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Selective dissolution and precipitation for mechanical recycling of post-use
plastics
Wenfa Ng
Novena, Singapore, Email Address: [email protected]
Abstract
Plastics is ubiquitous in almost all aspects of modern life – but characteristics such as good
durability and low mass-to-volume ratio that afford its use in myriad applications also present
significant challenges to its end-of-life disposal. In particular, poor biodegradability,
production from non-renewable resources, and, more important, the propensity of emitting
hazardous substances during incineration meant that plastics use incurs a significant
environmental footprint. Although various policy initiatives (ranging from reuse, reduce and
recycle) have been promulgated for tackling the problem, the relatively low take-up of such
initiatives around the world meant that significant challenges remain in solving the plastics
disposal problem. This essay aims to provide readers with a snapshot of the environmental
challenges surrounding plastic use and the various methods available for recycling post-
consumer plastic waste – with special emphasis on the selective dissolution and
reprecipitation (SDP) approach. More important, problems such as deterioration of polymers‟
properties due to leaching of additives and stabilizers during recycling would also be
delineated. Given an expansive literature, discussion of the various plastic recycling methods
(such as mechanical, chemical/feedstock, and thermal) would inherently not be exhaustive.
Nevertheless, the conceptual basis, advantages and disadvantages of each class of methods
would be highlighted. While recovered polymers are usually employed in lower value
applications relative to the plastics‟ original use (known as “down-cycling”), the essay would
also discuss recent trends and proof-of-concept methods in “up-cycling” plastics waste for
use as adsorbents in wastewater treatment, self-healing thermal polymers, or as carbon
nanotubes in supercapacitor applications. Finally, substantial coverage would be dedicated to
explaining the working principles and performance parameters (e.g., choice of solvents and
anti-solvents, temperature gradient etc.) governing the application of SDP in mechanical
recycling of waste polymers. Briefly, SDP separates individual polymer types from a mixture
by utilizing the differential dissolution temperatures of different polymers in a particular
solvent. Subsequent addition of an anti-solvent to the polymer-solvent mixture induces the
precipitation and recovery of the dissolved polymer as granular materials – a form-factor
well-suited for a variety of applications and polymer fabrication techniques. Collectively,
besides highlighting the environmental sustainability challenges surrounding plastic use, the
current exposition should also be useful as a general introduction to various plastic recycling
methods. Discussion of up-cycling approaches further illuminates an important trend in
environmental research: i.e., treading away from accepting redeployment of recycled
materials for original or low-value use to developing innovative approaches for converting
waste into high performance materials. Such an approach, if successful, would provide a
sizeable market for recycled plastics – thereby, helping anchor recycling into the fabric of life
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by providing an economic incentive for an activity that hitherto relies on voluntary
participation.
Keywords: commingled plastic waste; polymer recycling; down-cycling; upcycling;
restabilization; environmental footprint; pyrolysis; polymer deconstruction; monomers;
selective dissolution and precipitation; waste repurposing;
Subject areas: environmental sciences; chemistry; physics; chemical engineering; polymer
science;
Conflicts of interest
The author declares no conflicts of interest.
Author’s contribution
Wenfa Ng reviewed the literature and wrote the manuscript.
Funding
No funding was used in this work.
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Introduction
Plastics have found applications in wide-ranging areas such as insulation materials for
electrical cables, disposable carrier bags, beverages bottles and packaging materials - and is
almost a necessity in modern life. Although properties such as chemical inertness and
durability have contributed to plastic‟s widespread adoption, they are also partially
responsible for plastics‟ disposal problems. With increasing consumerism and use of
disposable products, the volume of plastic waste has increased over recent decades; for
example, according to the U.S. Environmental Protection Agency, the fraction of plastics in
municipal solid waste has increased from 0.5% to 12.4% during the period 1960 to 2010.23
Given the difficulty of disposing poorly biodegradable plastics, many initiatives have been
implemented (at least at the pilot or proof-of-concept stage) for reducing the amount of
plastic waste disposed either in landfill or via incineration. These efforts include: (i) reducing
use of plastic bags via imposing a surcharge on a per use basis; (ii) an outright ban (e.g., in
Delhi (India), state of Mahaeashtra (India), San Francisco (United States) and Rwanda29
), or
encouraging the use of alternatives (such as reusable and durable carriers based on materials
such as polyhydroxybutyrates). With greater awareness of the many toxic substances emitted
during plastic waste incineration and recycling operations, there are even calls for classifying
plastic waste as hazardous substances.33
Perhaps with the exception of poly(ethylene
terephthalate) (PET) – which is amenable to biodegradation by enzymes from many bacterial
species11
32
- most polymers such as polypropylene (PP),9 polyethylene (PE), polystyrene
(PS), and poly(vinyl chloride) (PVC) are poorly biodegradable, and thus, would remain in
their original state in landfills for many decades. Additionally, plastic waste takes up a large
volume for a given mass;34, 35
thus, making landfilling an unsustainable disposal option,35
a
significant problem particularly in land-scarce cities around the world. This, coupled with the
large amount of plastics waste generated36
- and the landfill‟s attendant short service life -
presents a challenging problem, the solution of which would have major implications on
environmental sustainability in general and the carbon and energy footprint of society in
particular.
