1. Recycling Automotive Shredder Residue and Plastics using Thermal Depolymerization Process
   G. Kinslow, KBS Consulting-USCAR, T. Adams, Changing World Technologies.
   Shredder residue is a complex mix of many different materials that includes plastics, rubber, glass, metals and other materials such as rocks and dirt. The metal recyclers create this shredder residue mix as part of a recycling process to recover metals. The actual input stream for metal recycling is end of life automobiles, white goods and a variety of other metal intensive parts including industrial scrap waste. This shredder residue is currently landfilled and the European Union has implemented laws to reduce the amount of shredder residue from automobiles that can go into landfills. The Vehicle Recycling Partnership (VRP) is working with different collaborators to evaluate different technologies including automated plastic recovery as a means to reduce the amount of plastics that go to landfill in shredder residue.

   A new technology that is under investigation by the VRP is Thermal Depolymerization that was developed by Changing World Technologies (CWT). CWT has developed a pilot plant at the Philadelphia Navel Business Center in Philadelphia, PA. This process can convert hydrocarbons and organic materials into marketable high-quality, clean fuels and specialty chemicals for industrial and commercial use. The end product (recovered) is partly a function of feedstocks and partly a function of the specific combination of temperature, pressure and residence time utilized. CWT processed a small amount of shredder residue that was supplied from OmniSource Corporation and this paper discussed the results of this initial investigation.

2. From PET Bottle Flakes to Final Products: Product Quality is Determined by Melt Filtration
   Monika Gneuss, Gneuss Inc.
   
   Improvements in the collection systems of PET bottles as well as new legislations present new possibilities for the PET industry. There are a number of products where the substitution of virgin with recycled material makes economic and processing-technical sense, e.g. staple fiber, thermoforming sheet, nonwovens or strapping.

   EACH OF THESE PRODUCTS PLACES REQUIREMENTS ON THE PROPERTIES OF THE RECYCLED PET, WHICH ARE CLOSE TO THOSE OF VIRGIN MATERIAL. APART FROM THE INTRINSIC VISCOSITY AND COLOR/TRANSPARENCY, FOREIGN PARTICLES OR CONTAMINATION IN THE MELT AFFECT THE PRODUCT QUALITY.

   PET bottle flakes are processed into high quality pellets or are added directly to virgin material during the production of final products. Today, direct recycling, the use of 100 % flakes in the manufacturing of end products without the intermediate repelletizing step, is becoming popular. The melt filtration step plays an important role in all these processes and determines the end quality that can be achieved.

   The paper first discusses the technical and economical demands made on a filtration system used in PET bottle flake applications. Then, the fully-automatic Rotary Filtration System is introduced, which is well suited for the processing of bottle flakes. The possibilities it offers for direct recycling are explained. Then, various direct recycling concepts are described. These concepts differ regarding pre-drying, extruder type and demands on the filtration system. The different requirements and solutions regarding the filtration step are explained.

3. USCAR U.S. Field Trial for Automotive Polymer Recycling
   W. Gallmeyer, Gallmeyer Design and Development and Claudia Duranceau, Ford Motor Company
   
   The United States Field Trial was chartered by the United States Council for Automotive Research/Vehicle Recycling Partnership with the objective of evaluating the feasibility and viability of collecting and recycling automotive polymers from domestic End-of-Life Vehicles (ELVs). European concerns regarding vehicle abandonment risks, decreasing landfill capacity, and disposal practices have resulted in the legislated treatment of ELVs in Western Europe. The emergence of attendant material collection schemes promoting material recycling may not apply to the free-market economic conditions prevalent in North America vehicle recycling infrastructure. Although ELVs are among the most widely recycled consumer products, 15-25% of their total mass is currently discarded with no material recovery although their residue, when permitted, is a preferred landfill day cover in some areas. A portion of the vehicle remainder that is polymeric has the most potential for further recycling. In order to determine the potential success of polymeric recovery for further vehicle recycling within the North American recycling market, the United States Field Trial (USFT) was initiated in 1998 with interim documentation in 2000 (SAE 2000-01-0735). With the trial now completed, this paper reports on the entire project. It has identified North American ELV recycling practices, explored ELV plastic material recovery, and studied alternative scenarios for plastic material handling, local transportation, sorting, processing and compounding. Specifically, recovered ABS and PP plastic materials were formulated to OEM specifications and molded using production tooling to establish the viability and economics of the pursuit of these materials as a commercial enterprise. Conclusions indicate that while the materials and parts are acceptable, the economic incentives and altered logistics needed to support this endeavor will not currently be borne by existing North American market economics.
   
4. Utilizing Post-Consumer Polyethylene Fuel Tanks to Create a Thermoplastic Fiber Mat Product
   Claudia Duranceau, Ford Motor Company, W. Gallmeyer, Dallmeyer Design and Development
   
   A research project to determine the feasibility of utilizing polyethylene post-consumer automotive fuel tanks as a source raw material was funded by Visteon and included Exxon/Mobil and Brooks Associates. Brooks Associates launched this project in the last quarter of 2000 to demonstrate the feasibility of utilizing high-density polyethylene (HDPE) post-consumer automotive fuel tanks in combination with wood fiber to create a new material suitable as an automotive substrate. The concept for the project was based on proven technology that processes wood material into fiber utilizing steam explosion. The existing manufacturing method is used to form the wood fiber into a mat, which has been commercially sold as sheet products under the brand names ‘Masonite’, or ‘MDF’. The purpose of this project was to add an equal part of post-consumer polyethylene from automotive fuel tanks to determine the viability of HDPE fuel tanks as a raw material source, the potential usefulness of the end products and the limitations or consequences of the process. Plastic fuel tanks were retrieved from scrapped automobiles and reduced to HDPE chips. These chips were combined with wood from size-reduced, scrap wood pallets, and the mixture was successfully subjected to the steam explosion process. The exploded product was processed into a fiber/PE mat, which was found to be formable into an automotive door panel. Subsequent analysis indicates that the processed plastic/wood combination is free of organic volatiles (residual fuel). The exact makeup of the gasses given off by the ‘explosion’ process that created the fibers is still undetermined. Post-processing of the mat material involved heat and pressure to create specific shapes. The sugars in the wood fiber create a noticeable odor, which would suggest that they are either burning or are combining with other materials. While the final laminate material, may be applicable to products in many fields, automotive interiors would not be appropriate. To be acceptable in new vehicles, the odors created by the final processing heat would have to be eliminated.
   
5. “VacuRema” and Bottle Recycling
   Mike Horroks, EREMA
   
   EREMA have produced lines for recycling PET since early in the 1980's. The original EREMA concept was to make the recycling of light and thin materials such as film and fibres more production/operator friendly and reduce the cost of recycling. Conventional recycling systems were based on pre-cutting of recyclate, often with intermediate storage, followed by stuffing and cramming systems feeding into a standard extruder.

   In this conventional type of system, energy is used and then lost during transport or storage at each stage of the preparation of the material, it can be seen as labour intensive and a good production flow can be difficult to achieve. EREMA designed their system to alleviate some of the problems they felt were common to many conventional processes.

   The concept behind the "classic" EREMA system is that material is fed directly via a conveyor into a large drum (cutter/compactor) containing cutting knives. The cutting knives are mounted on a high speed-rotating disc. In the cutter/compactor the material is cut and pre-heated. The heat is created simply by friction. The cutter/compactor is mounted directly onto the extruder and the preheated material is fed, continuously, direct onto the extruder screw. Feeding onto the screw is very efficient as it is forced onto the screw intake by the high speed rotation created by the cutting disc and knives within the cutter/compactor. As material is taken out of the cutter/compactor new material is fed into the cutter/compactor in order to maintain the level and thus the frictional heat. This is done automatically.

   The majority of the energy used in cutting and heating created through friction is then used in the extrusion process.

   The material is constantly flowing within the cutter/compactor drum allowing for the exposure of a large surface area to heat and drying.

   This allows the EREMA system to be based on short extruders, often with no shear which then can result in less heat history on the recyclate.

   There have been some 2000 " Classic" EREMA systems delivered world-wide.

6. Effects of Regrind/reprocessed Materials on Thermoplastics
   Susan DeGrood, Visteon Corporation
   For optimal use of raw materials and existing/future regulations on recycling, addition of re-processed material in engineered thermoplastics is an on-going practice in the automotive industry. This can take the form of regrind or treated scrap materials. Many considerations must be made as to the handling, re-introduction into the process, and effects on the properties and stabilization of the polymer, particularly in the case where subsequent heating or chemical treatment of the polymer occurs. It is recommended that determination of optimal addition of regrind be done as part of the development of the application and not introduced as an after-thought once production has begun and scrap materials appear. Considerations and guidelines for use of reprocessed material are provided. Suggested testing and evaluation of materials are outlined.

