Engineering Polymer Recycling Solutions - CarE-Service project · 2020. 12. 11. · Brief...

EXPLOITATION WEBINAR

Engineering Polymer Recycling

Solutions

9th December 2020

Riccardo Galeazzi

Susanna Caprotti

Claudio Ghilardi

Agenda

1. RadiciGroup High Performance Polymers. Brief introduction

2. Development of engineering polymer recycling solutions

3. Environmental impact assessment

4. Recycled material usage: from characterization to real application

RadiciGroup High Performance PolymersBrief introduction

V I S I O NGrowth through Innovation,

with a focus on speciality products,

mainly based on polyamide grades.

Sustainability commitment

along our entire

production chain.

FA C T S

Main Brands:

Vertically integrated production of

PA 6 Radilon® S, PA 6.6 Radilon® A,

PA 6.10 Radilon® D, PA 6.12

Radilon® DT and copolymers.

Worldwide production and sales

network. Manufacturing footprint in

Europe, Americas and Asia.

Complete range of materials

available in all countries, including

high performance products and

special custom grades.

Our people's expertise and support for the development of new applications

and solutions on a global level. We consider our approach to innovation as a

competitive advantage – from CAE design to product development.

Our commitment to sustainability

We support the circular economy. Our

15-year-old commitment to sustainability

is embedded in the RadiciGroup Mission

set down back in 2000.

Is it possible ?

Solution development stages

Preliminary

study

Component

selection and

pre-treatment

evaluation

Formulation

tuningScale-up

Environmental

impact

assessment

(LCA)

and

demonstration

phase

70%

Product definition by material source

Intermediates,

polymers

Finished product:

Prime material

Polymerization,

textile and

manufacturing

scraps

Finished product:

Post-industrial recycled material

Preliminary

treatments

Recompounding

End-of-life cars

or other EOL sources

Finished product:

Post-consumer

recycled (PCR)

material

Engineering

polymer

components

VIRGIN MATERIAL POST-INDUSTRIAL POST-CONSUMER

Development of engineering polymer recycling solutions

FINAL GOALS

The expected results are:

• First, controlling (limiting) the property variability of the post-consumer recycled material.

• Second, preserving material performance or trying to increase it (even better).

Formulation Tuning of

Post-Consumer Material

Reduce

Variability

Preserve/Increase

Performance

Ma

teri

al P

rop

ert

y

Prime

Material

Post-Industrial

Material

Post-Consumer

Material

Mean

Lower Limit

Upper Limit

Legend

Post-Industrial

Applications

Prime

Applications

Post-Consumer

Applications

• Third, assessing the economic sustainability of the post-consumer recycling process.

Development of engineering polymer recycling solutions 1/4

METHODOLOGY Dismantling, Cleaning and Selection

3 - Cleaning 2 - Polymer selection, and metal separation.

Visual

technique

1- Dismantling*

*Many other polyamide components were dismantled from cars, while measuring the effort required in

terms of “Time Spent“. The selected components had a better ratio between weight or polymer quality

and time spent (refer to Deliverable 1.2 – Deliverable 3.2 – Deliverable 5.3).

Components* Quantity

External door handle ≈ 30kg

Cooling fan 5 units

Rear wiper ≈ 30kg

Wheel covers ≈ 30kg

Engine cover 5 units

Radiator tank 5 units

Airbags ≈ 30kg


METHODOLOGY Formulation tuning

6 - Oven drying

9 - Production (extrusion)

8 - Formulation tuning Post-

consumer materials produced are:

- 18 scouting materials- 6 reference materials

7 - Lab analysis of raw materials:- FTIR (Fourier-transform infrared spectroscopy)

- DSC (Differential scanning calorimetry)

- Ashes

- Viscosity

5 - Metal

separation*

*These activities were conducted in collaboration with STIIMA-CNR.

4 - One-step 6 mm grinder*

24 different

materials

Finished product appearance


METHODOLOGY Pilot results and validation

Here you can see the best results obtained

using airbags and wheel covers as source

materials (PA 6.6 base polymer)

Wheel cover source

Airbag source Rear wiper source

Validated by rear wiper source

(PBT-PET base polymer)


METHODOLOGY Scale-up

1,240 kg of airbags and 1,200 kg of wheel covers were processed by industrial

methods to assess the effects of the process on final properties.