Problems associated with poor biodegradability of plastics – such as paucity of
environmentally friendly final disposal options - are not confined to terrestrial systems. Small
millimetre sized plastic waste, for example, has been found on ocean surfaces, which presents
a threat to aquatic birds and marine animals as they may inadvertently ingest the micro-
plastic particles as food.20
Most commonly observed as large patches of floating plastics on
the ocean surface - such as that observed in the Pacific gyre – the propensity of plastics in
adsorbing recalcitrant pollutants such as polychlorinated biphenyls (PCBs) and polycyclic
aromatic hydrocarbons (PAHs), meant that microplastics could act as carriers for the toxins.
Thus, bioaccumulation of the chemicals up the food chain through the accidental ingestion of
microplastic particles by marine organisms is a real possibility – and its impacts on
ecosystem health and human safety should not be underestimated. Given differing surface
characteristics and hydrophobicity of different polymers, significant differences exist in the
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types and relative amount of compounds attracted to the polymer surface (i.e., binding
affinity and uptake capacity, respectively). Indeed, a recent field experiment has
characterized the relative affinity of various common plastics for PCBs and PAHs:
specifically, amount of PCBs and PAHs sorbed onto HDPE, PP, and LDPE are consistently
higher than those on PET and PVC.57
Difficulty of finding environmentally acceptable and sustainable methods of
disposing plastic waste and producing native polymers from fossil fuels, has motivated the
search for alternative feedstocks (preferably renewable) for producing plastics. Specifically,
alternatives to petroleum-based plastics, known broadly as bioplastics, are derived from
biomass or microorganisms.35, 37, 38
Though often touted to be more environmentally friendly
than their fossil fuel-derived counterparts, careful accounting of materials and energy flows -
from biomass cultivation to harvesting and final bioplastic production – is needed to quantify
the true environmental impact (especially concerning greenhouse gas emissions) of
bioplastics production.35
Specifically, cradle-to-grave life cycle assessment (LCA), a popular
analytical framework for tracking the performance – from a holistic perspective - of a
particular material across its entire lifespan, suffers from inconsistencies arising from the
large variety of assumptions used in accounting for material and energy flows. Hence,
comparisons across studies for the same polymer is difficult.35
This short-coming reduces the
informational value and utility of such life cycle analyses – which are undertaken and
conducted with much effort and time. Additionally, the high production costs of most
bioplastics – particularly those requiring extraction from microbial production hosts – hamper
the widespread adoption of this class of environmentally friendly polymers; thereby,
restricting their use to niche applications with specific performance requirements usually
beyond those available in petroleum-derived commodity polymers.
Hence, given the poor cost competitiveness of bioplastics and resulting low market
access, policy instruments available for mitigating the environmental challenges of plastics
use are confined to the trios of reduce, reuse and recycle. Reuse of plastics in similar or
alternate applications, though best-in-class in terms of environmental protection, is
nevertheless limited by gradual material degradation, which will eventually results in final
disposal given unacceptable performance characteristics. On the other hand, recycling – for
example, deconstructing polymers into monomers, separating individual polymer types from
a plastic mixture, or converting plastic waste into fuels - is a proven approach (albeit at the
technical rather than socioeconomic level) for managing the burgeoning volume of plastic
waste, whose chemical inertness and low mass-to-volume ratio lead to significant challenges
in final disposal via landfilling. Nevertheless, a significant challenge exists in obtaining
recovered polymers with properties and at prices comparable to those of native polymers –
performance criteria critical for making recycling a viable business venture. Finally, while
incineration is the go-to option for reducing the volume of waste – particularly, in many land-
scarce cities around the world, possibilities of emitting toxic substances such as dioxins and
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furans during incineration of plastics (and its associated additives and stabilizers) raises
concerns, amongst the general population and city planners, concerning the eco-sustainability
of this disposal approach.
