increases with every completed recycling loop. Higher concentrations of carboxylic end-groups make the polymer more susceptible to hydrolysis and increase the SSP process time needed to achieve the specified intrinsic viscosity for carbonated soft drink bottles. To overcome this problem, the recycled PET has to be blended with a certain amount of virgin PET in industrial processes.     

Influence of chain extension on the compatibilization and properties of recycled poly(ethylene terephthalate)/linear low density polyethylene blends

Polymeric methylene diphenyl diisocyanate (PMDI) was added as chain extender to a blend of recycled poly(ethylene terephthalate) (R-PET) and linear low density polyethylene (LLDPE) with compatibilizer of maleic anhydride-grafted poly(styrene-ethylene/butadiene-styrene) (SEBS-g-MA). Hydroxyl end groups of PET can react with both isocyanate groups of PMDI and maleic anhydride groups of SEBS-g-MA, which are competing reactions during reactive extrusion. The compatibility and properties of the blends with various contents of PMDI were systemically evaluated and investigated. WAXD results and SEM observations indicated that chain extension inhibits the reaction between PET and SEBS-g-MA. As the PMDI content increased, the morphology of dispersed phase changed from droplet dispersion to rodlike shape and then to an irregular structure. The DSC results showed that the crystallinity of PET decreased in the presence of PMDI, and the glass transition temperature (T_g) of PET increased with addition of 0-0.7 w% PMDI. The impact strength of the blend with 1.1 w% PMDI increased by 120% with respect to the blend without PMDI, accompanied by only an 8% tensile strength decrease. It was demonstrated that the chain extension of PET with PMDI in R-PET/LLDPE/SEBS-g-MA blends not only decreased the compatibilization effect of SEBS-g-MA but also hindered the crystallization of PET.     

Structure and properties of compatibilized recycled poly(ethylene terephthalate)/linear low density polyethylene blends

Blends of recycled poly(ethylene terephthalate) (R-PET) and linear low density polyethylene (LLDPE) were compatibilized with poly(styrene-ethylene/butyldiene-styrene) (SEBS) and maleic anhydride-grafted poly(styrene-ethylene/butyldiene-styrene) (SEBS-g-MA). Effects of compatilizer were evaluated systematically by study of mechanical, thermal and morphology properties together with crystallization behavior of PET. Tensile properties of the blends were improved effectively by the addition of 10 wt% SEBS-g-MA, elongation at break and charpy impact strength were increased with the increasing content of compatilizer. SEBS-g-MA is more effectual on mechanical properties of R-PET/LLDPE blends than SEBS. DSC analysis illustrates crystallinities of PET and LLDPE were increased by compatilizer at annealing condition. WAXD and FT-IR spectra show that annealing influences crystallization behavior of PET. Different compatilizer content results in different morphology structure, in particular, higher SEBS-g-MA content can induce the formation of a salami microstructure.     

热处理条件对R-PET/LLDPE-g-MA共混物中PET玻璃化转变行为的影响

对回收聚对苯二甲酸乙二酯(R-PET)/LLDPE-g-MA马来酸酐改性的线性低密度聚乙烯共混物进行不同条件的热处理, 采用差示扫描量热仪(DSC)研究共混物基体PET的玻璃化转变行为. 结果表明, 当热处理温度低于PET的玻璃化转变温度(Tg)时, PET的玻璃化转变区域出现热焓松弛现象. 随着热处理温度的增加, PET的Tg逐渐升高; 在50~70 ℃下热处理48 h后, PET的Tg逐渐稳定. 当热处理温度高于PET的Tg而低于100 ℃时, PET的玻璃化转变区域出现2个热流转变, FTIR分析表明, PET分子构象开始发生变化. 当热处理温度为100 ℃时, DSC曲线上PET的玻璃化转变消失, PET的结晶度明显增加, 说明PET开始冷结晶的温度在90~100 ℃之间.     