   When additional reprocessing steps are added, such as repelletization or coating removal, the condition and properties of the regrind must be carefully evaluated. The effects must be thoroughly understood, identified and compensated for, if necessary. It may be possible to correlate standard lab testing and long-term material performance to assess the reprocessing effects in order to shorten test time. One potential short-term test method to evaluate stabilizers is the Oxidative-Induction Time of Polyolefins by Differential Scanning per ASTM D3895. Data from use of this method is reviewed and the pros and cons are discussed.

7. Innovative “Green” EMI Shielding Based on Polymer Film Material
   Rocky Arnold, WaveZero
   
   For many years, OEMs and their plastic molder partners have achieved electromagnetic compliance (EMC) by painting or electroplating the inside surfaces of the plastic housing with a metallic material. This approach to EMI shielding is now problematic because of the emergence of the European Union (EU) Waste Electrical and Electronic Equipment (WEEE) Directive.

   From an OEM perspective, the problem is one of designing new electronic products with a high degree of certainty that they will function properly, be compliant with the EU WEEE Directive, and meet stringent U.S. and International electromagnetic compliance requirements.

   A new EMI shield material has been developed which relies upon a designed-in and thermoformed (polymer film) shape that is vacuum metalized to achieve conductivity. The product has been adopted by three major OEMs and more are currently evaluating its performance.

   The resulting product has been shown to be superior to existing techniques for achieving EMC compliant electronic product design and both processes and resulting product are environmentally compliant. Innovative uses for the end-of-life materials were developed thus minimizing waste. The design chain and supply chain efficiencies lower the cost of developing new electronic products.

   This paper will review the development process and discuss the entirely green processes and total recyclability of the final product.

8. Electronics Equipment Plastics Recycling Update: Emerging Opportunities and Challenges
   Darren Arola, Brian Rise, Mike Biddle, MBA Polymers, Inc.
   The economic viability of any electronic equipment plastic recycler’s business is based on finding sources of raw material, employing economical plastics recovery methods, meeting property requirements, developing markets for the products, and selling the plastics. Recycling campaigns, governmental mandates/regulations, and material restrictions (e.g. very low allowable levels of heavy metals) have brought new opportunities and challenges to plastics recyclers. Understanding their impact upon the evolution of the plastics recycling industry is important to policy makers, manufacturers, recyclers, and consumers.

   Over the past ten years, MBA Polymers, Inc. has processed over 12 million pounds of highly mixed plastic-rich streams from a wide variety of post-consumer feedstocks. This has provided MBA with a unique and valuable perspective on the challenges and opportunities in this emerging industry.

   This paper will provide important information on electronic equipment recycling developments over the past few years, and how they’ve impacted plastics recyclers such as MBA Polymers. We will share plastic recovery and reuse success stories and provide recommendations for facilitating increased recovery and reuse of recycled plastics within new electronic equipment and other applications.

9. Study on Recyclibility of In-Mold Decorated Plastics Parts
   D. Schnecke, Motorola – Germany and J. Gunther, Kunststoff Institute – Germany
   
   
10. Updates on End-Of-Life, Safety, and Regulatory Aspects for Flame Retarded Plastics used in Electrical and Electronic Equipment
    R. Dawson and S. Landry, Albemarle Corp.
    End-of-life (EOL) issues for electrical and electronic equipment (EEE) continue to be a major concern throughout the world. Various waste EEE recovery mandates now exist, such as the EU WEEE and California SB 20, with others in the process of developing. Plastics used in EEE applications represent approximately 20% by weight of materials recovered from waste EEE. Since these plastics have a variety of EOL options, a tremendous opportunity exists to recover value from this resource. In addition to EOL concerns, product safety and compliance with regulations are important issues of consideration for EEE.
    This paper is a continuation of previous papers. It will update the safety, worldwide regulatory, and end-of-life concerns for plastics used in EEE. It will examine the effect that particular flame retardants can make toward meeting various demands placed on electrical and electronic equipment.
    
11. Physico-mechanical Properties of “Green” Composites from Polylactic acid (PLA) and Cellulose Fibers
    M. S. Huda, A. K. Mohanty, L. T. Drza, M. Misra, Michigan State University, E. Schut, CreaFill Fibers Corp.
    There is a growing interest in the uses of natural fibers as the reinforcements for biodegradable polymers because natural fibers not only have the functional capability to substitute the widely used glass fibers but they also have advantages from the point of view of the fiber-matrix adhesion, specially with polar matrix materials. In that respect the aim of this study was to make an investigation how polylactic acid (PLA) will act as matrix material for natural fiber composites if natural fibers can be used as reinforcement in polymers based on renewable raw materials. The influence of wood pulp-based cellulose fiber on the mechanical properties of the cellulose fiber-reinforced PLA composite materials that processed by a DSM micro compounding and molding system were studied. Preliminary results show that the mechanical properties of PLA and cellulose fiber composites are promising. The impact and tensile strengths increased with the presence of cellulose content. The thermal behavior of the composites studied by differential scanning calorimetry (DSC) and thermogravimetric analysis (TGA). DSC thermograms of neat PLA and the composites exhibit the glass transition temperature, crystallization temperature and melting temperature at nearly same temperature range. TGA studies indicated the thermal stability of the composites. Moreover, the effect of temperature on the mechanical properties of composite materials was studied with dynamic mechanical analysis (DMA) and the morphology was studied with Environmental Scanning electron microscopy (ESEM). ESEM showed for composite samples that with increasing cellulose contents the existence of the aggregation of cellulose fibers increases. Further, because of the brittle nature of PLA, the compatibilizer for neat PLA and the composites was tested in order to improve the mechanical properties. It was found that wood pulp-based cellulose fiber could be a good candidate for the reinforcement fiber of high performance biodegradable polymer composites. The future work will include efforts to evaluating the biodegradability of these biocomposites.
    
12. Epoxy/Organoclay Nanocomposites Synthesized with Thermal and Microwave Methods
    S. Zhou. A. Wood, K. Boyapati, M. Hawley, A.le, L. Kempel, Michigan State University
    Two epoxy/organoclay nanocomposites were synthesized in-situ with both thermal and microwave heating methods. The epoxy materials are diglycidyl ether of bisphenol A (DGEBA)/ m-phenylenediamine (mPDA) and DGEBA/ diethyltoluenediamine (Epi-cure W). The morphologies of the nanocomposites were studied with X-Ray diffraction (XRD) and Transmission Electron Microscopy (TEM) techniques. Scanning Electron Microscopy (SEM) was used to obtain the microscale dispersion. The TEM results revealed the coexistence of intercalated and exfoliated clay layers in both epoxy systems. In in-situ synthesis of nanocomposites, the clay interlayer distance increases with the progress of intragallery (i.e. interlayer) reaction, and suppressed by the extragallery reaction. Higher degree of exfoliation could be obtained for systems with higher diffusion rate into the clay interlayer. Microwaves improved the exfoliation for both epoxy nanocomposites, possibly because the direct absorption of microwave energy by the reactive molecules enhanced their diffusion into the clay interlayer. Dynamic mechanical properties of the nanocomposites were measured with Dynamic Mechanical Analyzer (DMA). Glass transition temperature was determined with the peak in Tan delta curve. The effects of structures on nanocomposites properties were studied.
    
13. Comparison of the Engineering Properties of Recycled Plastic Aggregates (RPA), and Natural Aggregates (NA) for use in Concrete
    D. Negussey, C.General, A. Reiner, Geofoam Research Center, Syracuse University
    
14. Feasibility of Analysis and Screening of Plastics for Heavy Metals with Portable X-ray Fluorescence Analyser with Miniture X-ray Tube
    Stan Piorek, Niton LLC
    Abstract
    Metals and metal compounds have been used for many years in the manufacture of plastic products. The metallic compounds added to plastics although encapsulated in polymer matrix are usually not chemically bound to polymer molecules and consequently can gradually be released to environment over the service life of a plastic made object.

    Similarly, when disposing of plastic waste either by incineration or by placing it in a landfill, toxic metals released from plastics can enter atmosphere or leach into soil. Environmentally responsible handling of plastics requires monitoring of potentially toxic elements in plastics during their production, recycling and disposal operations.

