CREAToR achieved progress in the following areas:
• Online and offline identification and sorting of FR-containing polymers
The focus was LIBS technology, however mid-wave infraded spectroscopy, XRF and GC-MS were also used to analyse the BFR contamination of waste.
A LIBS pilot line was set up, showing its potential as an identification tool to be combined in recycling lines with float-sink technology, electrostatic sorting or dismantling processes, to separate BFR-contaminated waste streams. Valuable insights were obtained with models based on partial least square regression algorithms for the automated inline recognition and classification of BFR-containing plastic waste.
The potential of mid-wave infrared spectroscopy for the polymeric detection of technical plastics was also evaluated. Furthermore it was concluded that a combination of XRF and GC-MS-analysis can ensure compliance with all regulations.
• Material purification to remove FRs
The extractive extrusion process using scCO2 and NADES in extrusion was tailored to remove BFR contaminants. Suitable extraction materials were selected depending on the polymer matrix and the FR to be removed. CREAToR removed up to 99 % of BFRs from the waste stream in the state-of-the-art batch process within several hours, and up to 50 % in the extractive extrusion within minutes.
• Reusing the generated secondary raw materials
CREAToR developed new FR recipies to replace legacy FRs with eco-friendly but still economically viable substitutes.
It also showed that the recycled, purified materials can be reused in new industrial applications. EPS-based insulation panels were processed to construct a demonstrator wall, automotive interior parts were injection moulded in a 3D geometry with the aesthetic appearance demanded in this sector, and 3D printing filaments were developed with and without FRs and processed into aeronautic fairings and cable clips.
• Optimised logistics concept
CREAToR developed a reverse cycle design and evaluation method for reverse cycle logistics. The method considered all processes and coordination mechanisms needed for the transportation and storage of materials and information flows within the network. Despite its theoretical foundation, it allows an operational derivation of a specific logistics concept for an individual reverse cycle network. Case studies showed the model’s feasibility for the strategic set up of a recycling process, including the selection of the recycling site and process equipment.
• Creating a harmonised classification of the material purity
CREAToR introduced a smart labelling system indicating the components of the (purified) waste streams and linking them with material properties. It includes information on the material’s mechanical properties and its purity from hazardous substances.
Potential impacts:
The project results firstly impact the sectors represented in the consortium (construction, aerospace and automotive, recycling and recycling machinery).
Until CREAToR, it was not commercially viable for recyclers to market any fraction arising from FR polymers, due to the uncertain properties of polymer waste and the likely presence of hazardous substances.
CREAToR demonstrated routes to reliably identify the presence of hazardous substances, to remove them, and to provide a high-quality secondary raw material for new industrial applications.
A clear environmental impact is that less material will be landfilled and/or incinerated. This was validated in the LCA on the identification, sorting and purification process stream.
CREAToR’s targeted social impact is the creation of > 4 500 EU jobs in the short term. As it comprises partners from the whole value chain, a simultaneous market push and market pull will be created, strengthening the collection, purification and sustainable reuse of secondary raw materials.
Through CREAToR, more secondary raw materials will be implemented in products, and also labelled and certified as such. This will support public acceptance of recycled plastics, and generate trust in the purification systems developed. Overall, CREAToR will help generate a market pull and also a public demand for reused materials, closing the loop into the circular economy and hence contributing to the EC’s circular economy roadmap.
CREAtoR’s policy brief specifies policy recommendations but also research and innovation needed to enable a circular economy in plastics.