The role of crystalline, mobile amorphous and rigid amorphous fractions in the performance of recycled poly (ethylene terephthalate) (PET)

The action of thermo-mechanical degradation induced by mechanical recycling of poly(ethylene terephthalate) was simulated by successive injection moulding cycles. Degradation reactions provoked chain scissions and a reduction in molar mass mainly driven by the reduction of diethyleneglycol to ethylene glycol units in the flexible domain of the PET backbone, and the formation of -OH terminated species with shorter chain length. The consequent microstructural changes were quantified taking into account a three-fraction model involving crystalline, mobile amorphous (MAF) and rigid amorphous fractions (RAF). A remarkable increase of RAF, to a detriment of MAF was observed, while the percentage of crystalline fraction remained nearly constant. A deeper analysis of the melting behaviour, the segmental dynamics around the glass-rubber relaxation, and the macroscopic mechanical performance, showed the role of each fraction leading to a loss of thermal, viscoelastic and mechanical features, particularly remarkable after the first processing cycle.     

The effect of gamma irradiation on mechanical, and thermal properties of recycling polyethylene terephthalate and low density polyethylene (R-PET/LDPE) blend compatibilized by ethylene vinyl acetate (EVA)

A study has been made on the compatibility of recycled polyethylene terephthalate (R-PET) and low density polyethylene (LDPE) blend in the presence of ethylene vinyl acetate (EVA) as a compatibilizing agent prepared by extrusion hot stretching process. EVA content in the blend as a compatibilizing agent was an enhancement effect on radiation crosslinking of R-PET/EVA/LDPE blends and the highest radiation crosslinking was obtained when the EVA content was reached at 10 % EVA when irradiated by gamma irradiation. Blends containing different (EVA) ratios were irradiated to different doses of gamma irradiation 25, 50 and 100 kGy. The effect of the compatibilizer and radiation on mechanical, thermal properties of R-PET together with LDPE and morphology has been investigated. It was found that gamma irradiation together with the presence of compatibilizing agent (EVA) has positive effect on the mechanical and thermal properties of R-PET/LDPE blend. The structural properties of R-PET/LDPE modified by gamma irradiation and EVA as compatibilizing agent was examined by SEM. Also, it was found that the optimum concentration of EVA and gamma irradiation dose was found to be 10 % EVA and 100 kGy, respectively.     

Sustainability performance of polyethylene terephthalate,clarifying challenges and opportunities

Publications on polyethylene terephthalate (PET) continue to increase including the number of publications on recycling. PET is a versatile material with the ability to be remade from its polymer state through mechanical recycling and even back to its original monomer through advanced recycling. The scale of PET's use affords continued research and applications in improved recycling. Publications on new uses of discarded PET and the ability to clean and convert it into many forms including alternative materials are expanding with an attempt to complete circular use or improve the end of life. As indicated in life cycle assessment studies, increases in recycling lower the energy required to manufacture products. The future for PET will reduce energy demands further with the largest breakthroughs in recycling technologies and bio-sourced resins trending toward zero energy and carbon negative solutions. Opportunities remain for improvement in the use of PET with light weighting. The testing of new resins, development of bio-feedstocks, improvements in engineering, processing, recycling, and design continue to provide benefits. This review provides context for these developments.     

Experimental and numerical investigations of bi-injection moulding of PA66/LSR peel test specimens

Bi-injection moulding is a widely used process to manufacture engineering products and consumer goods. Typically, a thermoplastic is combined with rubber or another thermoplastic to create colour differences or hard and soft areas, respectively. The aim of this study was to optimise the injection parameters and processing conditions for the moulding of two-component standard peel test specimens with suitable functional properties. In this work, all parameters of thermo-rheo-kinetic behaviour were identified to predict the entire filling stage and the effect of a liquid silicone rubber cross-linking reaction during the injection moulding process. The models of Carreau-Yasuda and Isayev-Deng regarding the thermal dependence assumed by Arrhenius’ law were used. In our study, over-injection moulding is simulated and examined using finite element software (Cadmould 3D) to investigate the thermo-rheo-kinetic behaviour and the adhesion of liquid silicone rubber during the filling mould process in over-moulding. Numerical simulation results were then compared with the experimental results, and good agreement was obtained.     