    In this paper we report on application of a small, lightweight (1.5 kg), battery operated portable X-ray fluorescence analyzer for in-situ analysis and screening of plastic for toxic metals.

    Introduction
    Elements such as lead, cadmium, chromium, mercury, bromine, tin and antimony are or have been added to polymers as pigments, fillers, UV stabilizers, and flame retardants. Typically these elements are added as compounds which often do not chemically bond with molecules of plastic but rather create a suspension in solid plastic polymer. Therefore, in time they may potentially dislodge from plastics matrix. The finer the particles of added compound the easier it is for them to be removed. A visible symptom of such process is hazing on the surface of some plastics caused by migration of bromine from the bulk of material to its surface. The PVC based plastics contain considerable amounts of chlorine which, when released, facilitates leaching of metals into environment. This creates serious health and environmental problems since most of these elements have been identified as toxic to humans. Specifically, since so many toys and other objects of common use are made of plastics, they pose particular danger for small children. The initiatives undertaken to correct this growing problem target maximum allowable concentrations of toxic metals in plastics, and ultimately aim at their complete elimination from production.

    The first regulations that specifically target heavy metals in plastics were introduced in mid nineties by European Community. European Community “Packaging Directive” - EC-Directive 94/62/EEC, [1] regulate the total amount of metals such as Cd, Cr, Hg and Pb in plastic packaging materials to less than 100 mg/kg. Another EU Directive, 91/338/EC [2], sets the maximum allowable concentration of cadmium in plastics used for consumer goods at 100 mg/kg. In the US, the “Proposition 65” introduced in California banned cadmium from use. Separate effort is directed at proper handling of plastic waste. Specifically, European Council Directive 2002/96/EC on waste electrical and electronic equipment (WEEE) [3], mandates removal from such waste all plastic containing brominated flame retardants, all mercury containing components, batteries, etc.

15. Cotton-Based Composites for Automotive Applications
    G. Bhat, G.Kamat, University of Tennessee, D.Mueller, University of Bremen, M. McLean, Cotton Inc.
    The rationale behind this research has been to produce compostable cotton fiber-based composites that can be safely disposed off after their intended use without polluting the environment, in an environmentally safe manner. It is evident from studies being done at the University of Tennessee, Univ. of Bremen, Germany and USDA, New Orleans, that by suitably combining cotton, with an appropriate thermoplastic biodegradable fiber in the right combination, a moldable fabric can be produced. These cotton-based nonwovens will be manufactured using blends of cotton, flax and a biodegradable thermoplastic fiber. Cellulose acetate, Eastarâ Biomax, and other thermoplastic fibers will function as the binders, thus eliminating the use of any non-biodegradable synthetic fiber or a chemical binder. Moldability of cotton/flax with (thermoplastic) biodegradable fibers/polymers is being investigated, and suitable compositions for such products will be determined. As a result, composite products that are totally biodegradable, and made of cotton fibers, will be available for use in the automobiles.
    
16. Chemical Risk Assessment in Europe: the Past, Present, and Future
    R. Johnson, Rohm and Haas
    The European Union has established a rigorous procedure for evaluating the possible risks associated with the use of chemicals. This process compares known hazardous effects of a chemical with estimates of real exposures to understand the possible risks involved. For unacceptable risks, the EU then has procedures in place to take appropriate safeguard measures. This talk will review several of the risk assessments that have been performed on chemicals involved in plastics, including the outcomes and actions. It will also look at more recent assessments, changes in the risk assessment process, and the implications of the new REACH chemicals program now under discussion within the EU.
17. -
18. Drivers & Rationale for Use of Biobased Materials Based on Life Cycle Assessment (LCA)
    R. Narajan, Michigan State University
    Sustainability, industrial ecology, and green chemistry are new principles that are guiding the development of the next generation of materials, products and processes. Biobased materials hold great promise for achieving the goals of sustainable development and implementing the principles of industrial ecology. Biobased materials and products offer value in the sustainability/life-cycle equation by being part of the biological carbon cycle, especially as it relates to carbon-based polymeric materials such as plastics, water soluble polymers and other carbon-based products like lubricants, biodiesel, and detergents. LCAs of these biopolymer materials often show reduced environmental impact and energy use when compared to petroleum-based materials.

    Biobased polymers are synthesized by many types of living matter - plants, animals, and bacteria - and are an integral part of ecosystem function. Because they are synthesized by living matter, biopolymers are generally capable of being utilized by living matter (biodegraded), and so can be disposed in safe and ecologically sound ways through processes like composting, soil application, and biological wastewater treatment.

    Biodegradable plastics and biobased polymer materials based on annually renewable agricultural and biomass feedstocks can form the basis for a portfolio of sustainable, ecoefficient products that is an environmentally preferable, sustainable alternative to current materials based exclusively on petroleum feedstocks. Two basic routes are possible. Direct extraction from biomass yields a series of natural polymer materials (cellulose, starch, proteins), fibers, and vegetable oils that can form the platform on which polymer materials and products can be developed. Alternatively, the renewable resources/biomass feedstock can be converted to bio-monomers by fermentation or hydrolysis and then further converted by chemical synthesis to biodegradable polymers like polylactic acid. Bio-monomers can also be microbially transformed to biopolymers like the polyhydroxyalkanoates. Surfactants, detergents, adhesives, and water-soluble polymers can be engineered from biomass feedstocks. Vegetable oil based lubricants and urethane foams can be prepared.
    In conclusion, biobased polymer materials will likely play an increasingly important role in a society moving towards a sustainable and environmentally responsible materials base. This presentation captures the rationale and drivers for such a change towards biobased polymer materials, presents the LCA’s of biobased materials and showcases the various technological and commercial successes of bio-based polymer materials.

19. Design and Engineering of Biodegradable Blown Film
    S. Balakrishnan, R. Narajan, Michigan State University
    Environmental, societal, and regulatory drivers are creating a need for single use disposable packaging film for automotive parts and other products to be biodegradable or recyclable. Current polyolefin films in use today are not biodegradable. They are potentially recyclable, however, recycling of these films contributes more environmental burdens from collection, transport, etc, and is also economically not viable.

    Single use, biodegradable films have now been engineered with the performance properties of today’s films and the biodegradability of paper. After use the films can be biodegraded in composting operations or in soil to become part of the microbial food chain -- they fit into the cradle to cradle biological metabolism cycle

    The resins were manufactured in a twin-screw co-rotating Century extruder (L/D = 40) using a aliphatic-aromatic copolyester processing aids and inorganic fillers. The screw configuration comprising of both conveying and kneading elements was used. The compounded resin was then blown into film using a Killion single screw extruder. Several tests were run to analyze both the initial polyesters and the compounds. Tensile tests were run on 4” x 1” rectangles of film. All other tests were run using pellets.

    The performance properties and processing of these new engineered biodegradable films and the biodegradability data will be presented.

20. Thermally Stable Lubricants from Vegetable Oils
    R. Vicray, D. Graiver, K.Farminer, R. Narajan, Michigan State University
    There is a resurgence of interest in the use of annually renewable feedstocks like vegetable oil for fuel and industrial product applications. The use of agricultural feedstocks allows us to manage our carbon cycling in a more efficient manner and reduce CO2 emissions. LCA documents reduced energy consumption and a positive environmental profile for biobased products.

    The major problems in using vegetable oils as lubricants is its low thermal and oxidative stability at elevated temperatures due to presence of double bonds and a low pour point (high viscosity) at low operating temperatures. We have developed novel ozone based chemistry to convert these vegetable oils to oxidative and thermally stable fluid products which can function as lubricants. We will describe this one-step manufacturing process and the properties of the resultant products.

