Combination of three-stage sink-float method and selective flotation technique for separation of mixed post-consumer plastic waste

The aim of this research was to separate the different plastics of a mixed post-consumer plastic waste by the combination of a three-stage sink-float method and selective flotation. By using the three-stage sink-float method, six mixed-plastic wastes, belonging to the 0.3-0.5 cm size class and including high density polyethylene (HDPE), polypropylene (PP), polyvinylchloride (PVC), polystyrene (PS), polyethylene terephthalate (PET) and acrylonitrile-butadiene-styrene copolymers (ABS) were separated into two groups, i.e., a low density plastic group (HDPE and PP) and a high density plastic group (PET, PVC, PS and ABS) by tap water. Plastic whose density is less than that of the medium solution floats to the surface, while the one whose density is greater than that of the medium solution sinks to the bottom. The experimental results elucidated that complete separation of HDPE from PP was achieved by the three-stage sink-float method with 50% v/v ethyl alcohol. To succeed in the separation of a PS/ABS mixture from a PET/PVC mixture by the three-stage sink-float method, a 30% w/v calcium chloride solution was employed. To further separate post-consumer PET/PVC and PS/ABS based on plastic type, selective flotation was carried out. In order to succeed in selective flotation separation, it is necessary to render hydrophilic the surface of one or more species while the others are kept in a hydrophobic state. In flotation studies, the effects of wetting agent, frother, pH of solution and electrolyte on separation were determined. The selective flotation results showed that when using 500 mg l(-1) calcium lignosulfonate, 0.01 ppm MIBC, and 0.1 mg l(-1) CaCl2 at pH 11, PET could be separated from PVC. To separate ABS from PS, 200 mg l(-1) calcium lignosulfonate and 0.1 mg l(-1) CaCl2 at pH 7 were used as a flotation solution. Wettability of plastic increases when adding CaCl2 and corresponds to a decrease in its contact angles and to a reduction in the recovery of plastic in the floated product.     

Processing plastics from ASR/ESR waste: separation of poly vinyl chloride (PVC) by froth flotation after microwave-assisted surface modification

The feasibility of the selective surface hydrophilization of poly vinyl chloride (PVC) using microwave treatment to facilitate the separation of PVC via froth flotation from automobile shredder residue (ASR) and electronic waste shredder residue (ESR) was evaluated. In the presence of powder-activated carbon (PAC), 60-s microwave treatment selectively enhanced the hydrophilicity of the PVC surface (i.e., the PVC contact angle decreased from 86.8° to 69.9°). The scanning electron microscopy (SEM) and X-ray photoelectron spectroscopy (XPS) results are consistent with increased hydrophilic functional groups (i.e., ether, hydroxyl, and carboxyl), amounting to significant changes in the morphology and roughness of the PVC surface after treatment. After only 60 s of microwave treatment, 20 % of the PVC was separated in virgin and ASR/ESR plastics with 33 and 29 % purity, respectively, as settled fractions by froth flotation at a 150 rpm mixing speed. The microwave treatment with the addition of PAC had a synergetic effect with the froth flotation, which brought about 100 and 90 % selective separation of PVC from the other virgin and ASR/ESR plastics, with 91 and 82 % purity. The use of the combined froth flotation and microwave treatments is an effective technology for separating PVC from hazardous waste plastics.     

Flame treatment for the selective wetting and separation of PVC and PET

Flame treatment has been used for many years to modify the surface of plastics to allow coatings to be added. The effect of the treatment is to produce hydrophilic species on the surface of the plastic making it water-wettable. The production of hydrophilic plastic surfaces is also required in the selective separation of plastics by froth flotation. For the process to be selective one plastic must be rendered hydrophilic while another remains hydrophobic. In this study the potential for separation of PVC and PET has been investigated. Flame treatment was shown to be very effective in producing a hydrophilic surface on both plastics, although the process was not selective under the conditions investigated. Raising the temperature of the plastics above their softening point produced a hydrophobic recovery. As the softening point of PVC was significantly lower than for PET it was possible to produce a significant difference in hydrophobicity, as judged using contact angle measurement. When immersed in water the contact angle of the PVC was found to be strongly dependent on the pH. Good separation efficiency of the two plastics was achieved by froth flotation from pH 4 to 9. One particular advantage of the technique is that no chemical reagents may be required in the flotation stage. The practicalities of designing a flake treatment system however have to be addressed before considering it to be a viable industrial process.     