Material production

PA6.6 (GF+MD) 30

Glass Fibre Mineral Filler

Wheel coversPost-Industrial

PA 6.6

AIRBAG SOURCE WHEEL COVER SOURCE

Dilution

Material production

Airbags +

Silicon Polymerization

ScrapYarn Scrap

PA 6.6Base

PA6.6 MP1/K

Glass Fibre Additives

PA6.6 GF030/1K

PA6.6 GF050

PA6.6 GF25 HF


METHODOLOGY Results

This material, still in the scouting phase, is PA 6.6, with 30% glass fibre, thermal

stabilizer and black colour, produced using airbag source.

5 repetitions performed for each case at 23°C – RH 0%

The cotton stitching obstructed

the extruder filter.

The procedure to replace the filter took

into account the material loss. The

extruder had to be stopped and opened.


METHODOLOGY Results

This material, still in the scouting phase, is PA 6.6, with glass fibre, mineral filler

and black colour, produced using wheel cover source.

5 repetitions performed for each case at 23°C – RH 0%

Inclusion of extraneous material from

chromium plating can be seen. This

could be a problem for processing and

structural applications. Applications

should be selected carefully.

Demonstration phase - Ongoing

Can the recycled materials designed in this project be used to produce real

components?

INJECTION MOULDING TRIALS 3D PRINTING TRIALS

Agenda

1. RadiciGroup High Performance Polymers. Partner introduction




The Eco-design strategy wheel. (Source: Brezet and van Hemel 1997: 81)

assessment of policies (models for

recycling, etc.)

substance and material flow analysis; hazard

and risk assessment of chemicals

risk analysis and risk management of

facilities and plants;

product stewardship, supply chain management

inclusion of environmental aspects in product

standards, life cycle management

quantification, monitoring and reporting of entity

and project emissions and removals, and

validation,

verification and certification of greenhouse gas

emissions

environmental management accounting, life

cycle costing

LCA (ISO 14040) - A.1 integration of environmental aspects into product design and development (design for environment)

(ISO/TR 14062)

Environmental impact assessment – LCA

Solution development stages

Preliminary

study

Component

selection and

pre-treatment

evaluation

Formulation

TuningScale-up

Environmental

impact

assessment

(LCA)

and demonstration

phase

70%




assessment of policies (models for

recycling, etc.)

substance and material flow analysis; hazard

and risk assessment of chemicals

risk analysis and risk management of

facilities and plants;

product stewardship, supply chain management

inclusion of environmental aspects in product

standards, life cycle management

quantification, monitoring and reporting of entity

and project emissions and removals, and

validation,

verification and certification of greenhouse gas

emissions

environmental management accounting, life

cycle costing

LCA (ISO 14040) - A.1 integration of environmental aspects into product design and development (design for environment)

(ISO/TR 14062)


Product assessment by material source

Data used to assess each unit processed

(product/process) within the systems boundary

(starting from the extraction of raw materials) can be

classified under major headings, as follows:

• Energy inputs, raw material inputs, ancillary

inputs and other physical inputs

• Products, co-products and waste

• Emissions to air, discharges into water and soil,

and other environmental impacts

In environmental law, the polluter pays principle

(PP Principle) has been enacted to make the party

responsible for producing pollution responsible for

paying for the damage done to the natural

environment.

.

Waste is an environmental burden generated by the production of a product.

The impact assessment of a product always includes the environmental “damage” caused by the waste generated

during its whole life cycle, according to the PP Principle.

That’s why products made from “waste” have no environmental burden for raw materials.

Assessing engineering polymer reuse and

recycling solutions

The products made from “waste” are

environmental burden-free ONLY with

respect to raw materials, NOT the

processes needed to make them suitable

for a new life cycle (RECYCLING).

As the new life cycle begins, a new environmental

accounting of:

• Energy inputs, raw material inputs, ancillary inputs

and other physical inputs

• Products, co-products and waste

• Emissions to air, discharges into water and soil, and

other environmental impacts.

begins as well.

The more difficult the waste is to recycle,

the more the environmental impact of the

recycling process increases.