21. Biodegradable Starch Foam Packaging for Automotive Applications
    Y. Nabar, R. Narayan, Michigan State University
    Today’s petroleum-based foam plastic protective packaging is a $3 billion market in the United States and growing 12% annually. This market is experiencing growing pressure from existing and proposed environmental and disposal regulations, and market based sustainability initiatives. -Foam packaging is a major problem as it is mostly air and so does not lend itself to a viable economic and environmentally responsible recycling operation. It is not biodegradable, and so does not lend itself to disposal in soil or composting operations. Issues such as sustainability, industrial ecology, biodegradability, and recyclability are becoming major considerations in a company’s product packaging design, especially with single use disposable packaging. ISO (International Standards Organization) 14000 environmental management standards are becoming a requirement in the market place and companies are actively positioning themselves to secure certification.
    The United States government recently enacted legislation requiring the federal government to purchase biobased products -- Farm Security and Rural Investment Act of 2002 (P.L. 107-171, 2002). The U.S. Department of Agriculture (USDA) is developing guidelines to designate biobased products that can be procured by Federal agencies.
    There is, thus, a market need for a, biobased, biodegradable foam plastic packaging that can be safely and effectively disposed of in soil or in composting operations, but retains all of the current foam plastics performance requirements. We have developed a one step, environmentally friendly extrusion process to manufacture biodegradable starch foam sheets that addresses this market need. Water functions as the plasticizer and blowing agent, and the addition of processing aids and additives helps control the cell structure, morphology and surface properties. After use, it can be completely disposed in an environmentally responsible manner in soil or in compost operations, where it becomes a nutrient (food) for the soil microorganisms – enters the microbial food chain or in composting operations. A local Michigan company, KTM Industries is commercializing this new bioplastic foam material which has the performance characteristics of today’s synthetic foam in targeted applications, and competitively priced.
    
22. Defining the Value Proposition of Recycled Plastics
    A.Robinson, The Plastic Lumber Company
    A recycle plastic product and their associate markets need to be analyzed in relation to the strength and weakness of the recycled product being proposed and its complex relationship to the competing or existing products within that marketplace. Where is the recycled plastic product development in relation to available technology, pricing, product performance, distribution or other market or technical maturity attributes that might make it a recycled plastic product a successful or a failure? An overview of the recycled plastic lumber industry and its existing or future product potential successes will be presented in an effort to help “Define the Value Proposition of Recycled Plastics.”
    
23. Recycling and Globalization
    R. Jones, Franklin International, LLC
    Post-industrial recycling has been a successful element of the plastics industry almost as long as the industry has existed. Post-consumer recycling, on the other hand, has been primarily driven by political and regulatory demands. Globalization is now leveling this playing field somewhat. Now that the recession is officially over, what sort of shape will recycling take in the future? How does China fit into the picture? This paper will attempt to answer these questions and point to possible future directions for recycling.
    
24. Outsourcing as a Means to the Development and Sustainable Growth of Recycled Materials
    Tony Bernardo, Alloy Polymers, Inc.
    The growth in importance of recycling plastics, pre or post consumer, has been offset by any number of non-technical hurdles to actually implement many solutions. Unlike glass or PET bottles, the cost of logistics systems, or recovery economics, or the finishing processes cannot support sufficient economic incentive to promote the use of the resulting recycled new raw material. Recycled materials do not support the economic goals of the buyer at the industrial level and the use of recycled materials, as a “noble contribution” doesn’t carry sufficient value to the bottom line. The consumer market is unaware and the end use market won’t pay. Under such circumstances, the investment of capital to reprocess these products rarely meets the criteria for return on investment or discounted cash flow. In short, it’s tough to justify investment in recycling when the market won’t pay the price for the resulting products. A solution in some, maybe many, cases may be to outsource the development and initial manufacturing process for the purpose of developing products that create value and scaling up those products to create a viable market. With risk reduced, and market growth initiated, investment of capital to support growth will provide adequate return on investment. The question then becomes, how do we find and choose outsourcing partners to contribute to the sustainable growth of recycled products.
    
25. Environmental Technologies Incorporated in Automotive Vehicle Interior
    R. Eller, Robert Eller Associates
    New end of life vehicle (ELV) legislation in Europe encourages the use of mono materials construction in automotive interiors. Current auto interior fabrication methods are inefficient with respect to both unnecessary unit operations and scrap generation. The imperatives of cost reduction will contribute to increased recyclabilty of automotive plastics and rubber components. This paper will review these trends for North American and European automotive fabrication.
    
26. The Impact on Biotechnology on the Chemicals and Plastics Industries
    M. Baumann, G.H. Associates
    The stage is being set for a biological transformation of the chemical industry in the 21st century. The blurring of traditional boundaries separating chemistry and biology in production strategies is a growing trend.
    Leading companies such as DuPont, Dow, Aventis (Hoechst and Rhone Poulenc merger), Novartis and Monsanto who will merge with Pharmacia-Upjohn are reinventing themselves as “life Sciences” companies or are using acquisitions and strategic alliances to take advantage of the increasingly important role of biotechnology.
    Companies like these are staying ahead of the curve in terms of both understanding the strategic pathways and exploiting these avenues. Through biotech-based R&D these companies will likely grow and prosper throughout the coming century.
    Advances in three key areas of biotechnology are driving this transformation of the chemical industry:
    Biocatalysis: the use of microorganisms and especially enzymes to catalyze certain reactions and the use of molecular biology techniques to modify enzymes so they will have specific catalytic properties.
    Metabolic Engineering- genetically engineering plants, animals and especially microorganisms, to have all the biocatalytic steps for production of a particular chemical contained within their cells so that the cells are in effect highly efficient mini-reactors.
    Plant Biotechnology- genetic engineering of plants to have specific characteristics (e.g. lower levels of lignin or higher levels of starch) which increase the efficiency and yield when they are processed into certain products.
    Lower capital expenditures, lower raw material costs, the ability to create new functionality and the promise of low environmental footprint are all potential benefits which are motivating the increased research in the field of biotechnology and industrial chemicals.
    
27. Aromatic Hydrocarbon Content of Common Plastic Packaging Materials
    M. Ezrin, G. Lavigne, University of Connecticut
    In previous work on recycled HDPE from dairy grade bottles the presence of trace levels of aromatic hydrocarbons was detected, including benzene, toluene, 3 xylenes and naphthalenes. The source of these hydrocarbons was not related to recycling because the same compounds were found in bottles off the shelf of a supermarket. At a paper presented at the 1995 SPE Plastics Recycling Conference, it was suggested that the source of the hydrocarbons is from gasoline vapor in the air. The method of analysis is thermal desorption GC/MS (gas chromatography/mass spectroscopy). The excellent detectability is because heat is used to remove compounds rather than solvent.

    Recent work has been done with other plastic packaging materials, including PET, PS and PVC. All contained readily detected levels of aromatic hydrocarbons; the highest levels were in PS. We have purged the hydrocarbons in the plastics as received using supercritical fluid extraction with carbon dioxide. Analysis confirmed the substantial freedom of hydrocarbons. The plastics were then exposed to atmosphere to allow the plastics to reabsorb the hydrocarbons from the air. The likely source is gasoline vapors because the composition and relative amounts of hydrocarbons are similar to that in gasoline.

28. Perfecting PLA properties: A Succesful University Collaboration
    J.Dorgan, D.Knauss, J.Janzen S.Hait, L. Bao, Colorado School of Mines
    J. Randal, M.Mang, P. Gruber, Cargill-Dow LLC
    Polylactides (PLAs) are commercially produced polymers based on renewable resources; they hold significant energy and environmental advantages when compared to other materials using a Life Cycle Analysis. Despite their significance, the literature on basic chain properties is disjointed and inconsistent. Under support from the Department of Energy, a comprehensive and well-controlled set of experiments was combined with consistent numerical analyses to resolve existing literature contradictions. Polymers spanning wide ranges of molecular mass and stereoisomer proportions were prepared by ring-opening polymerizations and characterized by several means. The data imply polylactides are typical linear flexible polymers. Unperturbed PLA chain dimensions are describable in terms of a characteristic ratio in the range 6.5 ± 0.9. Precise Mark-Houwink and Schulz-Blaschke constants for dilute PLA solutions in chloroform and in THF were determined. The melt rheological properties were also comprehensively investigated. Specialized software was then developed that allows the prediction of melt rheological properties (flow curves) based on single point solution viscosity measurement. This tool was transferred to the industrial partner and is being made available to parties interested in adopting PLA in place of traditional petroleum based polymers thus expediting the acceptance and spread of the use of PLAs. Insights garnerd during these fundametal studies led to the development of a PLA blend with an aliphatic-aromatic tercopolymer that appears particularly promising for injection molding applications, the blend possessing both improved flow and mechanical properties.
    