拉伸热历史对取向聚对苯二甲酸乙二酯膜在热处理过程中收缩和伸长的影响

弄清取向非晶态聚合物在热处理过程中的收缩和伸长的变化规律,以及所对应的结构变化,有较大的实用意义和科学意义。 对于取向聚对苯二甲酸乙二酯的热收缩和热伸长已有很多研究,但对于拉伸热历史对取向PET在热处理过程中的尺寸变化的影响尚缺乏系统的研究。在热拉伸的过程中发生分子链的取向、热弛豫和结晶三个相互竞争的过程。因此,改变拉伸条件可以得到具有各种不同取向和结晶的PET试样。当非晶态PET膜片在80-105℃以较低     

Coil extension stage in the cold drawing of glassy polymers

Cold drawing is known as a thermodynamically reversible process for glassy polymers. In the extension process, there might be a stage in which the global structure of chain coils extends in the drawing direction. This extension stage has not been clearly identified because of the lack of a quantitative relationship between the global structure evolution and the local structure reorientation. We have developed a theoretical method to elucidate the relationship, which is based on a simulated chain conformational distribution and a relationship between the chain conformations and the extension. Any local structure, such as the fraction of trans conformations of ethylene glycol of poly(ethylene terephthalate) (PET), can then be calculated with an ensemble average as a function of the system extension. Combined with infrared conformational band measurements, the coil extension stage has been characterized in the cold drawing of amorphous PET. This stage does not start from the yielding point but instead begins nearly at the end of the stress softening. In the recovery process, the experimental measurements and theoretical predictions are well correlated. © 2002 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 40: 2646–2652, 2002     

Injection stretch blow moulding process of reactive extruded recycled PET and virgin PET blends

Reactive extruded recycled PET (RER-PET) was blended with virgin PET in order to find optimum composition for producing bottles using injection stretch blow moulding (ISBM) process. Two variables were investigated namely, RER-PET concentration in the blend with virgin PET and RER-PET intrinsic viscosity, [η]. The variability of [η] was facilitated by changing PMDA chain extender concentration in the production of RER-PET. Different molecular, mechanical, barrier and optical tests such as infrared, burst pressure, top load strength, drop impact, environmental stress cracking, liquid permeation, gas permeation, and clarity were conducted. The aim was to evaluate the properties of the bottles in response to different blends compositions. Bottles made from RER-PET and virgin PET blends showed similar and better mechanical and barrier properties at certain compositions to those made from Virgin PET. The effects of RER-PET molecular properties such as intrinsic viscosity, chain orientation and conformation on bottles mechanical, barrier and optical properties are detailed.     

Effect of small amounts of poly(lactic acid) on the recycling of poly(ethylene terephthalate) bottles

Poly(ethylene terephthalate) (PET) is one of the most used commodity polymers, especially for food and beverage applications, and its recycling is of great importance because of the possible use in the textile and construction industries. On the other hand, the interest in biodegradable polymers has led, in recent years, to the use of materials such as poly(lactic acid) (PLA) also in the food and beverage industry. The presence of small amounts of PLA in the PET waste can significantly affect the post-consumer recycling process. In this work, the effect of the presence of small amounts of PLA on the recycling of PET bottles is investigated by rheological, mechanical, morphological and thermogravimetric analysis. The results indicate that this presence can significantly affect the rheological properties under non-isothermal elongational flow, while the mechanical properties were considerably affected only in some circumstances and the thermal stability was not significantly modified.     

Microencapsulation of bisphenol-A bis (diphenyl phosphate) and influence of particle loading on thermal and fire properties of polypropylene and polyethylene terephtalate

Microencapsulated flame retardant, bisphenol-A bis (diphenyl phosphate) (BDP), with a silane shell was prepared by sol–gel process with the goal of incorporating them in polymeric matrices by melt blending to improve the flame retardancy of isotactic polypropylene (iPP) and polyethylene terephtalate (PET). The influence of the loading content on thermal transitions has been studied by differential scanning calorimetry (DSC), the thermal stability of the polymer/microcapsules composites has been assessed by thermogravimetric analysis (TGA) and cone calorimetry has been used to study the fire reaction. It was noticed that the microcapsules have a limited influence on the thermal transitions of iPP matrix, but a decrease of the melting and glass transition temperatures was detected for the PET microcomposites. TGA results showed that the addition of microcapsules could improve char formation of the PET systems both in nitrogen and in air atmospheres, whereas only a small improvement of the thermal stability was detected in oxidative atmosphere for the iPP samples. Furthermore, cone calorimeter experiments show that the incorporation of microcapsules in the iPP gives almost no improvement in the iPP fire reaction. However, the microcapsules act as flame retardant in PET reducing the heat release rate during the combustion and the total heat evolved. Therefore, microcapsules can act as a char promoter agent to enhance the fire resistance in the case of PET.     