Safety and health issues associated with plastic recycling
Though often presented as an environmental friendly option for tackling plastic waste,
recent studies have shown that there is an under-appreciation of the safety and health risks
associated with plastic recycling – particularly concerning worker exposure to toxic
substances through the inhalation and dermal exposure routes. Specifically, concentrations of
poly(brominated diphenyl) ether (PBDE) in soil, sediment and hair of workers at plastic
recycling facilities is significantly higher than background levels; thus, highlighting the
environmental and health concerns of labour-intensive plastic recycling operations. In fact,
the levels detected are similar to those observed in electronic waste recycling operations,17
which is known to pose some of the most significant health risks to workers. Even though a
large proportion of plastic recycling facilities in developed countries have relatively high
levels of automation, and generally adheres to stringent environmental safety and health
regulations, the situation in many developing countries where an increasingly fraction of
lower end plastic recycling is performed is diametrically opposite. Specifically, heavy
reliance on manual labour, and relatively lax environmental laws in many developing
countries, meant that workers‟ health in relation to the potential environmental benefits of
plastic recycling should be construed as a trade-off, where the lever of balance hinges on
society‟s views on environmental sustainability vis-à-vis human safety. Finally, in addition to
tackling problems associated with recycling plastic waste generated within developing
countries, there is an increasingly trend of shipping plastic waste from developed to
developing countries, where low wage cost helps improve the economics of recycling. But
the practice raises serious questions concerning intra-generational equity, safety, and transfer
of environmental costs between societies. Despite the aforementioned concerns, plastics
recycling remains environmentally preferable to other disposal schemes if the recycling
process is designed and conducted with best-available technologies and adheres to
environmental health and safety standards. Naturally, such a goal is easier to achieve in
developed economies relative to developing ones. But greater awareness of the environmental
impact and safety concerns of inter-boundary shipment of plastic waste as well as
international agreements limiting such waste transfer, together with offers of technical
assistance to developing countries for improving safety and health standards of plastic
recycling, would help reduce health and safety issues associated with plastic recycling
operations in less developed economies.
Requirement for pre-sorting; an Achilles’ heel of plastic recycling
Surveys and studies have indicated that recycling rates are gradually increasing across
major cities around the world, but the percentage of plastics recycled remains unsatisfactory;
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for example, in 2010, only about 28% of HDPE bottles and 29% of PET bottles and jars are
recycled.9 Specifically, the key issue afflicting the plastic recycling industry is the low
fraction of pre-sorted plastic in the waste stream – an important requirement of downstream
recycling processes such as mechanical and chemical/feedstock recycling. Such a constraint
places great pressure on the economic viability of plastics recycling and, by extension, the
willingness of industry players to bring more capacity on-stream to tackle increasing volumes
of plastic waste given the high cost of separating commingled multi-component plastic waste.
In general, most of the post-consumer/ post-industrial plastic waste exists as a highly
compacted, multi-component and commingled mixture – thereby, presenting serious
challenges for many plastic recycling methods requiring pre-sorted plastics feedstock. Thus,
assuming that we are unable to increase the pre-sorting of plastics at source, the challenge is
in developing effective and economical processes for separating large volume of commingled
plastic waste into its constituent polymer types with purity levels sufficient for downstream
processing. By using near-infrared spectroscopy9 and machine-learning algorithms, robotic
systems have been demonstrated to be useful in identifying and sorting different types of
plastics.
Currently, many methods such as mechanical,34, 41-43
chemical/feedstock44-47
and
thermal recycling (i.e., using waste plastics as a source of fuel48
), exist for recycling post-
consumer/ post-industrial plastic waste and they each have their own advantages and
disadvantages.49, 50
In general, recycled plastics are less costly than their native counterparts if
the cost associated with the separation and recycling processes are well-controlled.
Additionally, many recycled plastics are only suitable for low-value applications.9 But, as
will be discussed later, efforts are underway in developing high value applications for
recycled polymers through up-cycling or repurposing post-use plastics.
Mechanical recycling
Mechanical recycling is perhaps the most visible and well-known approach of plastic
recycling. From the sorting of plastic waste at source to the use of various optical and
physical methods for separating commingled plastic waste, mechanical recycling is usually
the first step in the plastic recycling process, where the sorted plastics (relatively free of other
contaminants) would be channeled to other recycling methods, preferably for generating
higher value products. One approach of mechanical recycling is selective dissolution and re-
precipitation (SDP). Others include density flotation and optical separation etc. Nevertheless,
leaching of additives and stabilizers from polymers during mechanical recycling approaches
that require solvent dissolution (e.g., SDP) is an important problem precluding the application
of recovered polymers to high value – or sometimes, their original - applications without
reintroducing the additives necessary for conferring desired physical and chemical properties.
In particular, stabilizers are needed for protecting plastics against photo-oxidative
degradation, but they tend to leach out during polymer dissolution. Thus, in a process known
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as restabilization, stabilizers are added to the recycled polymer for enhancing the processing
stability and service life of the recyclate.9 Of the various polymer types, PP is most affected
by performance degradation arising from leaching of additives, since presence of tertiary
carbon atoms in the polymer backbone render it vulnerable to thermo-oxidative degradation
during melt-processing or photo-oxidative degradation during use.9 Thus, restabilization is
critical to recycling PP for a variety of applications – particularly for use as crates and films,
where significant photo-oxidative damage is expected without the protection offered by
stabilizers and other additives.9
Chemical/feedstock recycling
Another approach for recycling plastics is chemical/feedstock recycling, which
includes the deconstruction of waste plastic into monomers, and the conversion (through
pyrolysis) of post-use plastic into useful materials or fuel oil for heating applications.
Comparing the two approaches, waste pyrolysis converts plastic waste into a mixture of small
molecules with high calorific value or useful properties via high temperature induced
degradation, while polymer deconstruction (whether by chemical or enzymatic means)
involves the breakdown of long-chain polymers into their constituent monomers. Similar to
other chemical processes, the objective is to optimize reaction conditions such that high
purity products are obtained together with small amounts of byproducts.