29. The Vinyloop® PVC Recycling Technology –Two Years of Industrial Experience
    P. Crucifix, Solvay, Belgium
    The Vinyloop(r) technology developed in the late nineties to recycle PVC waste materials, benefits now from 2 years of industrial experience in the first industrial plant in Italy.
    Since the first batch of regenerated PVC, produced in February 2002, the production has been increased to reach 90% of the nominal capacity at the end of 2003. The technological jump ( x 80), from the pilot line to the industrial plant has offered the opportunity for a lot of improvements. The plant recycles essentially two types of residues. The major one is the plastic fraction of the cable waste residues, from which the regenerated PVC compound is sold in various applications, such as tunnel watertight membranes, flexible hoses and doormats. The second stream is PVC/PE blister coming from packaging applications.
    Tests have been successfully performed in the plant on post-consumer roofing and flooring residues. The technological success of this first unit permits the further development of the other projects. Joint Ventures will be launched in Japan and in France and several other projects are currently running through feasibility studies in UK, Belgium, Germany and Spain.

    To be presented by Patrick Crucifix - Vinyloop Project Leader.

30. Design for Repurpose: Where Environmental Regulations and Business Strategies Meet
    B.Bachman, J. Zollo, W.Kiert, N. Desai, Motorola Inc.
    Cell phones are being classified as hazardous waste materials along with the previously categorized electronics products such as computers and televisions. The faster new superior (electronic) products are created, the faster existing ones become obsolete. The United States (US) electronics industry has approached the waste issue by: repairing electronic products, reclaiming high value elements, limiting the number of different materials in a product, labeling of plastic molded parts, using recycled content rather than newly synthesized materials, reducing or eliminating specific toxic chemicals such as bromine or lead, creating collection programs with municipalities, and exporting waste to developing Asian countries. The European Union (EU) has taken a strong stand on the electronic waste through directives and treaties.

    This paper proposes that products be designed from the outset so that, after their intended initial useful lives, products or products’ components can provide nourishment for something new and not become obsolete. The components can be conceived as “technical nutrients” that will continually circulate as vital and valuable materials within closed-loop industrial cycles, rather than being considered only for reclaiming, recycling or downcycling into separate or low-grade materials and uses. The proposal offered provides a path to take a potential threat and turn it into a new business growth opportunity.

31. Investigation of Effects of Culture Medium Components on Polyurethane (IMPRANIL DLN) Biodegradation by Psedomonas Chlororaphis
    Ying Zheng, Ernest Yanful, Amarjeet Bassi, University of Western Ontario, Canada
    With more and more plastics being utilized by society, the environmental problems caused by their non-biodegradable characteristics are receiving greater attention. Much research has been done on the mechanism of plastic waste biodegradation, plastic biodegraders, the process of biodegradation and plastic biodegrading enzyme. Moreover, the methods of applying these research results in practice have become increasingly important because of the limited capacity of the environment.

    This research focuses on the biodegradation of polyurethane, which is a base material widely used in many ranges of industries and employed everyday applications. The objective of the research is to investigate PUR degradation by the bacteria, Pseudomonas chlororaphis. In order to confirm that Pseudomonas chlororaphis can consume PUR as a sole carbon and nitrogen source, several experiments were conducted. By changing components of the culture medium, optimal components of the culture medium were obtained. Also, taking advantage of FTIR, the mechanism of PUR biodegradation by Pseudomonas chlororaphis was concluded. In the long term, the research seeks to explore some applications of PUR biodegrading, such as PUR waste concentrated treatment, the application of PUR breakdown products and the possibility of PUR biodegrading in soils or in landfills.

32. Successful Pilot Processing of Computer Plastics into Separate Streams of Brominated and Phosphated Flame Retardant Categories with RPI's "Skin Flotation" Technology
    Ron Kobler, RPI Inc.
    Testing results and methods are described, wherein commingled post consumer computer plastics flakes are separated into streams of PC-ABS (P) and ABS(br) flame retardant types. This key separation allows reuse of both the PC-ABS(P) and ABS(br) materials. Described are the skin flotation techniques employed. Results include: feed materials characterization, process flow chart, product stream purities, physical properties, operating costs, pelletizing studies, and customer reuse base. Also described are ongoing plant processing findings, including customer usage methods, and multiple plant expansion plans.

    Over the previous 18 month period, RPI utilized its Salt Lake City pilot production facilities to study the technical processing of post consumer end of life electronics plastics. Early in the program, material supplies were identified in quantities exceeding 250 million pounds yearly. Virtually all electronics plastics are currently incinerated for metal content, land filled for disposal purposes, or shipped to Asia for making mixed low value products.

33. Recycling of Headliner Rigid Foam, Headliner Scrap and Post Consumer Headliners
    D.Schomer, Bayer Corp.
    This presentation describes a new and promising method for recycling polyurethane headliner foam scrap and scrap from the production of complete headliners as well as post consumer scrap from automotive dismantling of end-of-life vehicles. The process handles headliner scrap comprising adhesive, glass or natural fibers, textiles, paper and rigid foam that are particularly difficult to recycle mechanically.
    It uses a modified rebond foam technique to first produce large buns which can be cut into slices and processed again to make valuable new parts. The modification is necessary to adapt the rebond foam process to the rigid foam character of headliner foam. This innovative approach has the following significant advantages:
    · It uses a known and proven manufacturing technique, which is available at many locations worldwide. So no new technology has to be developed and existing equipment and standard chemicals can be used.
    · It produces intermediate products that can be processed with the same thermoforming technique as the virgin foams have been. Possible automotive applications are parcel shelves, A, B, C panels, trunk floors, interior door trim.
    · It produces excellent properties, specially acoustic properties that are better than the starting headliner foams.
    · The sound dampening profile also opens up especially good prospects for applications in the construction industry, in addition to utilizing the materials in automotive interiors.
    · Apart from thermoforming, impregnation and reshaping processes can also be used; cuttings from the buns can be used for low-end energy- absorbing purposes.
    This paper will further provide data comparing the physical properties of virgin rigid headliner foam with the rebonded scrap.

    This technology opens an effective and economic route for recycling polyurethane rigid foams and composite headliners, which have not so far been considered effectively mechanically recyclable.

34. PERMBLOCK AS6: An Innovative Structure for PZVEV Compliant Plastic Fuel Tanks
    B. Bonazza, P. Delbarre, M. Belkacem, Ti Automotive LLC, Germany
    F. Bertoux, Autofina, Germany
    TI Automotive and ATOFINA have jointly developed an innovative multi-layer plastic structure able to meet the most stringent requirement on evaporative emissions, while still offering the superior performance level associated with plastic fuel tanks: crash worthiness, design flexibility, low weight, excellent chemical and corrosion resistance.

    When combined with the “Ship In a Bottle” technology (“SIB”) introduced by TI Automotive in 2002, it represents a highly flexible solution for production units, offering a quick and easy switch-over process from a LEV II compliant system (SIB + conventional PE / EVOH COEX) to a PZEV compliant system (SIB + PERMBLOK® AS6).

    The construction, incorporating ORGALLOY® FT-104, a barrier material as the inner layer, offers an outstanding process robustness, especially at the pinch-off line, reputed to be a significant contributor for permeation rates. This guarantees the compliance to the extended long-term durability requirement .

    Speciation studies have been run, comparing conventional 6 Layer COEX (PE / EVOH) and PERMBLOK® AS6 structures exposed to CARB Ph II and TF1. They show that PERMBLOK® AS6 does not only reduce the permeation rates compared to conventional coextruded structures, but that it mostly acts on aromatics (Toluene, benzene, …), known as the most severe pollutants.

35. Recycling Used Polypropylene and Polyester Rags, Including Solvent Rags into Vehicle Parts
    D. Briggs, Mobile Fluid Recovery, E. Effler, Contec, Inc.
    This paper discusses how Mobile Fluid Recovery, Inc. (MFR), and Contec, Inc. (Contec) were able to recycle polypropylene and polyester wipers into automobile parts. In some cases they were able to take advantage of the regulatory exemptions for textiles, which would otherwise be classified as waste solids containing flammable liquids, and obtain raw materials for manufactured automobile parts. The textiles are isopropyl alcohol (IPA) pre-soaked polypropylene wipes and solvent soaked polyester tube wipes. The project not only minimized Resource Conservation and Recovery Act (RCRA) hazardous waste and saved money but it is increasing the recycled content of vehicles produced. The discussion includes a description of regulatory issues addressed as the process was implemented.

    Both the polypropylene IPA and polyester solvent wiper programs were initially tested and implemented at the DaimlerChrysler Warren Truck Assembly Plant through the co-operative efforts of the Environmental Specialists, Sandi Lopez and Brian Miller.

    CONCLUSIONS
    Recycling used polypropylene and polyester rags to make useful parts has proven itself to be a valid process, minimizing waste, reducing cost, and increasing recycled content of the product being manufactured.

