Periodic Reporting for period 1 - SURPASS (Safe-, sUstainable- and Recyclable-by design Polymeric systems - A guidance towardS next generation of plasticS)
Reporting period: 2022-06-01 to 2023-11-30
Plastic waste outlive us on this planet as they take centuries to break down. The hazard of endocrine disruption by leached substances, fast growing and pollution of land, air and water as well as greenhouse gas emissions are only some of the adverse effects of plastic waste on public and environmental health. Still, 70% of plastic waste collected in Europe is landfilled or incinerated.
The aim of SURPASS project is to lead by example the transition towards more Safe, Sustainable and Recyclable by Design (SSRbD) polymeric materials.
The SURPASS consortium of 13 partners develops SSRbD alternatives with no potentially hazardous additives through industrially relevant case-studies targeting the three sectors representing 70% of the European plastic demand:
- Building: bio-sourced polyurethane resins with enhanced vitrimer properties to replace PVC for window frames
- Transport: lightweight, therefore less energy-consuming epoxy-vitrimer, as alternative to metal for the train structure, anticipating emerging use of non-recyclable composites.
- Packaging: MultiNanoLayered films involving less compatibilizers to replace currently non-recyclable multi-layers films.
Along with the development of innovative materials, the project optimize reprocessing technologies adapted to the new SSRbD systems to support the achievement of ambitious recyclability targets.
The project is also developping a scoring-based assessment to guide material designers, formulators and recyclers to design SSRbD polymeric materials, operating over the plastic’s entire life cycle, including hazard, health, environmental and economic assessment.
All the currently generated data and the associated relevant methodologies will be made accessible on a digital infrastructure.
SURPASS address in particular its results to SMEs and has an outstanding potential to contribute to the transition towards green economy.
The aim of SURPASS project is to lead by example the transition towards more Safe, Sustainable and Recyclable by Design (SSRbD) polymeric materials.
The SURPASS consortium of 13 partners develops SSRbD alternatives with no potentially hazardous additives through industrially relevant case-studies targeting the three sectors representing 70% of the European plastic demand:
- Building: bio-sourced polyurethane resins with enhanced vitrimer properties to replace PVC for window frames
- Transport: lightweight, therefore less energy-consuming epoxy-vitrimer, as alternative to metal for the train structure, anticipating emerging use of non-recyclable composites.
- Packaging: MultiNanoLayered films involving less compatibilizers to replace currently non-recyclable multi-layers films.
Along with the development of innovative materials, the project optimize reprocessing technologies adapted to the new SSRbD systems to support the achievement of ambitious recyclability targets.
The project is also developping a scoring-based assessment to guide material designers, formulators and recyclers to design SSRbD polymeric materials, operating over the plastic’s entire life cycle, including hazard, health, environmental and economic assessment.
All the currently generated data and the associated relevant methodologies will be made accessible on a digital infrastructure.
SURPASS address in particular its results to SMEs and has an outstanding potential to contribute to the transition towards green economy.
Within the first 18 months of the project activities the progress has been substantial. The main focus of the technical activities was on the development of the polymeric systems and their (re)processing.
In parallel, plastics-related EU and National regulatory landscape were analysed and monitored. The operationalization of the SSbD framework to polymeric materials was also an important aspect of the work conducted in RP1.
A preliminary inventory of additives was compiled and will be completed with toxicity data along the project.
In parallel, plastics-related EU and National regulatory landscape were analysed and monitored. The operationalization of the SSbD framework to polymeric materials was also an important aspect of the work conducted in RP1.
A preliminary inventory of additives was compiled and will be completed with toxicity data along the project.
The analysis of the regulatory landscape for the development of SSRbD polymers aims to provide end-users with a comprehensive compilation of current policies and regulations within each industrial sector. The translation of the EC JRC framework was conducted by employing a holistic life cycle approach through the implementation of the Safe-Sustainable-and-Recyclable-by-Design (SSbD) Approach. This SSbD analysis methodology has been applied to three case studies and has been adapted for each specific application and domain.
The SURPASS integrated approach allows to include the JRC SSbD approach in the process design of a new plastic products driven by researchers, including the link between product or material functionality with the innovation process for the development of SSRbD strategies. Recyclability and redesign is a technical function included in the Surpass framework to enable these eco-design issues to be addressed from the earliest stages of product design. Data collection for LCA and LCC has been merged to improve the efficiency and relevance of data collection and analysis. The next step will be to merge this questionnaire with the hazard and exposure data collection questionnaires.
Case study 1: It focuses on developing a sustainable bio-based Polyurethane (PU) formulation for insulating windows, considering factors like bio-based content and viscosity. The successful creation of this formulation is a significant step towards a more promising and eco-friendly future. Notably, LEITAT’s research introduced disulphide bonds for end-of-life reprocessing, while CEA have also achieved a 90% efficiency in infusing activators (reversible and dynamic bonds) to PU powder, creating a vitrimer material for reprocessing. CS1 involves integrating WP2 and task 3.1 where task 3.1 focuses on reprocessing PU material at the end of its life through the incorporation of sulphide bonds during PU manufacturing or creating a PU vitrimer. Initial results from both techniques are satisfactory, but further process optimisation is necessary.