Thermal analysis as a quality tool for assessing the influence of thermo-mechanical degradation on recycled poly(ethylene terephthalate)

Mechanical recycling of poly(ethylene terephthalate) (PET) was simulated by multiple processing to assess the effects of thermo-mechanical degradation, and characterized using rheological and thermal analysis techniques. Thermo-mechanical degradation under repeated extrusion induces chain scission reactions in PET, which result in a dramatic loss in the deformation capabilities and an increase in the fluidity of the polymer under reprocessing, reducing its recycling possibilities after four extrusion cycles. Multiple reprocessing severely affects the storage modulus and the microstructure of recycled PET, both in the amorphous and crystalline regions. Multimodal melting behavior is observed for reprocessed PET, indicating heterogeneous and segregated crystalline regions. A deconvolution procedure has been applied to individually characterize each crystalline population in terms of lamellar thickness distribution and partial crystallinity. Thermal analysis techniques such as differential scanning calorimetry (DSC) and dynamic-mechanical analysis (DMA) have proved to be suitable techniques for the quality assessment of recycled PET, giving unequivocal information about its degree of degradation compared to the common technological measurements of melt-mass flow rate (MFR) or oxidative stability (T_Ox).     

High-temperature reactions of hydroxyl and carboxyl PET chain end groups in the presence of aromatic phosphite

When melt-extruded in the presence of triphenylphosphite (TPP), the molecular weight of polyesters such as poly(ethylene terephthalate) (PET) increases with time. Analysis of the PET chain end groups and model studies of high-temperature reactions indicate that, most likely, the process leading to chain extension of PET in the presence of TPP takes place in two steps. In the first step, TPP rapidly reacts with the hydroxyl end groups by displacing one phenoxy group from the TPP. In the second step, a slow reaction takes place between the alkyldiphenyl phosphite and carboxylic chain end groups, forming an ester bond between the carboxyl and alkyl groups, and producing diphenylphosphite (DPP) as a reaction by-product. The DPP tautomerizes to its pentacovalently bonded stabler form of diphenylphosphate, the form in which the DPP was usually detected in our analyses. The ester formation results in the extension of the PET chains. Model studies are presented which support the proposed mechanism.     

Recycling technology of poly(ethylene terephthalate) materials

Poly(ethylene terephthalate) (PET) has become one of major post consumer plastics wastes, in addition to polyethylene (PE), polypropylene (PP), polystyrene (PS) and poly(vinyl chloride) (PVC). The challenge to large-volume plastics companies is to learn how to collect, separate, reprocess and market their low-cost products and make a profit, too. The effort of PET recycling, however, is the most successful story in the plastic recycling technology, including both reclaim and upgrade of PET waste. Beverage bottles made of PET are recycled more than 20% of the total production. The technology of today can reclaim the post-consumer PET bottles to produce high-quality granulated PET with better than 99% purity. A practical reclaim process for recycling PET bottles (including bottle, HDPE base cup, aluminum cap, liner, label and adhesive) is available by the Center for Plastics Recycling Research in USA. PET recycling process, like for other plastics, can be divided into three categories: incineration, physical recycling, and chemical recycling. To make the plastic recycling business pay requires more than simple recovery and marketing. Greatest profit potential is in upgraded and value-added reclaim products. Upgrading involves compounding with additives to make material more processable, adding reinforcement, or producing extrusions or finished parts from reclaim resins. For instance, a modified injection-moldable resin made from PET bottle scrap is claimed to provide high impact and processability at less cost than competitive materials. It is foreseen that chemical recycling of waste PET bottle becomes feasible if the price of raw material goes up. Three economical processes are involved in this technology: pyrolysis, hydrocracking, and hydrolysis. The hydrolysis process is presently employed to recover the raw material for unsaturated polyester resin manufacture or polyols for the production of polyurethane resin. It is reported in this presentation that polymer concrete could be a huge potential market for chemical reclaim of PET materials, especially for green or mixed-color PET, which are priced lower than colorless PET reclaim materials.     