36. Converting Reclaimed Scrap PET to Useful Process Chemicals (pdf)
    Scott. O. Seydel, EvCO, Inc.

37. Soy vs. Petro Polyols, A Life Cycle Comparison
    J. Pollack, Omni Tech International, Ltd.
    The 2002 Farm Bill contains a section that mandates all federal agencies establish a preferred procurement action program for the purchase and use of biobased products. In support of that mandate, the USDA is charged with issuing criteria that would qualify products for such preference. USDA is also directed to establish a voluntary labeling program known as: “USDA Certified Biobased Product.” This program will require the use of life cycle modeling.

    To assess the feasibility of this initiative, a life cycle project was conducted to compare the environmental impacts of two soy polyol materials with a conventional petroleum derived polyol. These polyols are a primary ingredient in manufacturing polyurethane foam products for a variety of applications. This modeling was conducted using the U.S. National Institute of Standards and Technology (NIST) updated BEES software model. Omni Tech Int’l. Ltd. of Midland, MI was the consulting firm used to gather mass balance data for the production of the soy polyols.

    The soy based feedstocks showed only about one quarter the level of total environmental impacts with significant reductions in global warming, smog formation, ecological toxicity and fossil fuel depletion. This life cycle information is now available to any product developer who is considering the use of a soy-based feedstock and wishes to conduct life cycle assessments on their downstream commercial products.

    The presentation will describe how this information was gathered, used and interpreted.

38. Low Cost Bio-composite Sheet Molding Compound Panel: Processing and Property Evaluation
    G. Mehta, A. K. Mohanty, K. Thayer, L. T. Drzal, M. Misra, Michigan State University
    Biocomposites were made by a novel high volume processing technique named ‘bio-composite sheet molding compound panel’ (BCSMCP) manufacturing process. This process design was inspired by the commercial glass fiber-polyester resin composite fabrication method called sheet molding compounding. This process yields continuous production of bio-composites on a large scale, and thus can be easily adopted in industries. A unique fiber dispersion method, which enabled uniform distribution of natural fibers, was used in this process. Consistency of the process was tested by repeatability studies, and evaluation of mechanical properties. The low cost bio-composites produced as a result of the processing will be used for various panel applications like in housing & transportation. The molded test samples were tested for various mechanical and thermal properties, in accordance with ASTM procedures. The biocomposites were made with various natural fibers including, flax, big blue stem grass, hemp, jute, henequen, kenaf, coir, green flax core, etc. By combination of different natural fibers in varying mass fractions, hybrid biocomposites were used made using this process. Grass fiber reinforced polyester bio-composites processed by SMC line show very promising results. The technology developed under this project will be used by PATH (Partnership for Advancing Technologies in Housing) for future American housing.

39. Environmentally Conscience Production of Thermoformable Sheet and Film Products
    Siegfried Lackner, Senoplast Klepsch & GmbH Co., Germany
    For the 47-year old company, pro-active environmental protection is a declared aim backed up by impressive achievements: the planting of extensive green areas and a sustainable biotope (1978), the Austrian industry award for environmental protection (1985), the implementation of ISO 9001 and 14001, and most recently the Austrian Environmental Reporting Award (2001). Such recognition has only strengthened Senoplast’s resolve to continue working for a healthy and beautiful natural environment in the province of Salzburg (Austria).

    As a firm believer in the climate alliance, Senoplast has signed up to a voluntary reduction of greenhouse gas emissions. Its new biomass thermal energy facility enables waste heat from the manufacturing process to be used purposefully, creating a symbiosis between production and heating operations. Throughout the year, a heat exchanger captures waste heat from the production process and turns it into hot water at a special plant for 86 public and private sector customers. With annual mid-term savings of 200,000 liters of heating oil, CO2 emissions are drastically down, resulting in improved air quality.

    Such measures also protect the amphibians living around the company site. A new amphibian control system has been developed in-house to protect the biotope, which now borders on a busy traffic and employment area due to the expansion of the commercial zone towards the center.

40. Environmental Protection from Plastic Waste Menace
    A. Zadgaonkar, College of Engineering, Nagpur (INDIA)
    There is no dispute about the fact that plastics have become an Indispensable part of our lives, as in certain applications they have an edge over conventional materials. Indeed, their light weight, durability, energy efficiency, coupled with a faster rate of production and more design flexibility, have allowed breakthroughs in fields ranging from non-conventional energy, to horticulture and irrigation, water-purification systems, and even space flight.

    Plastic waste contributes significantly to the problem of waste management world over. A majority of landfills, allotted for plastic waste disposal, are approaching their full capacity. Thus recycling becomes increasingly necessary.

    Expenditure incurred on disposal of waste plastic throughout the world is around US$ 2.00 Billion every year. Even a small country like Hong Kong spends around US$ 14.00 Million a year on the exercise.
    
    The real un-quantifiable cost is damage to ENVIRONMENT.

    The Process:
    A process is developed to overcome the above mentioned drawbacks and limitations. In our process the waste plastic is converted into value added fuels. Thus two Universal problems i.e. Problem of waste plastic and Fuel shortage are being tackled simultaneously.

    The process involves depolymerisation of waste plastic under controlled batch reaction resulting in conversion of waste plastic in a mixture of fuels at atmospheric pressure and room ambient temperature. Liquid fuels consists of fraction of Gasoline (motor Spirit commonly known as Petrol), Diesel, Crude Lubricating oil. In the process of conversion by products such as gases and coke are also formed. Gases are tested and majority of the gases are proved to be in the range of L.P.G. The coke is available as residue in the process which is also a saleable product.

41. Development of a Tough and Flexible Halogen Free Dual Layer Wire Insulation System for Electronics Appliance Wire Applications
    Akshay H. Trivedi, Ph.D., Sr. R&D Engineer, Judd Wire, Inc.
    Due to strict environmental regulations, insulating materials for electrical wires are required to be not only flame- retardant but also generate very low smoke upon flaming. Insulation systems containing halogens evolve harmful hydrogen halide gases upon burning. These gases are acidic and toxic in nature. Due to this reason, there have been increased requirements to use insulation systems that contain halogen free flame retardants. These materials do not evolve harmful, toxic gases and generate a very low amount of smoke upon flaming. However, in order to impart a similar level of flame retardency as halogen containing systems, these materials must have a very high level of fillers such as metal hydroxides and other inorganic materials. Unfortunately, such high loadings of halogen-free, flame-retarding agents adversely impacts the physical and mechanical properties (e.g., toughness, flexibility) and processability of the resulting insulating material.

    The present paper describes the development of a low-smoke, halogen free flexible dual layer insulation system (FlexradTM HF Dual Wall), which demonstrates excellent mechanical properties. The mechanical, thermal and flame characteristics of typical halogenated a halogen free and halogen free dual wall insulation systems are discussed. A key characteristic of the dual wall system is the ratio of the inner layer thickness to the outer layer thickness. The results of an experiment to determine the ratio of the inside XLPE layer to outside jacket layer are discussed. A ratio is determined such that a good balance of flame retardency, flexibility and mechanical toughness is achieved. We concluded that the thickness of the jacket layer relative to the thickness of the inside insulating layer will influence the ability of the wire to meet the stringent requirements of the UL VW-1 Vertical Flame Test. Further, this thickness ratio influences the ability of the wire to demonstrate satisfactory cut-through resistance. Characteristics of the dual wall insulation system are discussed in detail. This insulation system comprises of a cross-linked, highly flame-retardant and halogen-free XLPE first insulating layer and a tough, flexible second insulating layer. The resultant wire product is suitable for internal applications where improved mechanical properties like abrasion, cut through resistance, low deformation as well as flexibility are desired. The flexible design of the insulation system makes it suitable to be easily routed in very tight places. The product is rated at 105 oC and is recognized by UL under AWM style 3660 and also by CSA under AWM I A/B. It meets flame rating of VW-1 described in UL 94 and vertical tray flame rating of IEEE 383 as well as UL 1685 for low smoke emission. The results of these tests are discussed to demonstrate the performance characteristics of this new insulation system.

42. Plastic Omnium Auto Exterior: The first “Design for Recycling and Dismantling” Bumper,
    The ECODESIGN Program
    Xavier Maury, Plastic Omnium Auto Exterior (POAE)
    For the past two years, Plastic Omnium Auto Exterior (POAE) has been applying criteria of ecodesign to all its automobile parts development programs. These criteria were adopted after a cooperative effort between the GPA (Groupement de la Plasturgie Automobile (Automobile Plastics Industry Federation)), The "Ecole des Mines" technical institute in Paris and Plastic Omnium.
    This 2-year study led to the definition of these five criteria that are followed at each step of development.

