Plastic recycling

Plastic recycling
Plastic recycling is the process of recovering scrap or waste plastics and reprocessing the material into useful products, sometimes completely different in form from their original state. For instance, this could mean melting down soft drink bottles and then casting them as plastic chairs and tables. Typically a plastic is not recycled into the same type of plastic, and products made from recycled plastics are often not recyclable.

Challenges
When compared to other materials like glass and metal materials, plastic polymers require greater processing to be recycled. Plastics have a low entropy of mixing, which is due to the high molecular weight of their large polymer chains. A macromolecule interacts with its environment along its entire length, so its enthalpy of mixing is large compared to that of an organic molecule with a similar structure. Heating alone is not enough to dissolve such a large molecule; because of this, plastics must often be of nearly identical composition in order to mix efficiently. When different types of plastics are melted together they tend to phase-separate, like oil and water, and set in these layers. The phase boundaries cause structural weakness in the resulting material, meaning that polymer blends are only useful in limited applications. Another barrier to recycling is the widespread use of dyes, fillers, and other additives in plastics. The polymer is generally too viscous to economically remove fillers, and would be damaged by many of the processes that could cheaply remove the added dyes. Additives are less widely used in beverage containers and plastic bags, allowing them to be recycled more often. Yet another barrier to removing large quantities of plastic from the waste stream and landfills is the fact that many common but small plastic items lack the universal triangle recycling symbol and accompanying number. A perfect example is the billions of plastic utensils commonly distributed at fast food restaurants or sold for use at picnics. The use of biodegradable plastics is increasing. If some of these get mixed in the other plastics for recycling, the reclaimed plastic is not recyclable because the variance in properties and melt temperatures.[1]

Processes
Before recycling, plastics are sorted according to their resin identification code, a method of categorization of polymer types, which was developed by the Society of the Plastics Industry in 1988. Polyethylene terephthalate, commonly referred to as PET, for instance, has a resin code of 1. They are also often separated by color. The plastic recyclables are then shredded. These shredded fragments then undergo processes to eliminate impurities like paper labels. This material is melted and often extruded into the form of pellets which are then used to manufacture other products.

Monomer recycling
Many recycling challenges can be resolved by using a more elaborate monomer recycling process, in which a condensation polymer essentially undergoes the inverse of the polymerization reaction used to manufacture it. This yields the same mix of chemicals that formed the original polymer, which can be purified and used to synthesize new polymer chains of the same type. Du Pont opened a pilot plant of this type in Cape Fear, North Carolina, USA, to recycle PET by a process of methanolysis, but it closed the plant due to economic pressures.[2]

Plastic recycling

Thermal depolymerization
Another process involves the conversion of assorted polymers into petroleum by a much less precise thermal depolymerization process. Such a process would be able to accept almost any polymer or mix of polymers, including thermoset materials such as vulcanized rubber tires and the biopolymers in feathers and other agricultural waste. Like natural petroleum, the chemicals produced can be made into fuels as well as polymers. A pilot plant of this type exists in Carthage, Missouri, USA, using turkey waste as input material. Gasification is a similar process, but is not technically recycling since polymers are not likely to become the result.

Heat compression
Yet another process that is gaining ground with startup companies (especially in Australia, United States and Japan) is heat compression. The heat compression process takes all unsorted, cleaned plastic in all forms, from soft plastic bags to hard industrial waste, and mixes the load in tumblers (large rotating drums resembling giant clothes dryers). The most obvious benefit to this method is the fact that all plastic is recyclable, not just matching forms. However, criticism rises from the energy costs of rotating the drums, and heating the post-melt pipes.

Other processes
A process has also been developed in which many kinds of plastic can be used as a carbon source in the recycling of scrap steel.[3]