Flotability and flotation separation of polymer materials modulated by wetting agents

The surface free energy, surface tension and contact angles were performed to investigate the properties of wetting agents. Adsorption of wetting agents changes wetting behavior of polymer resins. Flotability of polymer materials modulated by wetting agents was studied, and wetting agents change significantly flotability of polymer materials. The flotability decreases with increasing the concentration of wetting agents, and the wetting ability is lignin sulfonate (LS) > tannic acid (TA) > methylcellulose (MC) > triton X-100 (TX-100) (from strong to weak). There is significant difference in the flotability between polymer resins and plastics due to the presence of additives in the plastics. Flotation separation of two-component and multicomponent plastics was conducted based on the flotability modulated by wetting agents. The two-component mixtures can be efficiently separated using proper wetting agent through simple flotation flowsheet. The multicomponent plastic mixtures can be separated efficiently through multi-stage flotation using TA and LS as wetting agents, and the purity of separated component was above 94%, and the recovery was more than 93%.     

Alkaline hydrolysis of PVC-coated PET fibers for simultaneous recycling of PET and PVC

Journal of Material Cycles and Waste Management - Polyvinyl chloride (PVC)-coated poly(ethylene terephthalate) (PET) woven fibers are one of the hardest-to-recycle polymeric materials. Herein we...     

Recovery of valuable metals from WPCB fines by centrifugal gravity separation and froth flotation

Journal of Material Cycles and Waste Management - This paper reports physical and physicochemical routes for the recycling of gold, silver, and copper from waste printed circuit boards (WPCBs). The...     

Boiling treatment of ABS and PS plastics for flotation separation

A new physical method, namely boiling treatment, was developed to aid flotation separation of acrylonitrile–butadiene–styrene (ABS) and polystyrene (PS) plastics. Boiling treatment was shown to be effective in producing a hydrophilic surface on ABS plastic. Fourier Transform Infrared analysis was conducted to investigate the mechanism of boiling treatment of ABS. Surface rearrangement of polymer may be responsible for surface change of boiling treated ABS, and the selective influence of boiling treatment on the floatability of boiling treated plastics may be attributed to the difference in the molecular mobility of polymer chains. The effects of flotation time, frother concentration and particle size on flotation behavior of simple plastic were investigated. Based on flotation behavior of simple plastic, flotation separation of boiling treatment ABS and PS with different particle sizes was achieved efficiently. The purity of ABS and PS was up to 99.78% and 95.80%, respectively; the recovery of ABS and PS was up to 95.81% and 99.82%, respectively. Boiling treatment promotes the industrial application of plastics flotation and facilitates plastic recycling.     

Microwave treatment combined with wetting agent for an efficient flotation separation of acrylonitrile butadiene styrene (ABS) from plastic mixtures

Journal of Material Cycles and Waste Management - Acrylonitrile butadiene styrene (ABS), as a main component of plastics of waste electrical and electronic equipment (WEEE), shows high potential...     

Application of dissolved air flotation on separation of waste plastics ABS and PS

The aim of this research was to separate waste plastics acrylonitrile butadiene styrene (ABS) and polystyrene (PS) by dissolved air flotation in a self-designed dissolved air flotation apparatus. The effects of wetting agents, frother, conditioning time and flotation time on flotation behavior of waste plastics ABS (w-ABS) and PS (w-PS) were investigated and the optimized separation conditions were obtained. The results showed that when using 25 mgL(-1) tannic acid, 5 mgL(-1) terpineol, 15 min conditioning time and 15 min flotation time, mixtures of w-ABS and w-PS were separated successfully by dissolved air flotation in two stages, the results revealed that the purity and recovery rate of w-PS in the floated products were 90.12% and 97.45%, respectively, and the purity and recovery rate of w-ABS in the depressed products were 97.24% and 89.38%, respectively. Based on the studies of wetting mechanism of plastic flotation, it is found that the electrostatic force and hydrophobic attraction cannot be the main factor of the interaction between wetting agent molecules and plastic particles, which can be completed through water molecules as a mesophase, and a hydrogen bonding adsorption model with hydration shell as a mesophase was proposed.     

