The Value in Recycled Polyamides
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The document discusses the development of recycled polyamides and the technical objectives aimed at enhancing the mechanical properties and value of recycled nylon derived from post-consumer carpet. It outlines a significant diversion of waste from landfills and highlights the use of functional additives to improve the performance of recycled materials. Key findings reveal that low molecular weight additives lead to significant enhancements in the properties of recycled nylon, approaching those of virgin materials.
The Value in Recycled Polyamides
- 1. The Value in Recycled Polyamides Polyfunc)onal Chain Extenders
- 2. Overview • Background - Industry, Materials, Technical Objectives • Technical Data - Rheological Analysis - Mechanical Analysis • Conclusion & Recommendation - Discussion, Product Comparisons 2 Cray Valley HSC
- 3. Background - Industry Objectives • “Developing market-based solutions for the recycling and reuse of post-consumer carpet” – Carpet America Recovery Effort slogan • Voluntary initiative by industry/government to prevent burdening landfills • Plan to achieve 40% landfill diversion by 2012 • 2002 diversion goal, 178 million pounds (3.8%) • 1.3 billion pounds diverted since 2002, 92% of which has gone into other value added products • Estimated 5 billion pounds landfilled, annually • 5 billion pounds can support the NA injection molding market 3 Cray Valley HSC
- 4. Background – Materials, Availability *Courtesy of Phantom Plastics 4 Cray Valley HSC
- 5. Background - Value-Added Process 5 Cray Valley HSC
- 6. Background - Limiting Factor Added Value Degradation Recycled Recycled Virgin Fiber Virgin Fiber Injection Injection Specifications Specifications Nylon Nylon Grade Grade Molding Molding Mechanical Mechanical 1 Low 2 Med 3 High Properties Properties Molecular Molecular 1 Low 2 Med 3 High Weight Weight 6 Cray Valley HSC
- 7. Technical Objectives • Objective #1: Improve the mechanical properties of reprocessed recycled nylon derived from carpet using a functional additive • Objective #2: Impart value added properties to recycled nylon that stay within a low cost model 7 Cray Valley HSC
- 8. Theory - Recycled Nylon 5. Chain Extended FA FA FA 1. Dry Blending FA 4. Reaction FA FA 3. Homogenizing 2. Melt Processing Low Mw High Mw 8 Cray Valley HSC
- 9. Materials • Yan et al. documented the importance of diffusion of reactive species • Hargreaves et al. described the reaction between amino group and anhydride 9 Cray Valley HSC
- 10. Materials Model Formulation • 98 to 99% r-PA (N66, >95% purity) • 1 to 2% Chain Extender* * LPBD were prepared on a porous silica at 70% active 10 Cray Valley HSC
- 11. Results • Grafted MA yielded more chain extension reactions • Low viscosity LBPD likely integrated more efficiently • Mobility of low Mw SMA led to shorter induction times 11 Cray Valley HSC
- 12. Optimization Results • Low shear viscosity attributed to increased branched structure • Increased long chain branching or MWD • Reactivity of graft versus in-chain anhydride 12 Cray Valley HSC
- 13. Results • SMA improved mechanical properties more than LPBD • Homogenization an important factor in additive selection • Chain extended r-PA has properties encroaching on virgin PA 13 Cray Valley HSC
- 14. Results • Thermal characteristic improved with low/high Tg additive • Extent of branching suggested by improvement in HDT • SMA more efficient at restoring properties of r-PA 14 Cray Valley HSC
- 15. Conclusion • Significant improvements in r-PA using low molecular weight anhydride functional additives • Anhydride grafted LPBD gave the greatest extent of reaction as shown by increased melt characteristics • Low molecular weight additives were deemed more beneficial due to increased mobility in the melt • Homogenizing the melt involved balance of reactivity and mobility 15 Cray Valley HSC
- 16. Cray Valley HSC • Leading global supplier of hydrocarbon resins, diene- based resins, and specialty monomers - Wingtack® and Norsolene® (C5 & C9 tackifiers) - Poly bd®, KrasolTM and Ricon® (low molecular weight liquid polybutadiene resins) - SMA® (styrene-maleic anhydride copolymer resins) - DymalinkTM (metal centered monomers) • Annual sales over $350 million and has more than 340 employees worldwide • Company’s more than 250 products are manufactured at 9 sites in 4 countries 16 Cray Valley HSC
- 17. Cray Valley HSC A Division of Total SA Upstream Downstream Chemicals • Oil & gas exploration • Trading & shipping • Base chemicals • Production • Refining & marketing • Industrial & consumer Focus • Gas & power • Commodity & specialty market specialty • Alternative energy fluids chemicals Sales $24.6 $163.4 $23.2 (billion) Employees 17,192 32,631 41,658 Total, a partner in your challenges 17 Cray Valley HSC
- 18. Cray Valley HSC Focus Markets • Performance • Pressure • Printed Growth Markets additives sensitive circuit boards Adhesives Rubber • Tire & hose • Reactive applications adhesives • Pigment Dispersants • Co-curing • Insulated agents Glass • Mineral Sealants Dispersants 18 Cray Valley HSC
- 19. Cray Valley HSC Global Presence 19 Cray Valley HSC
- 20. Cray Valley HSC • For additional information about Cray Valley, its products or its work in Hydrocarbon Specialty Chemicals, visit www.CVPolymerAdditives.com 20 Cray Valley HSC