Applications
PET
Post-consumer polyethylene terephthalate (PET) containers are sorted into different colour fractions, and baled for onward sale. PET recyclers further sort the baled bottles and they are washed and flaked (or flaked and then washed). Non PET fractions such as caps and labels are removed during this process. The clean flake is dried. Further treatment can take place eg melt filtering and pelletising or various treatments to produce food contact approved recycled PET (RPET). RPET has been widely used to produce polyester fibres. [4] This sorted post-consumer PET waste is crushed, chopped into flakes, pressed into bales, and offered for sale.[5] One use for this recycled PET that has recently started to become popular is to create fabrics to be used in the clothing industry.[6] The fabrics are created by spinning the PET flakes into thread and yarn.[5] This is done just as easily as creating polyester from brand new PET.[7] The recycled PET thread or yarn can be used either alone or together with other fibers to create a very wide variety of fabrics. Traditionally these fabrics were used to create strong, durable, rough, products, such as jackets, coat, shoes, bags, hats, and accessories. However, these fabrics are usually too rough on the skin and could cause irritation. Therefore, they usually are not used on any clothing that may irritate the skin, or where comfort is required.[8] But in today's new eco-friendly world there has been more of a demand for green products. As a result, many clothing companies have started looking for ways to take advantage of this new market and new innovations in the use of recycled PET fabric are beginning to develop. These innovations included different ways to process the fabric,[5] to use the fabric, or blend the fabric with other materials.[9] Some of the fabrics that are leading the industry in these innovations include Billabong's Eco-Supreme Suede,[9] Livity [10]'s Rip-Tide III,[11] Wellman Inc [12]'s Eco-fi(formerly known as EcoSpun),[4] and Reware [13]'s Rewoven.[7] Some additional companies that take pride in using recycled PET in their products are Crazy Shirts[14] and Playback [15].[6] Other major outlets for RPET are new containers (food contact or non food contact) produced either by (injection stretch blow) moulding into bottles and jars or by thermoforming APET sheet to produce clam shells, blister packs

Plastic recycling and collation trays. These applciations used 46% of all RPET produced in Europe in 2010. Other applications, such as strapping tape, injection moulded engineering components and even building materials account for 13% of the 2010 RPET production.

PVC
PVC- or Vinyl Recycling has historically been difficult to perfect on the industrial scale. But within the last decade several viable methods for recycling or upcycling PVC plastic have been developed.

HDPE
The most-often recycled plastic, HDPE or number 2, is downcycled into plastic lumber, tables, roadside curbs, benches, truck cargo liners, trash receptacles, stationery (e.g. rulers) and other durable plastic products and is usually in demand.

Other plastics
The white plastic foam peanuts used as packing material are often accepted by shipping stores for reuse.[16] Successful trials in Israel have shown that plastic films recovered from mixed municipal waste streams can be recycled into useful household products such as buckets.[17] Similarly, agricultural plastics such as mulch film, drip tape and silage bags are being diverted from the waste stream and successfully recycled [18] into much larger products for industrial applications such as plastic composite railroad ties.[19] Historically, these agricultural plastics have primarily been either landfilled or burned on-site in the fields of individual farms.[20] CNN reports that Dr. S. Madhu of the Kerala Highway Research Institute, India has formulated a road surface that includes recycled plastic. Aggregate, bitumen (asphalt) with plastic that has been shredded and melted at a temperature below 220 degrees C (428 F) to avoid pollution. This road surface is claimed to be very durable and monsoon rain resistant. The plastic is sorted by hand, which is economical in India. The test road used 60kg of plastic for an approx. 500m long, 8m wide, two-lane road. The process chops thin-film road-waste into a light fluff of tiny flakes that hot-mix plants can uniformly introduce into viscous bitumen with a customized dosing machine. Tests at both Bangalore and the Indian Road Research Centre indicate that roads built using this 'KK process' will have longer useful lives and better resistance to cold, heat, cracking, and rutting, by a factor of three.[21]

Financial justification
In 2008, the price of PET dropped from $370/ton in the US to $20 in November.[22] PET prices had returned to their long term averages by May 2009.[23]

Recycling rates
Plastic recycling rates lag far behind those of other items, such as newspaper (about 80%) and corrugated fiberboard (about 70%).[24] All plastic bottles were recycled at a rate of 24% in 2005.[25] The quantity of post-consumer plastics recycled has increased every year since at least 1990. In 2006 the amount of plastic bottles recycled reached a record high of 2.2 trillion pounds. The amount of PET bottles recycled in 2006 increased more than 102 million pounds compared to 2005. HDPE bottle recycling increased in 2005 to 928 million pounds.

Plastic recycling

Consumer education
United States
Low national plastic recycling rates have been due to the complexity of sorting and processing, unfavorable economics, and consumer confusion about which plastics can actually be recycled.[26] Part of the confusion has been due to the recycling symbol that is usually on all plastic items. This symbol is called a resin identification code. It is stamped or printed on the bottom of containers and surrounded by a triangle of arrows. (See the table in Plastic.) The intent of these arrows was to make it easier to identify plastics for recycling. The recycling symbol doesnt necessarily mean that the item will be accepted by residential recycling programs.[27]

United Kingdom
In the UK, the amount of post-consumer plastic being recycled is relatively low,[28] due in part to a lack of recycling facilities. The Plastics 2020 Challenge was founded in 2009 by the plastics industry with the aim of engaging the British public in a nationwide debate about the use, reuse and disposal of plastics, hosts a series of online debates on its website framed around the waste hierarchy.

