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Car plastic fuel tanks closed loop recycling process design and life cycle assessment

Deliverables

The objective of the project was to set up a Value Chain for the recycling of HDPE from used Plastic Fuel Tanks (PFT) back into the original application, with the aim to introduce 40% of the regenerate into the new PFT. Guidelines and tools for dismantling. Fluorinated surface evaluation technology. Fluorinated surface evaluation technology. Surface properties play an important role since one of the main qualities of the final product must exhibit is a good impermeability. This impermeability is achieved by the fluorination of the surface and it is imperative that the recyclate reacts, towards the fluorination, at least as well as the virgin one. The composition of the fluorinated layer and especially the concentration profiles near the surface have to be defined. ARXPS is an appropriate technique to evaluate fluorinated samples.
The objective of the project was to set up a Value Chain for the recycling of HDPE from used Plastic Fuel Tanks (PFT) back into the original application, with the aim to introduce 40% of the regenerate into the new PFT. Guidelines and tools for dismantling. Regeneration Process. A complete regeneration process has been developed and validated. This process includes the following steps: -Shredding (under water spray) and demetallization. -Removal of external coating by water cleaning (a prototype equipment has been built). -Solvent extraction of residual fuels. -Pelletization with repair additive and melt filtration. Conditions for a correct grafting of oxidized HOPE have been optimized. The process has been validated in a pilot plant where several tons of fuel tanks have been treated. Experimental series of PFTs incorporating 20-40% HDPE were manufactured by bow-molding and subjected to fluorination. These PFTs exhibit similar properties as virgin HDPE-based. A technical feasibility study was carried out on the basis of project's results. Basic engineering of a 5kt industrial plant is in progress. The facility would be located on a Watco site in the Netherlands.
The objective of the project was to set up a Value Chain for the recycling of HDPE from used Plastic Fuel Tanks (PFT) back into the original application, with the aim to introduce 40% of the regenerate into the new PFT. Guidelines and tools for dismantling. New Rheological Evaluation Methodology. A new methodology based on extensional viscosity measurements has been proven to be relevant for sagging and blowing evaluations of melt HDPE parisons. From the results of experimental trials, it has been concluded that: -Rheological characterization can differentiate samples of the same HDPE with different thermal and chemical stories. -Re-stabilization and readditivation can bring the rheological properties of recycled HDPE from plastic fuel tanks closer to the ones of virgin HDPE. -By grafting the repair additive developed in the project, viscoelasticity of the recycled material is almost totally recovered.
The objective of the project was to set up a Value Chain for the recycling of HDPE from used Plastic Fuel Tanks (PFT) back into the original application, with the aim to introduce 40% of the regenerate into the new PFT. Guidelines and tools for dismantling. Life cycle impact assessment methodology. New Life Cycle Impact Assessment methodology has been developed. Environmental Uncertainty Assessment (E.U.A.) and data quality methodology developed within the R.E.C.O.R.D. association were adapted to the project case study. The results consist in an improvement of the reliability and traceability of the inventory and its interpretation. The E.U.A. methodology aims at improving the robustness of the impacts interpretation of the LCA study. These methodologies will be applied to internal future LCA studies when appropriate.
The objective of the project was to set up a Value Chain for the recycling of HDPE from used Plastic Fuel Tanks (PFT) back into the original application, with the aim to introduce 40% of the regenerate into the new PFT. Guidelines and tools for dismantling. Fluorinated surface evaluation technology. Fluorinated surface evaluation technology. Surface properties play an important role since one of the main qualities of the final product must exhibit is a good impermeability. This impermeability is achieved by the fluorination of the surface and it is imperative that the recyclate reacts, towards the fluorination, at least as well as the virgin one. The composition of the fluorinated layer and especially the concentration profiles near the surface have to be defined. ARXPS is an appropriate technique to evaluate fluorinated samples.
The objective of the project was to set up a Value Chain for the recycling of HDPE from used Plastic Fuel Tanks (PFT) back into the original application, with the aim to introduce 40% of the regenerate into the new PFT. Guidelines and tools for dismantling. Regeneration Process. A complete regeneration process has been developed and validated. This process includes the following steps: -Shredding (under water spray) and demetallization. -Removal of external coating by water cleaning (a prototype equipment has been built). -Solvent extraction of residual fuels. -Pelletization with repair additive and melt filtration. Conditions for a correct grafting of oxidized HOPE have been optimized. The process has been validated in a pilot plant where several tons of fuel tanks have been treated. Experimental series of PFTs incorporating 20-40% HDPE were manufactured by bow-molding and subjected to fluorination. These PFTs exhibit similar properties as virgin HDPE-based. A technical feasibility study was carried out on the basis of project's results. Basic engineering of a 5kt industrial plant is in progress. The facility would be located on a Watco site in the Netherlands.
The objective of the project was to set up a Value Chain for the recycling of HDPE from used Plastic Fuel Tanks (PFT) back into the original application, with the aim to introduce 40% of the regenerate into the new PFT. Guidelines and tools for dismantling. New Rheological Evaluation Methodology. A new methodology based on extensional viscosity measurements has been proven to be relevant for sagging and blowing evaluations of melt HDPE parisons. From the results of experimental trials, it has been concluded that: -Rheological characterization can differentiate samples of the same HDPE with different thermal and chemical stories. -Re-stabilization and readditivation can bring the rheological properties of recycled HDPE from plastic fuel tanks closer to the ones of virgin HDPE. -By grafting the repair additive developed in the project, viscoelasticity of the recycled material is almost totally recovered.
The objective of the project was to set up a Value Chain for the recycling of HDPE from used Plastic Fuel Tanks (PFT) back into the original application, with the aim to introduce 40% of the regenerate into the new PFT. Guidelines and tools for dismantling. A new tool for fast and efficient fuel drainage has been developed and is now available for dismantlers. This tool is called "Recupcarbu". Corresponding guidelines have been drafted.
The objective of the project was to set up a Value Chain for the recycling of HDPE from used Plastic Fuel Tanks (PFT) back into the original application, with the aim to introduce 40% of the regenerate into the new PFT. Guidelines and tools for dismantling. A new tool for fast and efficient fuel drainage has been developed and is now available for dismantlers. This tool is called "Recupcarbu". Corresponding guidelines have been drafted.
The objective of the project was to set up a Value Chain for the recycling of HDPE from used Plastic Fuel Tanks (PFT) back into the original application, with the aim to introduce 40% of the regenerate into the new PFT. Guidelines and tools for dismantling. Life cycle impact assessment methodology. New Life Cycle Impact Assessment methodology has been developed. Environmental Uncertainty Assessment (E.U.A.) and data quality methodology developed within the R.E.C.O.R.D. association were adapted to the project case study. The results consist in an improvement of the reliability and traceability of the inventory and its interpretation. The E.U.A. methodology aims at improving the robustness of the impacts interpretation of the LCA study. These methodologies will be applied to internal future LCA studies when appropriate.