Up-cycling plastic waste into swellable super-sorbents

Environmental and economic assessment of mixed plastic waste pelletization in the Gulf Cooperation Council region

Pelletizing mixed plastic wastes (MPW) has gained interest as an upcycling technology and an alternative to conventional recycling. To investigate its potential, we conducted a cost analysis and life-cycle assessment (LCA) for a conceptual pelletization facility designed to produce 1 kg of pellets per batch of MPW (comprising polyethylene-PE and polypropylene-PP). This work has the following merits: (i) evaluating environmental impact (EI), cost analysis, and mechanical strength based on actual experimental data and its comparison with local and international manufacturers; (ii) enabling the evaluation of LCA impacts of MPW pellets; and (iii) emphasizing the significance of waste management in reducing EIs. The following ten EIs were assessed: climate change (CC), net energy, particulate matter formation, natural land transformation, metal depletion, marine ecotoxicity, ionising radiation, freshwater ecotoxicity, freshwater eutrophication, and terrestrial ecotoxicity. The CC of the as-synthesized pellets is 1.26 kg CO2 eq., significantly lower than the data obtained from the Gulf Petrochemicals and Chemicals Association (GPCA) and an actual plant in Gulf Cooperation Council (GCC) countries. Additionally, the net energy required for the production of 1 kg of pellets is 54.1 MJ, while the cost is around 0.55 USD. The tensile strength of MPW pellets (24.63 MPa) falls between that of PE virgin pellets (21.12 MPa) and PP virgin pellets (28.12 MPa). This suggests that the MPW pellets exhibit competitive strength characteristics, warranting its consideration for applications where moderate strength is required. Overall, the competitive cost, coupled with the reduced EIs, demonstrates the potential of pelletization as a sustainable and economically viable waste management solution.

Stretch-Induced Spin-Cast Membranes Based on Semi-Crystalline Polymers for Efficient Microfiltration

Microfiltration membranes derived from semi-crystalline polymers face various challenges when synthesized through the extrusion-casting technique, including the use of large quantities of polymer, long casting times, and the generation of substantial waste. This study focuses on synthesizing these membranes using spin-casting, followed by stretch-induced pore formation. Recycled high-density polyethylene (HDPE) and virgin polyethylene powder, combined with a calcium carbonate filler, were used as the source materials for the membranes. The influence of the polymer-filler ratio with and without stretching on the morphology, tensile strength, and water flow rate was investigated. Optimal conditions were determined, emphasizing a balance between pore structure and mechanical integrity. The permeable membrane exhibited a water flow rate of 19 mL/min, a tensile strength of 32 MPa, and a water contact angle of 126°. These membranes effectively eliminated suspended particles from water, with their performance evaluated against that of commercially available membranes. This research, carried out utilizing the spin-casting technique, outlines a synthesis route for microfiltration membranes tailored to semi-crystalline polymers and their plastic forms.

Prolonged Lifespan of Superhydrophobic Thin Films and Coatings Using Recycled Polyethylene

High-density polyethylene (HDPE) waste poses a significant environmental challenge due to its non-biodegradable nature and the vast quantities generated annually. However, conventional recycling methods are energy-intensive and often yield low-quality products. Herein, HDPE waste is upcycled into anti-aging, superhydrophobic thin films suitable for outdoor applications. A two-layer spin-casting method combined with heating-induced crosslinking is utilized to produce an exceptionally rough superhydrophobic surface, featuring a root mean square (RMS) roughness of 50 nm, an average crest height of 222 nm, an average trough depth of -264 nm, and a contact angle (CA) of 148°. To assess durability, weathering tests were conducted, revealing the films' susceptibility to degradation under harsh conditions. The films' resistance to environmental factors is improved by incorporating a UV absorber, maintaining their hydrophobic properties and mechanical strength. Our research demonstrates a sustainable method for upcycling waste into high-performance, weather-resistant, superhydrophobic films.

Transforming polypropylene waste into transparent anti-corrosion weather-resistant and anti-bacterial superhydrophobic films

The global pollution crisis arising from the accumulation of plastic in landfills and the environment necessitates addressing plastic waste issues. Notably, polypropylene (PP) waste accounts for 20% of total plastic waste and holds promise for hydrophobic applications in the realm of recycling. Herein, the transparent and non-transparent superhydrophobic films made from waste PP are reported. A hierarchical structure with protrusions is induced through spin-casting and thermally induced phase separation. The films had a water contact angle of 159° and could vary in thickness, strength, roughness, and hydrophobicity depending on end-user requirements. The Bode plot indicated enhanced corrosion resistance in the superhydrophobic films. Antibacterial trials with Escherichia coli and Staphylococcus aureus microbial solutions showed that the superhydrophobic film had a significantly lower rate of colony-forming units compared to both the transparent surface and the control blank sample. Moreover, a life cycle assessment revealed that the film production resulted in a 62% lower embodied energy and 34% lower carbon footprint compared to virgin PP pellets sourced from petroleum. These films exhibit distinctiveness with their dual functionality as coatings and freestanding films. Unlike conventional coatings that require chemical application onto the substrate, these films can be mechanically applied using adhesive tapes on a variety of surfaces. Overall, the effective recycling of waste PP into versatile superhydrophobic films not only reduces environmental impact but also paves the way for a more sustainable and eco-friendly future.

Repurposing the single-used-plastic for development of hydrophobic aerogels for remediation of oil spill and organic solvents

Currently, around 400 million tonnes of synthetic polymers are being dumped as waste annually and by this rate by 2050 the ocean would contain more such waste compared to the total weight of fish. As recycling could solve part of this problem, recently such waste is being reused for various purposes like composite preparation, oil production and various other use such as production of foams, sponges, and aerogels. However, there is a relatively limited literature available on the utilization of polyethylene polymer (like LDPE). The study presented in this article indicated that LDPE-based polymers could be reused (after modification) for preparation of hydrophobic, lightweight, and porous aerogels that have oil-spills and organic solvent adsorption capacity. The aerogels showed contact angle of 121.9o, bulk density below 0.25 g/cm3, and were found to be semi-crystalline. The aerogels showed oil and solvent adsorption more than that for their untreated counterparts. Also, the aerogels were found to be recycled for more than five cycles with very minimum loss of efficacy. This area of producing oil sorbents from single used plastic wastes is still very open for further research and seems to be a promising route for both waste reduction, and the synthesis of value-added products. This could be one of the most sustainable approaches for efficient single-used plastic wase management and environment clean-up.

Non-Wettable Microporous Sheets Using Mixed Polyolefin Waste for Oil-Water Separation

Mixed polyolefin-based waste needs urgent attention to mitigate its negative impact on the environment. The separation of these plastics requires energy-intensive processes due to their similar densities. Additionally, these materials cannot be blended without compatibilizers, as they are inherently incompatible and immiscible. Herein, non-wettable microporous sheets from recycled polyethylene (PE) and polypropylene (PP) are presented. The methodology involves the application of phase separation and spin-casting techniques to obtain a bimodal porous structure, facilitating efficient oil-water separation. The resulting sheets have an immediate and equilibrium sorption uptake of 100 and 55 g/g, respectively, due to the presence of micro- and macro-pores, as revealed by SEM. Moreover, sheets possess enhanced crystallinity, as evidenced by XRD; hence, they retain their structure during sorption and desorption and are reusable with 98% efficiency. The anti-wetting properties of the sheets are enhanced by applying a silane coating, ensuring waterless sorption and a contact angle of 140°. These results highlight the importance of implementing sustainable solutions to recycle plastics and mitigate the oil spill problem.