Chemical recycling of waste Poly Vinyl Chloride (PVC) by the liquid-phase treatment

Journal of Material Cycles and Waste Management - Liquid-phase treatment of waste Poly Vinyl Chloride (PVC) was performed. Chlorine change rate was high when using alcohol, cresol and terpene...     

Liberation characteristic and physical separation of printed circuit board (PCB)

Recycling of printed circuit board (PCB) is an important subject and to which increasing attention is paid, both in treatment of waste as well as recovery of valuable material terms. Precede physical and mechanical method, a good liberation is the premise to further separation. In this study, two-step crushing process is employed, and standard sieve is applied to screen crushed material to different size fractions, moreover, the liberation situation and particles shape in different size are observed. Then metal of the PCB is separated by physical methods, including pneumatic separation, electrostatic separation and magnetic separation, and major metal contents are characterized by inductively coupled plasma emission spectrometry (ICP-AES). Results show that the metal and nonmetal particles of PCB are dissociated completely under the crush size 0.6mm; metal is mainly enriched in the four size fractions between 0.15 and 1.25 mm; relatively, pneumatic separation is suitable for 0.6-0.9 mm size fraction, while the electrostatic separation is suitable for three size fractions that are 0.15-0.3mm, 0.3-0.6mm and 0.9-1.25 mm. The whole process that involves crushing, electrostatic and magnetic separation has formed a closed cycle that can return material and provide salable product.     

Modification of Thermo-Mechanical Properties of Recycled PET by Vinyl Acetate (VAc) Monomer Grafting Using Gamma Irradiation

Vinyl acetate (VAc) monomer of different percentage was grafted onto the recycled polyethylene terephthalate (r-PET) films using gamma irradiation. The properties of these modified films were characterized by Fourier transform infrared spectroscopy (FTIR), mechanical properties testing (Tensile strength, Elongation at break), dynamic mechanical analysis (DMA) and thermo-gravimetric analysis (TGA). The Tensile Strength (TS) of the modified PET film increased by 132.25?% to the highest value of 50.12 MPa at 15% VAc monomer concentration at 3 kGy gamma dose, while the elongation at break (EB) decreased by 31.83?%. FTIR was used to investigate the molecular interaction of the modified films. TGA revealed that curve of the modified PET film shifted toward higher temperature region by 95?°C, which is very close to that of PET film made from virgin flakes. The results indicate that modified PET films of better mechanical and thermal properties were successfully prepared using VAc monomer grafting by gamma irradiation technique.     

Factors affecting degradation of polyethylene terephthalate (PET) during pre-flotation conditioning

In general, plastics are exposed to different degrading agents in every procedure involved in their recovery from waste mixture and from subsequent recycling. In this study, two methods of pre-flotation conditioning were used to determine how these methods affect the general properties of the pre-conditioned PET particles to be recovered from the PET-PVC mixture. The first method comprised the conditioning of PET samples using an alkaline solution of nonionic surfactant (Triton X-100) based on the patent by the Goodyear Tire and Rubber Company. The second method, developed in this study, was a conditioning process which used an alkali-less solution of the same nonionic surfactant (Triton X-100) used in the first method. The following analytical methods were used to characterize properties of the pre-conditioned PET samples that were correlated to relative degradation of the samples: differential scanning calorimetry (DSC), for thermal behavior of the samples; FT-IR spectroscopy, for functional groups present in the samples; and, Pohl’s method, for carboxyl end-group concentration count. Results show that in addition to water the presence of NaOH in the conditioning solution contributes to the further degradation of the polymer.     