Plastic identification code

Five groups of plastic polymers,[29] each with specific properties, are used worldwide for packaging applications (see table below). Each group of plastic polymer can be identified by its Plastic Identification code (PIC) - usually a number or a letter abbreviation. For instance, Low-Density Polyethylene can be identified by the number 4 and/or the letters "LDPE". The PIC appears inside a three-chasing arrow recycling symbol. The symbol is used to indicate whether the plastic can be recycled into new products. The PIC was introduced by the Society of the Plastics Industry, Inc. which provides a uniform system for the identification of different polymer types and helps recycling companies to separate different plastics for reprocessing. Manufacturers of plastic products are required to use PIC labels in some countries/regions [30] and can voluntarily mark their products with the PIC where there are no requirements. Consumers can identify the plastic types based on the codes usually found at the base or at the side of the plastic products, including food/chemical packaging and containers. The PIC is usually not present on packaging films, as it is not practical to collect and recycle most of this type of waste.
Plastic Identification Code Type of plastic polymer Polyethylene terephthalate (PET, PETE) Properties Common Packaging Applications

Clarity, strength, toughness, barrier to gas and moisture.

Soft drink, water and salad dressing bottles; peanut butter and jam jars

High-density polyethylene (HDPE)

Stiffness, strength, toughness, resistance to moisture, permeability to gas.

Water pipes, hula hoop rings, five gallon buckets, milk, juice and water bottles; the occasional shampoo / toiletry bottle

Polyvinyl chloride (PVC)

Versatility, ease of blending, strength, toughness.

Blister packaging for non-food items; cling films for non-food use. Not used for food packaging as the plasticisers needed to make natively rigid PVC flexible are usually toxic. Non-packaging uses are electrical cable insulation; rigid piping; vinyl records.

Plastic recycling

5
Low-density polyethylene (LDPE) Ease of processing, strength, toughness, flexibility, ease of sealing, barrier to moisture. Frozen food bags; squeezable bottles, e.g. honey, mustard; cling films; flexible container lids.

Polypropylene (PP)

Strength, toughness, resistance Reusable microwaveable ware; kitchenware; yogurt containers; to heat, chemicals, grease and margarine tubs; microwaveable disposable take-away containers; oil, versatile, barrier to disposable cups; plates. moisture. Versatility, clarity, easily formed Egg cartons; packing peanuts; disposable cups, plates, trays and cutlery; disposable take-away containers;

Polystyrene (PS)

Other (often polycarbonate or ABS)

Dependent on polymers or combination of polymers

Beverage bottles; baby milk bottles. Non-packaging uses for polycarbonate: compact discs; "unbreakable" glazing; electronic apparatus housings; lenses including sunglasses, prescription glasses, [31] automotive headlamps, riot shields, instrument panels;