Polymer deconstruction for chemical/feedstock recycling necessarily requires good
chemical- or bio-degradability of the original polymers. For example, enzyme-mediated
degradation of biodegradable polymers into monomers suitable for future polymerization or
other applications has been demonstrated.11, 12
Moreover, given the substrate specificity of
most enzymes, tailored enzymatic cocktails could be formulated for degrading different
polymers in a plastic waste mixture. Although the aforementioned process could theoretically
be implemented as a one-pot approach (where all the required enzymes are brought into
contact with the plastic waste mixture at the same time), practical experience has shown that
the sequential use of polymer-specific depolymerizing enzymes would engender better
recovery of different monomers from mixed plastic waste through reducing the complexity of
the separation step necessary for differentiating between different monomers generated in the
one-pot approach.11, 12
Nevertheless, high cost of enzymes and their narrow operating
temperature window present obstacles to applying the approach to other classes of polymers
beyond the relatively more biodegradable polyesters.
In addition to enzyme-based methods for degrading (or deconstructing) polymers,
chemical methods of breaking down polymers either involve the use of chemicals or high
temperatures. Susceptibility to hydrolysis, for example, facilitates the recovery of polyols and
organic acids monomers from polyesters; thus, opening up the possibility of using chemical
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(water or alkaline)-induced depolymerization for recycling plastics. On the other hand, high
temperatures have also been used - for example, in fast pyrolysis - for inducing the thermal
degradation of otherwise recalcitrant long-chain polymers into smaller molecules. The
obtained products possess properties different from the original polymers, or, as a mixture,
retain a significant fraction of the energy encapsulated within the polymer bonds. For heating
applications, the desired product of pyrolysis is usually liquid oil, which in addition to being
easier to transport, also affords a greater degree of control during combustion. Thus, at least
in the case of generating liquid fuel from plastic waste, the primary advantage of pyrolysis
lies in converting a high energy value mixture whose combustion is difficult to control, to a
substance (usually oil) with good calorific value and, importantly, affords ease of
combustion. One example of pyrolysis involves rapid heating of the plastic mixture to 400 –
500 oC (in the absence of oxygen), followed by rapid cooling, and generates a mixture
comprising methane and oil. The latter component can be further refined into diesel and other
fuels.28
In fact, a table-top pyrolysis device is shown to be effective in producing oil from
plastic waste.28
Nevertheless, the oil obtained needs to be refined before use – a net energy
requiring and greenhouse gas generating process if powered by fossil fuels. Thus, taking into
account the various energy (and sometimes, material) inputs required, liquid fuels derived
from pyrolysis may not be more environmentally sustainable than gasoline, unless the
pyrolysis process is powered by low-carbon renewable energy sources such as solar or wind
power.28
Finally, polyvinylchloride (PVC) plastic waste is not a suitable feedstock for
pyrolysis since the high temperatures required would produce toxic dioxin compounds.28
Thermal recycling
Finally, thermal recycling of plastics fits into the broader approach of recovering
residual material and energy value from waste. Specifically, dwindling supply of virgin
material from natural ores or fossil reserves, coupled with an expanding population with
higher material and energy needs, places enormous pressure on Earth‟s resources. Motivated
by the desire to satisfy increasing need for materials and energy, while partially alleviating
the pressure on Earth‟s finite biodiversity and ecosystem resources, the concept of waste
refinery - a holistic approach of mining the residual energy and material value from various
types of waste - has been advocated, and in some cases, demonstrated to be feasible at least at
the proof-of-concept stage.18
In particular, development of the waste-to-energy concept is
more advanced in developed countries such as U.S., Japan and Europe, and has engendered
the sustainable waste management movement.6 Perhaps the term thermal “recycling” is a
misnomer, since energy is the main product of the thermal route, while the small amount of
residual ash would be either deposited in landfills or used in road construction; however, the
term remains commonly used in the plastic recycling literature. Extraction of energy through
plastic combustion in waste-to-energy (or thermal recycling) facilities eliminates the difficult
(and usually costly) separation step necessary in many plastic recycling methods.
Nevertheless, the concept is not without problems. For example, though plastics have high
energy densities, possible emissions of toxic substances – in particular furans and dioxins –
during combustion presents a significant regulatory barrier to its adoption. Specifically, the
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hazardous compounds typically arise both from the combustion of the polymer and the
multitude of additives present. Thus, the need of installing costly pollution control devices for
mitigating harmful emissions would mean that the waste-to-energy route for handling plastic
waste is likely to suffer from unfavourable process economics.