Cylinder cyclone (LARCODEMS) density media separation of plastic wastes

Cylindrical cyclone media separators using a suspended calcite separation media simulating industrial scale operations are demonstrated to effectively separate a wide variety of forms and a greater range of particle sizes of plastics by density than presently recycled. Purities of plastic products and recoveries obtained from mixed plastic wastes are comparable to those reported for established separations. Products of ≈100% purity with recoveries of >99% were obtained for high density fractions and >98% purities and recoveries for the low density fractions. Cyclonic centrifugal forces and/or the fine particle size of the separation media appear to minimize hydroscopic and particle shape effects.A mathematical model is proposed for defining plastic waste feed rates and treatable particle size ranges for the LARCODEMS media separator.Waste plastic separations yielded Ecart probable (Ep) values ?0.024 for a water only separation media. The Ep for 1.1 g cm^?3 separation medias was <0.032 with minimal to no variation in values for 1–8 mm particle sizes. Variation in the quality of separations is shown to be minimal with <72 μm, <45 μm and <2 μm media particle sizes. Media density offset created varied according to particle size.     

Effect of polyethylene terephthalate (PET) on the pyrolysis of brominated flame retardant-containing high-impact polystyrene (HIPS-Br)

Pyrolysis of brominated flame retardant-containing high-impact polystyrene (HIPS-Br) was performed at 430°C in the presence of 0.1 wt% of polyethylene terephthalate (PET) in a Pyrex glass reactor. Two different types of brominated flame retardants (decabromodiphenyl ether and decabromodiphenyl ethane) with or without antimony trioxide (as synergist) 5 wt% were used. The presence of PET had a significant effect on the material balance, decreasing the gaseous product and increasing the residue. The type of flame retardant had no effect on the yield of liquid product; however, the presence of Sb resulted in a marked difference in the distribution of decomposition products. Analysis by a gas chromatograph equipped with a flame ionization detector showed that the hydrocarbons were distributed in the range n-C₇ to n-C₂₅ with major peaks at n-C₉ and n-C₁₇. The presence of PET increased the formation of brominated compounds by several times and affected both the type and quantity of polybrominated compounds. The liquid products obtained from the pyrolysis of HIPS-Br/PET have to be treated before they can be used     

Simultaneous treatment of PVC and oyster-shell wastes by mechanochemical means

This work presents a new process for dechlorinating poly-vinyl chloride (PVC) by the use of oyster-shell waste. The process consists of milling of PVC waste with oyster-shell waste, followed by washing the milled sample with water. The milling of PVC and oyster-shell mixture results in size reduction and rupture in bonds, leading to mechanically induced reactions between the two to form CaCl2 and hydrocarbon with C=C bonds. Washing the milled mixtures with water at room temperature allows complete removal of chlorine from the milled sample. More than 95% of chlorine in PVC was removed when 2h grinding is conducted for the mixture. The present process could offer a potential route to the handling and disposal of oyster-shell and PVC wastes.     

A New Unsaturated Poly(ester-urethane) Based on Terephthalic Acid Derived from Polyethylene Terephthalate (PET) of Waste Bottles

The new unsaturated poly(ester-urethane) was synthesized by the reaction of 4,4??-methylenediphenyldiisocyanate with 4,4??-di(2,3-butenhydroxyl) terephthalate in the ratio of 1:1. 4,4??-di(2,3-butenhydroxyl) terephthalate was first prepared by reacting 2?mol of cis-2-butene-1, 4-diol with 1?mol of terephthalic acid. The terephthalic acid used was derived from the recycling of PET bottles via subjection to saponification process. The synthesized compounds were characterized by CHN analysis, FT-IR, ¹H NMR and UV?CVis spectroscopy, with consistency of results showing the presence of the new unsaturated poly(ester-urethane) II. Thermal properties of the new polymer was verified by differential scanning calorimetry and thermogravimetric analysis, whereas the mechanical properties were characterized by tensile, elongation, hardness, adhesion and impact testing. The electrical conductivity and the electrical resistance of the compound were observed with increasing applied voltage.     

Production of brown and black pigments by using flotation waste from copper slag.

One of the major problems in copper-producing countries is the treatment of the large amount of copper slag or copper flotation waste generated from copper slag which contains significant amounts of heavy metals such as Cu, Zn, Pb and Co. Dumping or disposal of such large quantities of flotation waste from copper slag causes environmental and space problems. In this study, the treatment of flotation waste from copper slag by a thermal method and its use as an iron source in the production of inorganic brown and black pigments that are used in the ceramic industry were investigated. The pigments were produced by calcining different amounts of flotation waste and chromite, Cr2O3, ZnO and CoO mixtures. The pigments obtained were added to transparent ceramic glazes and porcelainized tile bodies. Their colours were defined by L*a*b* measurements with a spectrophotometer. The results showed that flotation waste from copper slag could be used as an iron source to produce brown and black pigments in both ceramic body and glazes.     

