The effect of Pb and other elements found in recycled polypropylene on the manufacturing of lead-acid battery cases

Polypropylene (PP) is one of the most common plastics used in the manufacturing of lead-acid battery cases, where the recycling of the material has become common practice, being both economically viable and environmentally friendly. During the recycling process, the various components of the spent battery are separated, where the crushed battery case is washed in order to remove any excess acid and lead-containing particles. The plastic components are subsequently melted and extruded into pellets that are then blended with virgin material to injection mold new battery cases and lids. This study showed that a significant amount of lead-containing particles in the form of lead dioxide and lead sulfate remain in the recycled plastic, and are evenly distributed throughout the polymer matrix. TEM studies showed that the particles are less than 1 μm in size and X-ray diffraction analysis of ashed recycled PP samples showed the presence, amongst others, of talc, calcium carbonate, rutile and iron oxide. These compounds come from a range of fillers, flame-retardants, colorants and impurities that originated from the various original battery cases that were recycled. The study showed that modern X-ray fluorescence (XRF) analysis is a quick and reliable method to quantify the amount of the elements found in the plastic and that the concentration of Pb in the plastic can be used as a type of “tracer” to determine the amount of recycled PP used in the manufacturing of a particular battery case. The study also showed that there is possible environmental contamination, in particular with Pb and Br contained in recycled PP during the injection molding process and the burning of the plastic. The Pb- and Br-containing particles are small enough to become air-borne during the burning process of the plastic, resulting in them being part of the soot and other hydrocarbon oils that are emitted. No Pb was observed in the gases emitted during simulated low-temperature injection molding conditions; however, a significant amount of Br was detected in the gases at the lower temperatures. Clear environmental waste classification of the battery case plastic should be done before its final incineration where the amount of trace metals present and its possible contamination to the environment should be considered. Care should also be taken for machine operators who work with the recycled plastic, that no excessive exposure to the halogenated compounds is experienced.     

Application of the essential work of fracture concept to nanostructured polymer materials

The first part of the paper deals with a critical discussion of the methodical basis of essential work of fracture (EWF) concept with respect to the specimen geometry (especially the notch depth) and application to polymers. In the second part, an in situ testing device, which combines a tensile testing machine with an optical strain-field measuring system, has successfully demonstrated possibility of characterization of fracture behaviour of polystyrene-polybutadiene block copolymers and block copolymer/homopolymer blends as examples of nanostructured polymer materials. It has been shown that knowledge of the time evolution of the strain field close to the crack tips leads to a simple verification of the basic precondition for the applicability of the EWF concept, the precondition “plastic zone coalescence-before-stable crack propagation”.     

聚丙烯微孔膜基渐变聚合物的制备,结构与性能的研究

以聚丙烯微孔膜为基材，通过扩散控制原位共聚合的方法在人填充了组成沿膜的厚度方向逐渐改变的无规共聚物，Ｘ－光电子能谱（ＸＰＳ）、全反射红外光谱（ＡＴＲ）以及动态粘弹谱的分析结果。说明所制备得到的合膜具有明显的渐变聚合物性质。     

Influence of molecular characteristics on overall isothermal melt-crystallization behavior and equilibrium melting temperature of syndiotactic polypropylene

Overall isothermal melt-crystallization and subsequent melting behavior of metallocene-catalyzed syndiotactic polypropylene resins of various molecular weights were investigated using differential scanning calorimetry (DSC) technique. Two sets of molecular weight range were synthesized with two different metallocene catalyst systems. The kinetics of the overall isothermal melt-crystallization process was analyzed based on various macrokinetic models, i.e. the Avrami, Malkin and Urbanovici-Segal models. The effective activation energy describing the overall isothermal crystallization process over the crystallization temperature range studied was estimated based on an Arrhenius approximation of the obtained Avrami crystallization rate constants. The equilibrium melting temperature for each of these resins was estimated based on the linear and non-linear Hoffman-Weeks extrapolative methods.     

Photodegradation of polypropylene thermal bonded non-woven fabric

Samples of thermal bonded polypropylene non-woven fabrics were exposed to light from two TUV 30W G30T8 Philips lamps (λ = 253.7 nm) in a covered open-air chamber at room temperature (25 °C and 55% relative humidity) for different periods of time. In order to determine the state of degradation, the samples were examined by optical microscopy, scanning electron microscopy, staining with an isopropanol solution of methylene blue and Sudan III, colourimetry, Fourier transform infrared (FTIR) spectroscopy and density measurements. Although the bonded areas formed under complex thermal and mechanical deformations during the fabric production, no localized staining was observed. The colour of the irradiated and stained fabrics changed uniformly due to the even production of polar groups in the process of irradiation. It was found that the change of redness and blueness of degraded and stained samples can be correlated linearly with the evolution of POOH groups as determined by FTIR spectroscopy. Products containing carbonyl (CO), hydroxyl and/or hydroperoxide (POOH) groups increase with time of degradation with a non-linear relation. It was also observed that the density and 997 cm⁻¹/972 cm⁻¹ FTIR absorbance ratio increases with degradation time. Density fluctuation and the build up of degradation products caused fibre cracks and embrittlement.     