Properties and morphology of recycled poly(ethylene terephthalate)/bisphenol a polycarbonate/poly(styrene‐b‐(ethylene‐co‐butylene)‐b‐styrene) blends by low‐temperature solid‐state extrusion

Among the various methods available for recycling plastics waste, blending technology is a straightforward and relatively simple method for recycling. In this paper, a new blending technology, low‐temperature solid‐state extrusion, was discussed. Several recycled poly(terephthalate ethylene)/bisphenol a polycarbonate/poly(styrene‐b‐(ethylene‐co‐butylene)‐b‐styrene) blends (R‐PET/PC/SEBS blends) have been prepared by this technology. The results show that thermal and hydrolytic degradation of R‐PET is improved when extruding temperature was between the glass transition temperature (T_g) and cold crystallization temperature (T_cc). Elongation at break and notched impact strength were increased evidently, from 15.9% to 103.6, and from 8.6 kJ/m² to 20.4 kJ/m², respectively. The appropriate rotating speed of screws was between 100 and 150 rpm. At the same time, the appropriate rotating speed of the screws brings a suitable shear viscosity ratio of R‐PET and PC, which is of advantage to blending of R‐PET and PC together with SEBS. Dispersion of minor phase, PC and SEBS, became finer and smaller, to about 1 µm. Chain extender, Methylenediphenyl diisocyanate (MDI) can react with the end‐carboxyl group and end‐hydroxyl group of R‐PET. FT‐IR spectra testified that the reactions have been happened in the extruding process. A chain extending reaction not only increased the molecular weight of PET and PC, but also can synthesize PET‐g‐PC copolymer to act as a reactive compatilizer. An SEM micrograph shows that a micro‐fiber structure of PET was formed in the blend sample. Copyright © 2007 John Wiley & Sons, Ltd.     

Statistical models for optimisation of properties of bottles produced using blends of reactive extruded recycled PET and virgin PET

Blends of chain-extended reactive extruded recycled PET (RER-PET) and virgin PET were fed in injection stretch blow moulding (ISBM) process. The RER-PET blends have different RER-PET concentrations and RER-PET have different pyromellitic dianhydride (PMDA) chain extender concentrations. RER-PET composition and percentage in the blend were used as process variables. The resulted ISBM bottles were tested for burst pressure, top load, liquid permeation and carbonation loss. The experimental results were used in an optimisation process aiming to identify the best blend composition that produces best bottles properties. Models were fitted and statistically analysed to represent the bottles properties in the optimisation calculations. Two optimum points were found in which highest chain extender concentration in RER-PET were favoured. The optimum points showed different optimum RER-PET concentrations in the blend. The first optimum concentration is 20% RER-PET which resulted in best burst pressure and top load resistance. The second optimum point with RER-PET concentration of 29% produced minimum liquid permeation and carbonation loss. The results of the optimisation procedure are beneficial in identifying the possibility of the use of RER-PET for bottling application.     

Advances and approaches for chemical recycling of plastic waste

The global production and consumption of plastics has increased at an alarming rate over the last few decades. The accumulation of pervasive and persistent waste plastic has concomitantly increased in landfills and the environment. The societal, ecological, and economic problems of plastic waste/pollution demand immediate and decisive action. In 2015, only 9% of plastic waste was successfully recycled in the United States. The major current recycling processes focus on the mechanical recycling of plastic waste; however, even this process is limited by the sorting/pretreatment of plastic waste and degradation of plastics during the process. An alternative to mechanical processes is chemical recycling of plastic waste. Efficient chemical recycling would allow for the production of feedstocks for various uses including fuels and chemical feedstocks to replace petrochemicals. This review focuses on the most recent advances for the chemical recycling of three major polymers found in plastic waste: PET, PE, and PP. Commercial processes for recycling hydrolysable polymers like polyesters or polyamides, polyolefins, or mixed waste streams are also discussed.