Magnetic Cr(VI) Ion Imprinted Polymer for the Fast Selective Adsorption of Cr(VI) from Aqueous Solution

In this study, a novel magnetic Cr(VI) ion imprinted polymer (Cr(VI)-MIIP) was successfully synthesized and used as a selective sorbent for the adsorption of Cr(VI) ions from aqueous solution. It can be synthesized through the combination of an imprinting polymer and magnetic nanoparticles. The high selectivity achieved using MIIP is due to the specific recognition cavities for Cr(VI) ions created in Cr(VI)-MIIP. Also, the magnetic properties that could be obtained using magnetic nanoparticles, helps to separate adsorbent with an external magnetic field without either additional centrifugation or filtration procedures. The magnetic Fe₃O₄ nanoparticles (MNPs) were synthesized using an improved co-precipitation method and modified with tetraethylorthosilicate (TEOS) before imprinting. The magnetic Cr(VI) ion imprinted polymer was prepared through precipitation copolymerization of 4-vinylpyridine as the complexing monomer, 2-hydroxyethyl methacrylate as a co-monomer, the Cr⁶⁺ anion as a template, and ethylene glycol dimethacrylate (EGDMA) as a cross-linker in the presence of modified magnetite nanoparticles. This novel synthesized sorbent was characterized using different techniques. Batch adsorption experiments were performed to evaluate the adsorption conditions, selectivity, and reusability. The results showed that the maximum adsorption capacity was 39.3 mg g^?1, which was observed at pH 3 and at 25?°C. The equilibrium time was 20 min, and the amount of adsorbent which gave the maximum adsorption capacity was 1.7 g L^?1. Isotherm studies showed that the adsorption equilibrium data were fitted well with the Langmuir adsorption isotherm model and the theoretical maximum adsorption capacity was 44.86 mg g^?1. The selectivity studies indicated that the synthesized sorbent had a high single selectivity sorption for the Cr(VI) ions in the presence of competing ions. Thermodynamic studies revealed that the adsorption process was exothermic (\(\Delta H\)?<?0) and spontaneous (\(\Delta G\)?<?0). In addition, the spent MIIP can be regenerated up to five cycles without a significant decrease in adsorption capacity.     

New characterisation method of electrical and electronic equipment wastes (WEEE)

Innovative separation and beneficiation techniques of various materials encountered in electrical and electronic equipment wastes (WEEE) is a major improvement for its recycling. Mechanical separation-oriented characterisation of WEEE was conducted in an attempt to evaluate the amenability of mechanical separation processes. Properties such as liberation degree of fractions (plastics, metals ferrous and non-ferrous), which are essential for mechanical separation, are analysed by means of a grain counting approach. Two different samples from different recycling industries were characterised in this work. The first sample is a heterogeneous material containing different types of plastics, metals (ferrous and non-ferrous), printed circuit board (PCB), rubber and wood. The second sample contains a mixture of mainly plastics. It is found for the first sample that all aluminium particles are free (100%) in all investigated size fractions. Between 92% and 95% of plastics are present as free particles; however, 67% in average of ferromagnetic particles are liberated. It can be observed that only 42% of ferromagnetic particles are free in the size fraction larger than 20 mm. Particle shapes were also quantified manually particle by particle. The results show that the particle shapes as a result of shredding, turn out to be heterogeneous, thereby complicating mechanical separation processes. In addition, the separability of various materials was ascertained by a sink–float analysis and eddy current separation. The second sample was separated by automatic sensor sorting in four different products: ABS, PC–ABS, PS and rest product. The fractions were characterised by using the methodology described in this paper. The results show that the grade and liberation degree of the plastic products ABS, PC–ABS and PS are close to 100%. Sink–float separation and infrared plastic identification equipment confirms the high plastic quality. On the basis of these findings, a global separation flow sheet is proposed to improve the plastic separation of WEEE.