Assessing engineering polymer reuse and

recycling solutions

The higher the expected technical performance of the

recycled product, the higher the complexity of

formulation and process steps to achieve it.

In the Wheel Cover case, after the cleaning and sorting

phase, polymerization scrap or off-spec granule was

added to enhance the properties of the recycled

material.

In the Airbag case, an additional step had to be

performed (dilution), because of the presence of a

conflicting substance, to make the recycled material

suitable for compounding.

Each additional process step performed

and each virgin raw material added is

accounted for in the Life Cycle

Assessment of the recycled product.

Assessing engineering polymer reuse and recycling

solutions – impact assessment Results

This material, still in the scouting phase (not yet available), is PA 6.6 with 20%

glass fibre, 7% mineral filler and black colour, produced using wheel cover source.

Assessing engineering polymer reuse and recycling

solutions – Impact assessment Results

This material, still in the scouting phase (not yet available), is PA 6.6, with 30%

glass fibre, thermal stabilizer and black colour, produced using airbag source.

Key outcomes

› The materials presented here are more sustainable (up to 70-90% CO2

reduction) compared to the corresponding prime grades.

› Does all this compensate for the inevitable material property loss? The right

application must be selected.

› To foster recyclability, ecodesign must take place in the earliest stage of the

life cycle of the components.

› Recycling post-consumer waste is a challenge: the determination, knowledge,

expertise and environmental-orientation of everyone involved in the process is

required.

Agenda

1. RadiciGroup High Performance Polymers. Partner introduction




Performance loss of PCR materials:

Is it an issue?

CAE simulation tools can help design engineers to evaluate and choose the right material for an

application, as well as allow them to redesign the component to compensate for an unavoidable

loss of properties.

Harsh environmental conditions during the working life of components:

Heat ageing, UV rays, chemical action (oil, glycol…), etc.

Do we necessarily need to downgrade the material application?

Property Loss

CAE = Computer Aided Engineering

Many software tools are available to support technicians

and engineers in carrying out numerous tasks.

CAE often refers to software solvers using the FEM (Finite

Elements Method) to solve technical problems numerically

in different fields:

• Structural mechanics

• Kinematics

• Acoustics

• Electrodynamics

• Heat transfer

• Fluid dynamics

• (...)

CAE (Computer Aided Engineering)

CAE simulation at RadiciGroup

•Injection moulding and derived technologies (injection-compression, GAIM, micro-foaming, etc.)

•Flow, packing, cooling and warpage analysis

•Prediction of process-related defects and parameters

Process Simulation

•Static non-linear analysis, multi-body contact, stress and strain field prediction

•Failure prediction, thermo-mechanical effects and long-term behaviour (creep, fatigue)

•Dynamic analysis, impact, natural frequencies

Structural Simulation

•Taking into account process-induced microstructural properties in a structural study

•Anisotropic mechanical behaviour (GF orientation), welding lines, residual stress and warpage effects

•Multiscale and multipurpose material modelling

Integrated approach

Fundamental INPUTs for CAE simulation

An accurate material characterization of recycled grades and modelling their

rheological and mechanical behaviour help the designer to select the most

appropriate engineering applications for the green compounds.

Output = F (Material, Geometry + Mesh, Process Parameters)

F is the solver. The analysts (and material suppliers) are responsible for “feeding” it.

FEM

Solver

Material Characterization

3D Geometry

Boundary Conditions

Simulation ResultsGeometry Discretization (Mesh)

Material characterization: Process

• RADILON A RV300W 333 BK (PA66 GF30 Virgin grade benchmark )

• HERAMID A GF030/1K (PA66 GF30 Post-industrial grade from textile regrind scraps)

• RADILON CARE A GF030 (PA66 GF30 Post-consumer grade from airbags)[*]

• RADILON CARE A GFP3015 (PA66 GF+MD30 Post-consumer grade from wheel covers)[*]

• Rheological Curves

(Viscosity)

• Pressure-Volume-

Temperature (PVT)

• Heat Capacity

• Thermal Conductivity

• Mechanical Properties

EXPERIMENTAL

MEASUREMENTSMATHEMATICAL

MODEL BUILD-UP

MATERIAL CARD

READY FOR VALIDATION

[*] This material is still in the scouting phase (not yet available).