An emerging trend: up-cycling of recycled plastics
Besides the more common case of using recovered polymers in low-value
applications (i.e., down-cycling), there is an increasing emphasis, within the plastic recycling
field, at “up-cycling” plastic waste by converting them into higher value-added products such
as paramagnetic conducting carbon microspheres,51
carbon nanotubes,52
self-healing thermal
plastics, and biodegradable polyhydroxylalkanoate.53
More important, up-cycling falls under
the broader (and increasingly important) waste to high value product “remanufacturing”
approach. Even recovering the separated polymers as granular particles after precipitation
from polymer-solvent mixtures constitutes a form of up-cycling. Specifically, with high
surface area to volume ratio, hierarchical porous structure, and ease of packing within process
vessels, the recovered polymer, in its new lease of life as spherical particles, present myriad
application possibilities ranging from filler in impact-resistant materials to adsorbents for
wastewater treatment. Additionally, spherical polymeric particles are also more compatible
with existing polymer fabrication equipment such as those used in melt-extrusion or injection
molding.
Another example of up-cycling is the generation of microspheres through pyrolysis of
waste PET in supercritical carbon dioxide at 650 oC for 3 hours, followed by vacuum
annealing at 1500 oC for 0.5 hour.
58 Nevertheless, depending on process configurations and
operating strategies, the high temperature required meant that the approach‟s environmental
sustainability hinges on the process‟s overall energy utilization and carbon footprint. For
example, if fossil fuels are used for heating, the process may emit more greenhouse gases
than that arising from producing native PET from petroleum. Another approach uses catalytic
methods for carbonizing polypropylene, polystyrene and polyethylene into carbon nanotubes
suitable for fabricating into supercapacitors with good performance characteristics.13
Post-use
commercial high density polyethylene (HDPE) and regranulated HDPE (containing polyvinyl
chloride plasticizer) have also been converted, by a catalytic pyrolysis reforming process, into
hydrogen and carbon nanotubes.22
On the biological front, fermentation approaches are also
effective in using post-consumer polyethylene as substrates for microbial mediated
conversion into medium chain-length polyhydroxylalkanoate.14
In another study, L-Limonene
is first used as a solvent for precipitating polystyrene waste, and latter, as a monomer (with
polythiol as co-monomer) in ultraviolet light catalyzed thiol-ene polymerization reaction,
which yields a blended material comprising polystyrene dispersed within an elastomeric
poly(thioether) network. Characterization of the new material revealed enhanced mechanical
properties.4
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Beyond “upcycling”, repurposing used plastics with functionalities embedded during
synthesis
Finally, there is an emerging trend towards making polymer-based products more
amenable for reuse in the same or different applications; for example, high performance
cross-linked polymers with different functional groups have been designed and shown to be
easily repurposed through temperature-induced reshaping.39
Such repurposing (without
chemical treatment) approaches should be differentiated from the upcycling methods
mentioned above since the application versatility of the polymer is designed and “built-in”
prior to its production. In comparison, up-cycling, though more desirable that downcycling,
aims to move recovered polymers to higher value applications through targeted treatment
steps, which may yield recovered polymers of differing quality and properties depending on
the extent of damage of post-use plastics and the presence of other contaminants. Similar to
up-cycling, there are many different ways of repurposing plastics that lies on the continuum
from simple direct re-deployment of used plastics to an available application (e.g., using post-
use plastics as adsorbents in wastewater treatment) to more sophisticated re-use applications
such as the thermal re-shaping example described above, that require specific functionalities
to be “encoded” within the polymer at the synthesis stage. In the case of repurposing used
plastic as adsorbents for removing pharmaceutical and personal care products (PPCPs) from
wastewater, the plastic adsorbent and the adsorbed PPCPs can be incinerated for energy
recovery upon exhaustion of sorption capacity.24
Though conceptually feasible and attractive
given the use of a waste material for removing potentially deleterious chemicals from the
environment, practical implementation of the proposal may require further research
examining possible emission products during incineration of the PPCP laden plastics
adsorbents.
Factors affecting the choice of recycling methods
In general, no method is applicable for all situations and localities and the choice of
the recycling method depends on the social and economic realities in each locality.54, 55
Additionally, the environmental performance of the plastic recycling process should be
carefully scrutinized56
using a life cycle assessment (LCA)40
approach, which, in essence, is
an environmental performance audit that takes into account all the material and energy flows
of various processing steps. The LCA method can also be integrated with other modeling
approaches such as input-output analysis or material-flow analysis to gain both a static and
dynamic picture of energy and material cycling within plastic processing operations. Wide
variation in the assumptions used in conducting the audit, however, has hampered efforts
aimed at comparing the environmental performance of different recycling approaches for the
same polymer across studies. Finally, the selection of the recycling method also depends on
the characteristics of the plastic waste such as its source, degree of compaction and extent of
contamination by other types of waste.
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Commingled post-use plastic waste: A challenging waste stream
An analysis of the various sources of plastic waste in a typical city would reveal that
post-consumer commingled plastic waste is a particularly challenging waste stream given its
high degree of compaction and possible contamination with other types of waste material
such as paper, metals and yard waste. Studies have shown that the six principal types of
polymers found in municipal solid waste are PS, LDPE, HDPE, PP, PET and PVC,50, 59
which together accounts for up to 95% of plastic waste.60
Given the commingled nature of
municipal post-consumer plastic waste, the recycling method chosen should be able to
selectively separate various polymer types from a highly compacted waste source.