    They take into account current and future European regulations on processing vehicles at the end of their lives, and also the safety of persons, consumption of fuels and the used of recycled parts. This has been included in the pre-project phases.

43. Injection Molded “Green” Nanocomposite Materials from Renewable Resources
    M. Misra, H. Park, A.K. Mohanty, L.T. Drazal, Michigan State University
    ABSTRACT
    Injection molded 'green' nanocomposites have been successfully fabricated from cellulose acetate (CA), triethyl citrate (TEC) plasticizer and organically modified clay. The effects of processing conditions, amount of plasticizer, various types and content of organo-clays on the performance of these nanocomposites has been evaluated. The cellulosic plastic with 80 wt. % pure cellulose acetate and 20 wt.% triethyl citrate plasticizer was used as the polymer matrix for nanocomposite fabrication. The morphologies of these nanocomposites were evaluated through X-ray diffraction (XRD) and transmission electron microscopy (TEM) studies. The mechanical properties of nanocomposites have been are correlated with the XRD and TEM observations. Cellulosic plastic-based nanocomposites with 5 and 10 wt.% organo-clay showed better exfoliated and intercalated structure than the counterpart having 15 wt.% organo-clay. The tensile strength and modulus of cellulosic plastic reinforced with 10 wt.% organo-clay was improved by 75 and 180% respectively. Thermal stability of cellulosic plastic is increased as a result of nano-reinforcement.
         Keywords: Cellulose acetate, biodegradable, nanocomposite, plasticizer, organo-clay
    INTRODUCTION
    Advanced technology in petrochemical based polymers has brought many benefits to mankind. However, it has become evident that the ecosystem is being disturbed because of non-biodegradable plastic materials. The environmental impact of persistent plastic wastes is growing into a more global concern. Currently, there is considerable interest in biodegradable polymers, which can be used as alternatives to traditional plastics, thus reducing the pollution caused by plastic wastes.
    Development of polymer/clay nanocomposites (PCN)s is one of the latest evolutionary steps of the polymer technology.
    
44. Expanding the Use of Recycled SMC in BMCs
    Rebecca DeRosa, Eric Telfeyan, Steve Mayes
    New York State College Ceramics at Alfred University School of Engineering
    Recycling of thermoset molding compounds has been intermittently investigated for roughly 15 years. Currently size reduction is used to recycle SMC waste. Substituting recyclate of different sizes for various virgin materials has been widely investigated, however, no one has reported substitutions of SMC recyclate for different length virgin fibers (VF). In this study the flexural strength and modulus of BMCs with 70/30 wt% combinations of 6.35, 12.7, or 19.05 mm VF/recyclate were found. The 6.35 and 12.7 mm combinations had similar flexural strengths to the 3.17 and 6.35 mm VF BMC respectively. Reductions of 20% to 28% in flexural modulus were seen. If satisfactory, the combinations could replace shorter VFs.

    Another issue with recyclate substitutions is poor interfacial bonding with the new matrix. We investigated a three-step surface treatment to improve bonding. The final step introduced unsaturated C=C to the recyclate surface. The treatments were monitored using FTIR. After the third step a peak at 1648 cm-1 appeared, indicating the presence of C=C. However, treated BMCs had similar strengths as untreated BMCs. Micrographs of the fracture showed unimproved bonding, possibly due to an insufficient number of C=C.

45. Renewable Resources in Composite Materials
    Brian J Maas, John Deere Worldwide Combine Product Development
    The agriculture industry continually investigates new markets to utilize its products. As natural resources continue to be depleted, the need for renewable resources in production materials is on the rise. Both of these issues have been addressed through the development of composite materials that utilize soybeans and corn in their production.

    John Deere Harvester Works has incorporated renewable resources into SMC and RIM composite materials for styling panels used on combine harvesting equipment. HarvestFormTM SMC (Sheet Molded Compound) and HarvestFormTM Structural Foam RIM (Reaction Injection Molding) are being used as alternatives to the petroleum based SMC and RIM material. In HarvestFormTM SMC, a portion of the petroleum based polymer is replaced by a soybean / corn based polymer. In HarvestFormTM RIM, a portion of the petroleum based polymer is replaced by a soybean-based polymer.

    This paper will review the development, testing, and implementation of renewable resources in composite materials for SMC and Structural Foam RIM. An overview of material composition, along with other developing markets and processes for renewable resources in composite materials, will also be covered.

46. An Investigation of Techniques for Removal of Paints and Coatings from Automotive and Electronic Plastics for Recycling
    Trip Allen, Darren Arola, Michael Biddle, Michael Fisher, and Brian Riise MBA Polymers, Inc.
    Paints and coatings are often problematic when plastics are mechanically recycled. The American Plastics Council sponsored a study by MBA Polymers of Paint and Coatings Removal as part of an effort to address technical barriers to the mechanical recycling of plastics from durable goods. A number of different paint and plastic substrate systems were identified from automotive and electronic equipment applications. After reviewing commercially available technologies including both mechanical and chemical stripping systems a number of these techniques were tested. The most promising method of paint removal found was hot aqueous hydrolysis, which was developed and tested at MBA Polymers. Aqueous hydrolysis showed promise in removing paints in a broad range of systems and testing indicated that it was likely that many paints could be removed in this way without substantial damage to polymer substrates. Physical stripping techniques for paints found only limited success though these techniques were valuable in the removal of some metallic coatings, such as chrome plating, and in the removal of some types of labels.
    
47. Assessing the Workplace Environmental Performance of Organotin Stabilizers Used at PVC Processing Facilities, Tin Stabilizers Association
    Carol Boraiko, Ph.D., John Batt, Atofina Chemicals, Inc., Richard W. Johnson, Ph.D., Rohm and Haas Company
    In addressing environmental performance of plastics, one needs to look at all phases of the lifecycle, including the workplace. Organotin compounds are used extensively in the PVC industry as heat stabilizers, and it is important to determine that they can, and are being used safely . The paper reports on studies performed regarding exposures related to skin contact and airborne vapors. For vapors a study was conducted to provide an overview of worker exposure to organotin at a variety of PVC processing facilities, and to verify that these exposures are below the TLV set by the ACGIH for organic tin. The results show that worker exposure for all but one instance was at safe levels, sufficiently below the TLV. In one case, where air levels were high, the use of appropriate personal protective equipment kept exposure of the worker at safe levels. There were no incidents of over exposure. For skin exposure we assessed the dermal penetration rates of orgnotins, comparing human skin with rat skin, the usual test medium. The data show that the stabilizers penetrate skin more slowly than other, similar organotins, and that human skin is less permeable than rat skin. These results are discussed in light of their support for worker safety.
    
48. Twinshot: Cost Effective Recycling
    Joseph McRoskey, Spirex
    One tried and true technology for utilizing significant recycled thermoplastic resin in injection molding applications is Sandwich Molding, or Co-Injection. The basic technology has been successfully employed for decades. Briefly, the use of a virgin resin skin, encapsulating a recyclate core provides ample opportunity. The skin provides all the aesthetics and, in some cases, mechanical properties required for the injection molded application, while the core acts as a low-cost and/or high-modulus filler. The “sandwich” structure hides the encapsulated core, and the core is only exposed if the part is cross-sectioned.

    As advantageous and promising as the technology has proven, its market utilization has been limited by the complexity and expense of traditional co-injection equipment. Often, the cost savings associated with employing low-cost, recyclate core material is offset by the higher machine-time rates typical of high-priced and complex equipment. The net result can be no competitive advantage.

    Twinshot Co-injection addresses both equipment deficiencies: cost and complexity. Twinshot is the co-injection method that employs standard injection molding machines and controls. Consequently, it is simpler, more user-friendly, and less expensive than traditional methods.