References
[1] (http:/ / cygnus-group. com/ use-less-stuff/ Paper-and-Plastic-Grocery-Bag-LCA-Summary-3-21-08. pdf) [2] "DUPONT ENDS RECYCLING EXPERIMENT. | Chemicals > Chemicals Overview from" (http:/ / www. allbusiness. com/ chemicals/ chemicals-overview/ 9060603-1. html). AllBusiness.com. . Retrieved 2010-08-21. [3] Steel (http:/ / www. cnn. com/ 2005/ TECH/ 08/ 10/ plastic. steel. reut/ index. html) CNN. Retrieved 9.11.06. [4] "EcoSpun (Eco-fi) Clothing - Eartheasy.com Solutions for Sustainable Living" (http:/ / www. eartheasy. com/ wear_ecospun. htm). Eartheasy.com. . Retrieved 2010-08-21. [5] Idea TV GmbH. "Recycled plastic - the fashion fabric of the future" (http:/ / www. innovations-report. com/ html/ reports/ environment_sciences/ report-7183. html). Innovations-report.com. . Retrieved 2010-08-21. [6] 10:24 AM PT, November 13, 2009 (2009-11-13). "Trashy Chic: Recycled clothing from Playback - Brand X" (http:/ / www. thisisbrandx. com/ 2009/ 11/ trashy-chic-recycled-clothing-from-playback. html). Thisisbrandx.com. . Retrieved 2010-08-21. [7] "Reware's REWOVEN Technology Info: The Eco Narrative - Recycled PET" (http:/ / www. rewarestore. com/ tech_recycled_pet. html). Rewarestore.com. . Retrieved 2010-08-21. [8] "Billabong ECO Supreme Suede Boardshorts: Sustainable is Good Eco Products" (http:/ / www. sustainableisgood. com/ products/ 2008/ 04/ billabong. html). Sustainableisgood.com. 2008-04-09. . Retrieved 2010-08-21. [9] (http:/ / www. billabongbiz. com/ bethechange/ environment. php?page=sustainable) [10] http:/ / www. livity. org/ [11] "Rip-Tide "Eco Tech" Fabric Made From Hemp, Recycled PET" (http:/ / www. treehugger. com/ files/ 2008/ 03/ rip-tide-livity. php). TreeHugger. . Retrieved 2010-08-21. [12] http:/ / www. wellmaninc. com/ [13] http:/ / www. rewarestore. com/ [14] September 3, 2009 (2009-09-03). "Eco Friendly Recycled Board Shorts" (http:/ / www. gogreenstreet. com/ eco-friendly-recycled-plastic-bottle-board-shorts/ ). Gogreenstreet.com. . Retrieved 2010-08-21. [15] http:/ / www. playbackclothing. com/ [16] "Let Peanuts Live! Mail Boxes Etc. Recycles as Part ofNational Effort; Recycle Loose-fill, Foam `Peanuts' AtParticipating Mail Boxes Etc. Locations. | North America > United States from" (http:/ / www. allbusiness. com/ consumer-products/ office-supplies-equipment/ 6916130-1. html). AllBusiness.com. . Retrieved 2010-08-21. [17] Plastic trial procedure (http:/ / www. oaktech-environmental. com/ plastictrials. htm) Oaktech Environmental website. Retrieved 9.11.06. [18] Agricultural plastics recycling process (http:/ / www. rkoindustries. com/ id26. html) Agricultural plastics recycling website. Retrieved 07.11.08. [19] Plastic Composite Railroad Tie Facts (http:/ / www. rti-railroad-tie. com/ id5. html) Plastic Composite Railroad Ties website. Retrieved 01.21.08. [20] Recycling Used Agricultural Plastics (http:/ / environmentalrisk. cornell. edu/ AgPlastics/ References/ Garthe& Kowal-a. pdf) James W. Garthe, Paula D. Kowal, PennState University, Agricultural and Biological Engineering [21] Patel, Almitra H. (October 2003), Plastics Recycling and The Need For Bio-Polymers (http:/ / isebindia. com/ 01_04/ 03-10-2. html), 9, International Society of Environmental Botanists, [22] Page, Candace, Waste district raises recycling fees, Burlington Free Press, November 12, 2008

Plastic recycling
[23] Financial Times, May 15, 2009 (article by Max Hogg) [24] The Self-Sufficiency Handbook: A Complete Guide to Greener Living by Alan Bridgewater pg. 62--Skyhorse Publishing Inc., 2007 ISBN 1602391637, 9781602391635 [25] http:/ / www. headwatersrecycle. com/ why. html [26] Watson, Tom (June 2, 2007). "Where can we put all those plastics?" (http:/ / seattletimes. nwsource. com/ html/ homegarden/ 2003730398_ecoconsumer02. html). Seattle Times. . Retrieved 2007-06-02. [27] Where can we put all those plastics? By Tom Watson June 2, 2007 Seattle Times http:/ / seattletimes. nwsource. com/ html/ homegarden/ 2003730398_ecoconsumer02. html [28] Plastics (http:/ / www. wasteonline. org. uk/ resources/ InformationSheets/ Plastics. htm#_Hows) wasteonline.org.uk. Retrieved 10.18.07. [29] "Safe Use Of Plastic Food Packaging And Containers" (http:/ / www. ava. gov. sg/ FoodSector/ FoodSafetyEducation/ Food+ Facts/ SafeUsePlasticContainers/ index. htm). . [30] "19". Holt Chemistry (Florida edition). Holt, Rinehart, and Winston. 2006. p.702. ISBN0-03-039114-8. "More than hlf the states in the United States have enacted laws that require plastic products to be labeled with numerical codes that identify the type of plastic used in them." [31] "What is Polycarbonate (PC)?" (http:/ / www. recycledplastic. com/ resource/ plastic/ polycarbonate-pc/ ). .

External links
West, Larry. "Recyclable Plastic: Why are So Few Food Containers Made of Recyclable Plastic?" (http:// environment.about.com/od/reducingwaste/a/corn_plastic.htm). About.com. Retrieved 2009-05-04. Plastic Packaging Resin Codes (http://www.americanchemistry.com/s_plastics/bin.asp?CID=1102& DID=4645&DOC=FILE.PDF) data from the American Chemistry Council ISF's Plastics Recovery Manual American Chemistry Council Statement on Plastic Recycling (http://www.greenbuildingsolutions.org/ s_greenbuilding/sec.asp?CID=2134&DID=8972) Technology for plastic recycling (http://www.erema.at/en/1/)

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