Additionally, the process should be amenable to cost-effective scale up for handling the large
volume of plastic waste typical of mid-sized cities with substantial commercial and industrial
activity. A candidate recycling method capable of tackling such a waste stream is selective
dissolution and precipitation (SDP).
Selective dissolution and precipitation for polymer recovery
Briefly, the SDP process entails the separation of a mixture of polymers, in a defined
sequence, through addition of different solvents, or progressive temperature variation. Such
an approach selectively dissolves specific polymer types from a plastics mixture, where a
polymer-solvent solution containing the dissolved polymer would be formed, and separated
from the remaining undissolved polymers through simple filtration. Specifically, the
mechanistic underpinnings of the approach lies in the existence of distinct dissolution
temperature for particular polymer-solvent pair.34
Although possibility exists of using
different solvents for dissolving specific polymers present in the waste mixture, the higher
process cost associated with utilizing different solvents (and associated sample workup) and
resulting increased risk of contamination meant that progressive temperature variation (either
increasing or decreasing) is the common approach used in SDP. Viewed from a different
perspective, using an energy separating agent such as temperature would generally lead to
less cross contamination (and thus, higher purity of recovered polymer) relative to using
different solvents as mass separating agents. As will be discussed later, a linearly increasing
temperature profile is generally preferable to a decreasing one since the total mass of plastic
waste cum solvent mixture requiring heating gradually decreases with dissolution of different
polymer; thereby, helping reduce energy use, greenhouse gas emissions and the
environmental footprint of the process. Thus, assuming an increasing temperature profile, the
temperature would progressively increase to the next set-point at which the next polymer in
line would dissolve in the solvent, leading to the formation of distinct polymer-solvent
solutions. Recovery of the dissolved polymer from the polymer-solvent solution occurs
through the addition of a suitable anti-solvent for inducing polymer precipitation – which
typically yields spherical granules as this is the geometrical form with the lowest surface
energy.34
Thus, moving down the dissolution sequence with temperature variation (or, less
common, solvent change) would help separate and recover the different polymer types in a
plastic waste mixture.
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Selectivity of the SDP technique accrues to the existence of a unique temperature at
which a given polymer would dissolve in the chosen solvent. In general, high separation
selectivity could be achieved through a judicious choice of dissolution temperature and
solvent. Given the large variety of polymers present at varying relative abundances in typical
municipal and industrial plastic waste, “broad spectrum” solvents capable of dissolving a
variety of polymers at different dissolution temperatures would provide the necessary process
flexibility in tackling the anticipated batch-to-batch variation in plastic waste composition.
Doing so would also help reduce the number of solvents needed for separating a particular
waste mixture given the cost and process complexity associated with implementing mid-
sequence solvent change. Nevertheless, existence of unique dissolution temperatures enabling
the selective dissolution of individual polymer types in the chosen solvent will remain the key
criterion in solvent selection.
Based on studies in the literature, p-xylene and N-methyl pyrrolidone (NMP) are good
solvents for the SDP process. Similarly, 1-propanol is useful as an anti-solvent for
precipitating the dissolved polymer obtained in the first step of SDP.71
Specifically, many
studies in the literature document the utility and effectiveness of p-xylene and NMP in
dissolving a variety of native polymers such as PS,72
HDPE, LDPE,67
PET,61, 69
and PP49
in
single component recycling experiments. More recently, an interesting study demonstrates
the utility of using D-limonene as solvent for recovering polymers in SDP. Specifically, the
solvent is capable of dissolving polymers with high solubility and selectivity at ambient
conditions. More important, D-limonene can be recovered via vacuum distillation, and in
leaving a high purity polymer product behind, obviates the need of using an anti-solvent for
precipitating the dissolved polymer.
Advantages of SDP
Unlike in thermal or feedstock recycling where the plastic waste is converted to
energy and monomers, respectively, the ability to recover the original polymer is the key
advantage of SDP, which helps preserve the energy within the polymer‟s covalent bonds.61
Specifically, in removing the need for re-polymerization (such as in feedstock recycling),
SDP helps achieves significant savings in energy and material. Nevertheless, deconstructing
polymers into monomers (i.e., feedstock recycling) does offer greater application versatility,
particularly, in allowing the production of new polymer types (such as block copolymers)
from recovered monomers, which serve as modular building blocks. Additionally, compared
to most chemical/feedstock recycling methods, the SDP process is also capable of operating
at relatively low temperature and pressure,40, 45
which helps reduce the greenhouse gas
emissions and environmental footprint of plastics recycling. Depending on the solvent used,
SDP has also been shown to effect good dissolution of polymers from plastic waste at
ambient temperature and pressure. The ability to recover the solvent and anti-solvent via
distillation – and recycling them within the process - is another critical advantage of SDP,
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which helps reduce the need for large volumes of make-up solvent and anti-solvent.34
More
important, an intrinsic advantage of SDP over other mechanical recycling methods is its
ability to handle commingled plastic waste without any presorting. Polymers with physical
and chemical properties comparable to native ones are also recovered by SDP as shown by
analysis of the recovered polymers via a variety of instrumental analysis methods such as
Fourier transform infrared (FTIR) spectroscopy, differential scanning calorimetry and
viscosimetry. Additionally, FTIR spectroscopy also reveals that the characteristic peaks of
the recovered polymer are similar to those of native polymers, which indicates that the
polymers recovered by SDP are, in general, of good purity. Finally, SDP, together with
density flotation, can constitute a two-step separation method. Specifically, density flotation
could be used to first perform a coarse separation between groups of polymers with
significant density differences, while SDP could be subsequently deployed for performing a
fine-grained separation between polymers with smaller density differences. Although
theoretically feasible, the additional capital and operating costs associated with such a two-
step separation approach meant that single-step separation process – when feasible – would
always be preferable.