    This paper/presentation will focus on:
    · Co-Injection – What it Is … How it Works … and What Benefits it Provides
    · Twinshot Co-Injection – Simple Process … Standard Equipment … and Cost Effective Application Examples

49. Devulcanization of Recycled Tire Rubber using Supercritical Carbon Dioxide
    C. Tzoganakis, Q. Zhang, University of Waterloo
    Abstract
    In this work, an extrusion process has been developed for the devulcanization of rubber crumb from recycled tires employing supercritical CO2. For that purpose supercritical CO2 has been injected in a twin screw extruder to swell the rubber crumb and to facilitate the otherwise impossible rubber extrusion process. As a consequence, waste rubber can be processed under mechanical shear and extensional forces at various operating conditions that may lead to different degrees of devulcanization.
    Introduction
    Recycling of automobile rubber tires is an important issue in the rubber industry due to significant environmental concerns and several methods of recycling waste rubber tires have been proposed for the various markets of scrap tires over the years (1). Since the early 1990s’, more attention is given to resources exploration, and the market that can constructively reuse, recycle or recover the value remained in scrap tires and waste rubber has been growing at relatively rapid rates(2,3). The reasons for this rapid growth include lower costs for tire-derived fuel and lower emission levels. The use of scrap tires also increased in civil engineering applications, fabricated products and size-reduced rubber products.
    Ground rubber crumb is an important form in the rubber recycling industry and the market for ground rubber continues to grow. At present, ground rubber is mainly produced by reclaiming, ambient grinding, cryogenic grinding and wet or solution grinding. The ambient mechanical process uses a conventional high-powered rubber mill set at close nip. The vulcanized rubber is sheared and ground into small particles, and 10-30 mesh ground rubber is a very common product (4). The disadvantage of this processing method is that a significant amount of heat is generated in the rubber. Excess heat can degrade the rubber and it has the potential danger of combustion if not cooled properly. Cryogenic grinding usually begins with chips of a fine crumb, which is cooled with liquid nitrogen as the medium using a chiller or pre-cooler where it is sprayed with liquid nitrogen at –320oF or –195oC. This embrittles the rubber and makes it easier to grind to fine crumb (40 to 100 mesh). The frozen rubber is put through a high velocity impact type mill. Compared with ambient process, little or no heat is generated in this case, so less degradation occurs and the product has better flow characteristic than ambiently ground rubber. Finally, several studies have been done to compare the properties of rubber powder produced by these two (5-11). Numerous studies have addressed the incorporation of ground rubber crumb into compounds. However, untreated crumb only can be added in a small amount before the properties of the blend start to degrade. Once the ground rubber is already vulcanized, it is difficult to blend it with other existing polymers because there is little interfacial bonding between the rubber powder and the matrix. Therefore, a variety of technologies have been developed for
    
50. TBD
    Ken Stevens, DuPont
    
51. Automotive’s Bioplastic Future?
    Phil Sarnacke, United Soybean Board, David Reed, General Motors Corp.
    Sustainability, Renewability, Energy Independence, Biodegradability are the new mantra of the plastics manufacturers. According to a recent, August 27th, 2003, article in Chemical Marketing Reporter headlined, “Bioplastics Aren’t the Stretch They Once Seemed”, the development of Bioplastics is gathering momentum as increasing amounts of R&D and capital are committed by major chemical and plastics companies to their development and production. Noticeably absent from the article was any mention of automotive applications for these Bioplastics and the progress being made with biobased raw materials for several classes of thermoset polymers based on soybean oil. These omissions suggest the possibility that a need exists for a comprehensive assessment of the available Bioplastics and their suitability for the auto industry.

    This paper will review the current status of the Bioplastics development and propose a project for consideration by the transportation industry that would build a database of information for transportation industry suppliers to clarify the many issues that surround these new materials and to determine their suitability for transportation applications. Questions, surrounding the various Bioplastics versus the petroleum based plastics, that need supporting data might include: lifecycle analysis, current and projected costs, production capacities, alternative uses, durability, recyclability, and property performance profiles to mention a few.

52. Cesa-extend a User Friendly Technology to Enhance Reprocessing and Recycling of Condensation Plastics
    V. Karayan, Clariant Masterbatches, and M. Villalobos, Johnson Polymer
    Recycling of condensation thermoplastics such as polyesters (PET, PBT), polyamides (6, 6-6), polyurethanes, polycarbonates, and their blends, has found severe limitations owing to a simple reason: the costs associated to current process technology employed to revert MW degradation of these thermoplastics renders the recycled products uneconomical and/or unsuitable for many demanding applications. As a result, degraded post-consumer reclaimed plastics is still the main recycle stream, mostly directed to low value added applications such as fibers and film.

    During 2003, Clariant Masterbatches and Johnson Polymer jointly introduced to the market a family of chain extenders or "recycling aids" under the trademark Cesa-extend. These additives are based on proprietary technology of multi-functional acrylic oligomers formulated into masterbatches tailored for effective and user-friendly use in different thermoplastic systems. Cesa-extend products are characterized by their ability to dramatically increase the molecular weight, as well as the mechanical and rheological properties of virgin, reprocessed, and post-consumer recycled condensation plastics when used in very low concentration in simple extrusion or injection molding equipment.

    Multiple examples in which recycled feedstock has been enhanced with Cesa-extend products during a simple extrusion step to meet demanding engineering applications requirements will be given in the areas of polyesters, polyamides and other thermoplastics.
    

GPEC 2004 Student Posters

#1: Curing and Studies of Microwave Processed Bio-composites made from Epoxy
and Natural Fibers

Author(s): Nikki Sgriccia, M. C. Hawley, M. Misra, L. T. Drzal, A. K. Mohanty
Michigan State University

There is considerable interest in the field of biofiber composites in structural application, but little research has been done on microwave curing of these composites. In contrast to conventional thermal ovens, microwave heating is volumetric and not restricted to the surface. As a result, materials can be processed more quickly in a microwave oven. Curing studies have been performed on various natural fibers (hemp, kenaf, flax and henequen)-reinforced epoxy (Diglycidyl ether of bisphenol-A (DGEBA) with diaminodiphenyl sulfone (DDS) as crosslinking agent) composites. Samples were made using both microwave and thermal curing process for comparison. Differential scanning calorimetry was used to characterize the samples. The microwave cured natural fibers and epoxy composite samples reached their full cure faster than the oven-cured samples.

#2: Comparative Live Cycle Assessment of Biobased Composites and Conventional Composites

Author(s): Salil Arora1, A.K. Mohanty, L.T Drzal, M. Misra1, S. Joshi, and B.E. Dale
Michigan State University

Due to the ever-increasing consumption and dwindling supply of non-renewable resources, industries are forced to consider renewable or green alternatives to conventional materials and processes. Manufacturing of polymer composites is an energy intensive process and the issues associated with disposal of end products are of environmental significance. However, mere substitution of non-renewable materials with renewable materials doesn’t necessarily lead to an environmentally friendly profile. Life Cycle Assessment (LCA: “LCA is a compilation and evaluation of the inputs, outputs and the potential environmental impacts of a product system throughout its life cycle” (ISO 14040, 1997)) is an analytical tool used to suggest improvements and determine the sustainability of alternative industrial products and processes. The current research focuses on: i) developing cradle-to-grave inventories for conventional and bio-based composites; ii) assess the impacts of the inventories; iii) interpret the inventories and impacts to design eco-friendly composites. The inventory includes energy and materials usage, emissions to the environment including air emissions, wastewater discharge, and solid waste disposal. Polypropylene-glass fiber and polyhydroxybutyrate-kenaf fiber composites are being analyzed in this study. Future research will focus on developing life cycle inventories for other natural fibers such as switchgrass and bioplastics derived from various sources.

#3: Thermal and Mechanical Properties of Poly (trimethylene terephthalate) Clay Based “Green” Nanocomposites

Author(s): Yashodhan Santosh Parulekar and A. K. Mohanty, Michigan State University

There is a growing urgency to develop biobased materials as replacements/substitutes of currently dominated fossil-fuel based materials. Although fully renewable resource based materials are more eco-friendly but such materials may not satisfy performance attributes for certain industrial applications. The polymers and materials derived from mixed sources of renewables and fossil-fuels are not only showing strong promise in desired performance but also are moving more towards sustainability achievement. The DuPont SORONATM polymer e.g. poly(trimethylene terephthalate), PTT, a 3-carbon glycol terephthalate (3GT) is an example of a condensation polymer that can be made from 1,3-propanediol (derived from renewable corn sugar) and fossil fuel derived terephthalic acid (TPA). The PTT can be used as engineering thermoplastic because it possesses good thermal and mechanical properties. Nanocomposites of poly (trimethylene terephthalate) and organically modified clay were fabricated in a mini-compounder. Injection molded samples of these materials were evaluated through mechanical and thermal analysis. Enhancement of tensile, impact and flexural properties was studied and documented. These materials show significant improvement in properties and strong promise for structural applications.