Material characterization: Structural – integrated

• RADILON A RV300W 333 BK (PA66 GF30 Virgin grade benchmark – J2-EP pre-existing)

• HERAMID A GF030/1K (PA66 GF30 Post-industrial grade from textile regrind scraps)

• RADILON CARE A GF030 (PA66 GF30 Post-consumer grade from airbags)[*]

• RADILON CARE A GFP3015 (PA66 GF+MD30 Post-consumer grade from wheel covers)[*]

Tensile experimental data

@ 0°, 30°, 90°

@23°C DAM, 120°C DAM

Microstructure of specimens:

microtomography scan (μCT)

analysis

Micromechanical

material model

J2-EP + Failure Index

TH3D-TI

Reverse engineering

Digimat-MX

calibrating and fitting

the model

to experimental data

Verification

and

Validation

AVAILABLE FOR

ENGINEERING USE!

1st check: ISO527-1A

injected specimen

compliance

2nd check: 4PB “Demonstrator”

beam reproduction

(with Digimat-RP + Marc)

[*] This material is still in

the scouting phase (not

yet available).

Material card validation: Experimental test

• Test configuration:

4PB tests performed by

- “Demonstrator” ribbed beam

injected in 1 head gate

configuration

- Test results (force vs. standoff)

to be compared with FEM

predictions obtained with

previously calibrated models

Material card validation: Results

- Good repeatability for all grades

- Less distance between HER and CARE

030 compared to specimens

- FEM results slightly overestimate stiffness

especially at high warpage

- Failure deflection captured well (except

CARE 030 a little early)

PCR/Airbag

RAD CARE A

GF030 [*]

PCR/Wheel Cover

RAD CARE A

GFP3015 [*]

PIR - HER A GF030/1K


Real application: Gear-motor cover for electric

adjustable desk

Electric Adjustable Desk

Electric Gear-Motor

Cover made of

thermoplastic material

- RADILON A RV300W (PA66 GF30, Virgin Grade)

- RADILON CARE A GF030 [*] (PA66 GF30, PCR Grade)

Simulations and actual injection

moulding process were performed with

the following materials:

Courtesy of

[*] This material is still in the

scouting phase (not yet

available).

Process simulation: Melt flow front

RADILON A RV300W (PA66 GF30, Virgin Grade)

RADILON CARE A GF030 [*](PA66 GF30, PCR Grade)


Process simulation: Warpage – total displacement

RADILON A RV300W (PA66 GF30, Virgin Grade)

RADILON CARE A GF030 [*] (PA66 GF30, PCR Grade)

The PCR material has slightly higher warpage compared to the virgin material, but the

coupling between the two parts is guaranteed.

[*] This material is still in

the scouting phase (not

yet available).

Structural integrated simulation: Set-up

Ft

Fr

Fa

A

Cover

FEM Structural Model Boundary Conditions

GF Orientation (Process

Simulation)Mapping GF Orientation on

Structural Mesh

Structural integrated simulation: Failure index

RADILON A RV300W (Virgin Grade) RADILON CARE A GF030 [*] (PCR Grade)

Failure expected at 10.8 Nm of torque. Failure expected at 10.2 Nm of torque.

Failure is expected when the Failure Index reaches a value of 1.

Section View [1,0,0] Section View [1,0,0]


Injection moulding trials

Moulding Trials @Mould Mould

Opening

Cover Assembly Product Assembly

Yes it is possible!

THANKS FOR YOUR ATTENTION!

www.radicigroup.com

www.careserviceproject.eu

Follow us on:

Acknowledgements

• All third-party images and multimedia used in this presentation are the

property of their respective owners and, where not specifically mentioned

otherwise, are reported here under assumptions of “fair use”.

• Special thanks for valuable support and effective collaboration to:

– All participating colleagues from RadiciGroup High Performance

Polymers

– Angela Iannuzzo and Sandra Cherubini from E-Xstream engineering

– Giorgio Nava from Moldex3D Italy

– Pollini Lorenzo e figli Srl

– IMA GmbH

– Labormet Due Srl

– Luca Avataneo from Electro-Parts SpA

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Engineering Polymer Recycling Solutions - CarE-Service project · 2020. 12. 11. · Brief...

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