Disadvantages of SDP
As mentioned, possible leaching of additives from the polymers during the dissolution
step is one important drawback of SDP since additives help endow polymers with important
properties such as resistance to oxidation.34, 62-64
Nevertheless, since the recovered polymers
are unlikely to be used in the same applications as the original polymers, the loss of the
additives may even help facilitate the subsequent redeployment of the recovered polymers in
alternative applications where other additives are needed. On the other hand, there are also
cases where re-introduction of additives is not needed; for example, employing recovered
polymers as adsorbents for removing heavy metals and organic compounds from
wastewater.65, 66
Importance of dissolution sequence to SDP process design
Given that the dissolution sequence critically impacts on achievable purity and
percentage recovery of various polymers from the plastic waste mixture, its determination is
de rigueur in SDP process development. With various combinations of solvent, temperature
and their sequence of use existing within the operating envelope, determination of dissolution
sequence is also an area of creative process design. In general, the operating conditions (e.g.,
dissolution time, temperature, extent of mixing, type and concentration of solvent and anti-
solvent used, precipitation and filtration conditions) obtained from the single polymer
dissolution and precipitation studies would allow us to construct a dissolution sequence for
the progressive separation of the various polymer types in a plastic waste mixture.
Nevertheless, such an approach necessarily entails an important caveat: i.e., there would only
be small cross-interaction effects between different polymers (particularly those adjacent in a
14
sequence) on dissolution temperature and percentage recovery. Compared to few component
plastic waste mixture simulated using native polymers, determining the dissolution sequence
and other process parameters for actual post-consumer plastic waste is significantly more
difficult. Specifically, post-use plastics waste comprises other contaminants and the polymers
experienced varying levels of degradation during use, which, together will lead to
unpredictable effects on SDP selectivity and percentage recovery, and batch-to-batch
variation in process performance.
Criteria for evaluating SDP process efficiency
One of the key criteria for assessing the effectiveness of SDP in recovering waste
polymers is percentage recovery. In particular, percentage recovery is usually defined as the
percentage of polymer recovered from the original waste on a mass basis - assuming that
additives, fillers etc. only constitute a small fraction of the total mass and can be neglected.
Besides percentage recovery, selectivity is another important criterion for evaluating process
feasibility and efficiency. Universally applied in analyzing performance of separation
processes, selectivity is defined as the extent in which a sharp (or clean) separation exists
between two adjacent polymers in a dissolution sequence. Since SDP relies on selective
dissolution of individual polymer type for affording high polymer purity and percentage
recovery, determining the dissolution conditions for selective recovery of different polymers
is essential for process development. Nevertheless, clean separation between two polymers
with similar properties – though desired, is often difficult, and, in certain cases, unattainable,
given that co-dissolution of two or more types of polymers at a particular dissolution
condition might occur. Finally, though differences in dissolution temperatures between
polymer types offer opportunities for using a linear temperature profile to progressively
separate different polymers in a mixture, presence of additives and other impurities may
narrow or obviate the differences in dissolution temperatures; thereby, leading to the co-
dissolution of polymers which would otherwise be cleanly separated.
An increasing or decreasing temperature profile?
The SDP technique can be implemented either via an increasing or decreasing
temperature profile, but given the high specific heat capacity of most solvents and concerns
over the environmental footprint (i.e., greenhouse gas emissions) of heating large volumes of
solvent-cum plastic waste mixture, which profile is more environmentally friendly? The
answer depends, in large part, on the plastic waste composition: i.e., relative abundance of
high and low dissolution temperature polymers. Specifically, an increasing temperature
profile is more sustainable if a larger fraction of the plastic waste comprises high dissolution
temperature polymers, where progressive dissolution of different polymers meant that less
energy is required to heat the remaining polymers with higher dissolution temperatures.
Additionally, from a sustainability perspective, the requirement of heating the plastic waste
mixture to temperatures of more than 100 oC would, depending on the specific heat capacities
15
of the polymers and solvents, results in high energy consumption and a large carbon
footprint. Thus, practical application of the technique may involve the coupling of waste heat
generated during incineration of municipal solid waste to SDP.