Case study 2: a roadmap has been designed for the development and characterisation of a recyclable composite with improved fire properties with non-halogenated flame retardant additives for the railway sector. Following the work path, three epoxy-vitrimer based, intrinsically recyclable formulations have been developed. Modified with phosphorus-based, non-halogenated, commercial flame retardants, and compatible with the infusion and/or RTM process, they aim to meet the specifications described for the railway sector in terms of thermal, mechanical and fire properties.
Different routes have been proposed for the recycling of the composite, mechanical and chemical recycling. The three epoxy-based formulations developed have the ability to be reprocessed by applying heat and temperature, resulting in a recycled plate with mechanical properties similar to those of the starting resin. Additionally, 2 different ways of chemical recycling of the resin have been studied with the aim of recovering and reusing the initial components of the composite.
Case study 3: a Multinanolayer coextrusion processing campaign was developed, using an initial A/B/A configuration (via a three-layered feedblock). In case of the PE/EVOH blends without compatibilizer, increasing the number of layers between 3 and 65 layers has a positive impact on the mechanical properties and the oxygen transmission rate (OTR); where the 65 layered film showed a maximum value of 2.46 ml/(m².day), falling within the parameters outlined by the SURPASS Project (<10 ml/m².day). Nevertheless, persistent defects adversely affected the final appearance of the multilayer films. Consequently, for future multinanolayer coextrusion trials, a different configuration starting with a five-layered feedblock will be implemented. A pilot line for the continuous decontamination of the end-of-Life MNL was set up with throughputs up to 6,5 kg polymer and 4,5 kg supercritical CO2. First trials showed effective extraction of NIAS from the polymer processing of reducing the volatile organic compounds VOC resulting from degradation products by 87% for the PE/LLPE-g-MA/PA system and by 82% for the PE/LLPE-g-MA/EVOH system and a reduction of FOG resulting from degradation products by 79% for the PE/LLPE-g-MA/PA system and by 64% for the PE/LLPE-g-MA/EVOH system.
The SURPASS integrated approach allows to include the JRC SSbD approach in the process design of a new plastic products driven by researchers, including the link between product or material functionality with the innovation process for the development of SSRbD strategies. Recyclability and redesign is a technical function included in the Surpass framework to enable these eco-design issues to be addressed from the earliest stages of product design. Data collection for LCA and LCC has been merged to improve the efficiency and relevance of data collection and analysis. The next step will be to merge this questionnaire with the hazard and exposure data collection questionnaires.
Case study 1: It focuses on developing a sustainable bio-based Polyurethane (PU) formulation for insulating windows, considering factors like bio-based content and viscosity. The successful creation of this formulation is a significant step towards a more promising and eco-friendly future. Notably, LEITAT’s research introduced disulphide bonds for end-of-life reprocessing, while CEA have also achieved a 90% efficiency in infusing activators (reversible and dynamic bonds) to PU powder, creating a vitrimer material for reprocessing. CS1 involves integrating WP2 and task 3.1 where task 3.1 focuses on reprocessing PU material at the end of its life through the incorporation of sulphide bonds during PU manufacturing or creating a PU vitrimer. Initial results from both techniques are satisfactory, but further process optimisation is necessary.
Case study 2: a roadmap has been designed for the development and characterisation of a recyclable composite with improved fire properties with non-halogenated flame retardant additives for the railway sector. Following the work path, three epoxy-vitrimer based, intrinsically recyclable formulations have been developed. Modified with phosphorus-based, non-halogenated, commercial flame retardants, and compatible with the infusion and/or RTM process, they aim to meet the specifications described for the railway sector in terms of thermal, mechanical and fire properties.
Different routes have been proposed for the recycling of the composite, mechanical and chemical recycling. The three epoxy-based formulations developed have the ability to be reprocessed by applying heat and temperature, resulting in a recycled plate with mechanical properties similar to those of the starting resin. Additionally, 2 different ways of chemical recycling of the resin have been studied with the aim of recovering and reusing the initial components of the composite.
Case study 3: a Multinanolayer coextrusion processing campaign was developed, using an initial A/B/A configuration (via a three-layered feedblock). In case of the PE/EVOH blends without compatibilizer, increasing the number of layers between 3 and 65 layers has a positive impact on the mechanical properties and the oxygen transmission rate (OTR); where the 65 layered film showed a maximum value of 2.46 ml/(m².day), falling within the parameters outlined by the SURPASS Project (<10 ml/m².day). Nevertheless, persistent defects adversely affected the final appearance of the multilayer films. Consequently, for future multinanolayer coextrusion trials, a different configuration starting with a five-layered feedblock will be implemented. A pilot line for the continuous decontamination of the end-of-Life MNL was set up with throughputs up to 6,5 kg polymer and 4,5 kg supercritical CO2. First trials showed effective extraction of NIAS from the polymer processing of reducing the volatile organic compounds VOC resulting from degradation products by 87% for the PE/LLPE-g-MA/PA system and by 82% for the PE/LLPE-g-MA/EVOH system and a reduction of FOG resulting from degradation products by 79% for the PE/LLPE-g-MA/PA system and by 64% for the PE/LLPE-g-MA/EVOH system.