Thermal properties of polypropylene post-consumer waste (PP PCW)

Differential scanning calorimetry has been used to study the heat flow during melting and crystallisation of a range of polypropylene post-consumer waste (PP PCW) grades and blends. The heat flow curves and the heat capacity curves indicated that the PP PCW grades and blends contained contaminants even after manual sorting and a cleaning process. The enthalpies of the PP PCW grades were lower than that for the virgin grades, as a result of degradation. Small amounts of polymeric contaminants (up to 10%) did not affect the enthalpies of PP PCW although other contaminants may have had some effect. The enthalpies of the PCW blends could in general be predicted by a linear additive rule, which is of importance for recycling a variety of PP PCW products.The authors would like to thank Dr. M. Killen (Basell Australia Pty. Ltd.), Mr. P. Slaven (Citiwide MRF), Dasma Valley Waste Prop. Ltd. and Mr. I. Janetzki (Huhtamaki Australia Ltd.) for supplying materials for this project. Financial support for the project was provided by Basell Australia and Ecorecycle Victoria, Australia.     

HIPS／PP熔融反应共混及其动态力学性质

研究了高抗冲聚苯乙烯（HIPS）／聚丙烯（PP）共混物在过氧化二异丙苯（DCP）存在下的熔融反应过程及其动态力学性质．HIPS在DCP存在下以聚苯乙烯（PS）的降解为主，伴随着聚丁二烯（PB）的交联和接枝，PP在DCP存在下以降解为主，HIPS／PP在DCP存在下以PP同HIPS的反应接枝为主，这种原位生成的增容剂显著地改善了HIPS／PP两组份间的相容性，其分子运动特征较前两者发生明显变化，PS的Tg下降，PB和PP的Tg升高．     

Establishment of de facto standard catalysts in the polypropylene industry

Polypropylene (PP) has become an indispensable material in our daily lives. Annual worldwide production of PP is now more than 30000000 tons and is predicted to grow at an annual rate of about 6% during the first decade of the 21st century. Commercial production of PP began in 1957 with the use of TiCl(3) catalysts established by Ziegler and Natta. However, the low activities and low stereospecificities of the catalysts resulted in large amounts of catalyst residue and atactic PP in the product, necessitating steps for their removal in commercial production. As a means of finding appropriate catalysts, we developed MgCl(2)-supported TiCl(4) catalysts, which basic concept was introduction of organic compounds onto the inorganic crystal catalyst surface. This addition led to remarkable enhancements in stereospecificity with extremely high activity. Use of the new catalysts enlarged and simplified the PP production process by eliminating the steps previously required for removal of catalyst residue and atactic PP. In addition, it greatly improved the properties of the PP, enabling a much wider range of PP applications by replacing metal and engineering plastics with the highly stereoregular PP. Therefore, these catalysts helped the rapid establishment of the current PP industry and now play a major role in production. The latest MgCl(2)-supported TiCl(4) catalyst is providing precise control of the isotactic PP structure. Future expectations for this type of catalyst are to acquire a single-site nature and to contribute to the creation of a new class of hybrid materials.     

关于超高分子量聚丙烯超拉伸膜的结构性能的研究——Ⅱ.形态结构变化对力学性能的影响

用X-射线衍射、动态力学测定等手段研究了不同拉伸倍数的超高分子量聚丙烯薄膜的力学性能的变化.以X-射线衍射法并基于串联力学模型的假设得到的各样品的表观晶区模量E_c~(app)约为34-38GPa.样品模量E_b随拉伸倍数增加而逐渐增大,其变化趋势与非晶区取向因子的变化相类似,说明非晶区取向是左右样品模量的重要因素.室温下,69倍拉伸样品的模量为27GPa,约为表观结晶模量的3/4,且其值在-150-160℃的温度范围内没有急剧变化,说明超拉伸明显改善了材料的力学性能及热稳定性.在各拉伸样品中,考虑伸直链结晶生成的可能性,利用并串联力学模型对伸直链结晶的体积分数做了估算,并对X-射线衍射法所得表观结晶模量进行了修正,认为室温下聚丙烯的真正晶区模量约为47GPa.     

Morphology, crystallization behavior and properties of impact-modified polypropylene copolymer with or without sodium benzoate as a nucleating agent

 The morphology, crystallization behavior, and properties of an impact-modified polypropylene (PP) copolymer with or without sodium benzoate were investigated. The contents of ethylene–propylene rubber (EPR) in the reactor-made PP copolymer is about 15 wt%. For comparison, blends of PP and EPR containing the same EPR composition were prepared by melt-mixing. Morphological studies by scanning probe microscopy indicated that the impact-modified copolymer consists of three different phases, i.e., polyethylene, PP, and EPR phases, which is considerably different from the morphology of the conventional PP/EPR blend of the corresponding composition. The impact-modified PP copolymer exhibited a higher crystallization rate in terms of the lower crystallization half-time and thus higher thermal and mechanical properties, such as impact strength and hardness, than the PP/EPR blend did. The addition of sodium benzoate as a nucleating agent to the copolymer increased the crystallization rate and the mechanical properties. Received: 4 June 2001 Accepted: 31 October 2001