What does the future portends for SDP?
Thus far, many studies have been reported on using SDP for recycling low density
polyethylene (LDPE),67
high density polyethylene (HDPE),68
polypropylene (PP),49
polyethylene teraphathlate (PET),61, 69
polystyrene (PS),70
and the separation of a mixture of
LDPE and PP.71
Nevertheless, the aforementioned studies are predominantly proof-of-
concept experiments utilizing native polymers (purchased from chemical companies) for
demonstrating the feasibility of using SDP in one-component polymer recycling. Hence, a
knowledge gap exists in examining the feasibility of using the SDP technique for recycling
various common polymers (e.g., PS, LDPE, HDPE, PP, PVC and PET) in actual plastic
waste. Currently, lab-scale plastic recycling experiments typically simulates a particular type
of polymer waste using plastic material with that specific polymer type dominating the
material composition. For example, PET mineral water bottles are commonly used to
simulate PET plastic waste. Nevertheless, differences exist between actual plastic waste
collected from municipal sources and simulated waste – particularly in the amount of
polymer degradation after use, polymer particle size, degree of contamination with other
waste etc. Thus, moving forward, validation of the SDP approach necessitates the
demonstration of the technique‟s utility and effectiveness in enabling good recovery of
polymer with high purity and desirable material characteristics from actual post-use plastic
waste mixture. Upon demonstration of both the feasibility and effectiveness (i.e., purity and
recovery yield) of SDP in recovering polymer from single component plastic waste, further
studies can be conducted to evaluate the effectiveness of the approach in recovering polymers
from multi-component plastic waste. Finally, although lab-scale studies help us gain a better
understanding of the various operating conditions (such as types and concentrations of
solvents, anti-solvents, and dissolution temperatures) important for employing SDP in
polymer recycling, a significant gap remains between bench-scale experiments and industrial-
scale implementation of SDP for recycling heterogeneous, multi-component and highly
compacted plastic waste obtained from myriad sources. Hence, larger studies (such as those
at the pilot-plant scale) are critical for validating observed effectiveness of laboratory scale
implementation of SDP, and provide a window into the potential economic viability of SDP
in municipal scale plastic recycling.
Conclusions
Society‟s reliance on plastics for a variety of applications has generated challenging
disposal and environmental sustainability issues – but is the way forward the total elimination
of plastics use? Considering the many practical benefits and conveniences that plastics has
afforded us – a visible example of which is the significant reduction in weight of cars, which
16
enables the production of more spacious vehicles with the same mass – and the tight
integration of the material in our daily life, eliminating the use of this highly beneficial
material is almost impossible. Despite much effort by municipalities around the world in
promoting or encouraging waste recycling, plastic recycling rates have remained
unsatisfactory (though with small incremental increases over the years) in cities and countries
around the world, due primarily to low take-up by the populace. While the socioeconomic
factors that hinders the more widespread adoption of recycling by society is beyond the scope
of this article, attempts at increasing recycling rates should focus on education as the
inculcation of the practice in the young would help embed the practice within the social
fabric. Naturally, media campaigns and other initiatives (such as making pre-sorting of plastic
waste easier) are positive in nudging the adult population towards incorporating the practice
of recycling into their daily life – and which may help inch recycling rates upwards. But more
can and should be done. From a technical perspective, the requirement of pre-sorting plastic
waste prior to downstream recovery processes such as chemical and feedstock recycling –
and the generally lukewarm response to large-scale city or region-wide initiatives aimed at
promoting the self-sorting of plastic waste – meant that, at present, the low fraction of pre-
sorted plastic in the waste stream remains a significant problem hampering plastic recycling.
While various plastic recycling approaches such as chemical/feedstock and thermal recycling
helps deconstruct used plastics into monomers and energy, respectively, mechanical recycling
is the only approach capable of recovering the polymer; thereby, expediting the re-use of the
polymer in the same or different applications. When coupled with recent advancement in up-
cycling approaches – where conversion of recovered polymers into higher value-added
products provide a new lease of life to an otherwise “waste” material, mechanical recycling
of polymers such as that effected by selective dissolution and reprecipitation (SDP) offers a
tantalizing opportunity for expediting the cycling of the material and energy loop associated
with plastics use. Being able to accept commingled (i.e., not pre-sorted) plastic waste as
feedstock, SDP also circumvents an important conundrum hampering the wider adoption of
many plastic recycling approaches. Although leaching of additives during dissolution results
in some material degradation of the recovered polymers, and use of non-optimal dissolution
conditions as well as solvent and anti-solvent choice introduces process inefficiencies, the
technical challenges are not insurmountable, given that methodologies for generating the
requisite solutions are available. Demonstrated to be effective in recovering polymers from
single or few-component plastic waste with high selectivity and recovery, the next logical
step for future research is the examination of the utility of SDP in recovering polymers –
suitable for high value-added applications – from complex, multi-component post-use plastic
waste mixture.
17
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