Polymer recyclate processes and products

Abstract

Methods for processing HDPE recyclates including, but not limited to, polyethylene and polypropylene and compositions therefrom are provided. HDPE recyclate can be visbroken to improve processing characteristics and/or devolatilized to remove waste byproducts to produce processed HDPE recyclates. Processed HDPE recyclates are compounded with pre-consumer polyolefins to produce blend compositions having acceptable or even improved processing characteristics. Such pre-consumer polyolefins can also be visbroken to further tailor processing characteristics of such polymer blends. A combination of extruders and/or extruder zones can be used at the same or different locations for visbreaking and/or compounding of both HDPE recyclate and/or pre-consumer polyolefins.

What is claimed is: 
     
         1 . A method for processing high density polyethylene (HDPE) recyclate comprising:
 a. providing a HDPE recyclate feedstock having:
 i) a first density in the range of from 0.940 g/cm 3  to 0.970 g/cm 3 ; 
 ii) a first melt index (I 2 ) less than or equal to 1.0 g/10 min; 
 iii) a first molecular weight distribution (M w /M n ) greater than 10; 
 iv) a first weight average molecular weight (“M w1 ”) greater than or equal to 100,000 daltons; and 
 v) a first melt elasticity (“ER”) greater than or equal to 1.0; 
   b. adding the HDPE recyclate to a first extruder to produce a first HDPE recyclate melt; and   c. subjecting the first HDPE recyclate melt to visbreaking conditions to produce a second HDPE recyclate melt having:
 i) a second density, wherein the ratio of the second density to the first density is greater than or equal to 1.0; 
 ii) a second melt index, wherein the ratio of the second melt index to the first melt index is greater than or equal to 5.0; 
 iii) a second molecular weight distribution, wherein the ratio of second molecular weight distribution to the first molecular weight distribution is less than or equal to 0.70; 
 iv) a second weight average molecular weight (“M w2 ”), wherein M w2 /M w1  is in the range of from 0.10 to 0.70; and 
 v) a second melt elasticity, wherein the ratio of the second melt elasticity to the first melt elasticity is less than or equal to 0.50. 
   
     
     
         2 . The method of  claim 1 , wherein the HDPE recyclate feedstock comprises post-consumer recycled waste, post-industrial recycled waste, or a combination thereof. 
     
     
         3 . The method of  claim 1 , wherein the visbreaking conditions consist of thermal visbreaking. 
     
     
         4 . The method of  claim 3 , wherein thermal visbreaking is performed at a temperature greater than or equal to 300° C. 
     
     
         5 . The method of  claim 1 , further comprise further subjecting the first HDPE recyclate melt to devolatilization conditions to produce the second HDPE recyclate melt wherein:
 the HDPE recyclate feedstock has a first volatile organic compound content;   the first HDPE recyclate melt has a second volatile organic compound content; and   the ratio of the second volatile organic compound content to the first volatile organic compound content is less than or equal to 0.9.   
     
     
         6 . The method of  claim 5 , wherein devolatilization conditions comprise injection and withdrawal of a scavenging gas. 
     
     
         7 . The method of  claim 1 , wherein the method is characterized by one or more of the following:
 i) the HDPE recyclate feedstock has a first high load melt index (I 21 ), the second HDPE recyclate melt has a second high load melt index, and the ratio of the second high load melt index to the first high load melt index is greater than or equal to 5.0;   ii) the HDPE recyclate feedstock has a first melt index ratio (I 21 /I 2 ), the second HDPE recyclate melt has a second melt index ratio, and the ratio of the second melt index ratio to the first melt index ratio is less than or equal to 0.50;   iii) the HDPE recyclate feedstock has a first long chain branching parameter (g′), the second HDPE recyclate melt has a second g′, and the ratio of the second g′ to the first g′ is less than to 1.0, and/or the first g′ is in the range from 0.70 to 0.99;   iv) the HDPE recyclate feedstock has a first long chain branching index (“LCBI”) greater than or equal to 0.30, and the second HDPE recyclate melt has a second LCBI”) less than or equal to 0.20;   v) the HDPE recyclate feedstock has a first overall polydispersity measure (“PDR”), the second HDPE recyclate melt has a second PDR, and the ratio of the second PDR to the first PDR is less than or equal to 0.40;   vi) the HDPE recyclate feedstock has a first complex viscosity ratio, the second HDPE recyclate melt has a second complex viscosity ratio, and the ratio of the second complex viscosity ratio to the first complex viscosity ratio is less than or equal to 0.20, and/or the second complex viscosity ratio is less than or equal to 10; and   vii) the HDPE recyclate feedstock and/or MDPE recyclate feedstock have a first intrinsic viscosity, the second HDPE recyclate melt and/or MDPE recyclate melt has a second intrinsic viscosity, and the ratio of the second intrinsic viscosity to the first intrinsic viscosity is less than or equal to 0.90.   
     
     
         8 . The method of  claim 1 , wherein a HDPE recyclate product is formed by withdrawal of the second HDPE recyclate melt from the first extruder for further processing or pelletizing of the second HDPE recyclate melt. 
     
     
         9 . The method of  claim 8 , further comprising:
 adding the HDPE recyclate product and a first polyolefin blend component to a second extruder; and   effecting compounding conditions in the second extruder to form a polyolefin product comprising the melt-blended mixture of the processed HDPE recyclate product and the first polyolefin blend component.   
     
     
         10 . The method of  claim 9 , wherein the first polyolefin blend component comprises a virgin polyolefin, a polyolefin recyclate feedstock, a processed polyolefin recyclate, or a combination thereof. 
     
     
         11 . The composition of  claim 10 , wherein:
 a. the virgin polyolefin comprises a virgin LDPE, a virgin LLDPE, a virgin HDPE, a virgin MDPE, a virgin polypropylene, or a combination thereof;   b. the polyolefin recyclate feedstock comprises a LDPE recyclate feedstock, a LLDPE recyclate feedstock, a HDPE recyclate feedstock, a MDPE recyclate feedstock, a polypropylene recyclate feedstock, or a combination thereof; and   c. the processed polyolefin recyclate comprises a processed LDPE recyclate, a processed LLDPE recyclate, a second processed HDPE recyclate, a processed MDPE recyclate, a processed polypropylene recyclate, or a combination thereof.   
     
     
         12 . The method of  claim 11 , wherein the first polyolefin blend component comprises a virgin HDPE, a HDPE recyclate feedstock, a processed HDPE recyclate, or a combination thereof. 
     
     
         13 . The method of  claim 9 , wherein the HDPE recyclate product is added in an amount in the range of from 5 wt. % to 90 wt. % based on the combined weight of the HDPE recyclate product and the first polyolefin blend component. 
     
     
         14 . The method of  claim 9 , wherein the compounding conditions include a temperature less than or equal to 300° C. 
     
     
         15 . The method of  claim 9 , further comprising:
 adding a second polyolefin blend component to a third extruder;   effecting melt conditions in the third extruder to produce a second polyolefin blend component melt; and   withdrawing the second polyolefin blend component melt as the first polyolefin blend component.   
     
     
         16 . The method of  claim 15 , wherein the second blend component comprises a virgin HDPE, a HDPE recyclate feedstock, a processed HDPE recyclate, or a combination thereof. 
     
     
         17 . A composition comprising a polymer blend of:
 a. a first polymer, wherein the first polymer:
 i) is a first processed HDPE recyclate; and 
 ii) is present in an amount in the range of from 5 wt. % to 90 wt. %; and 
   b. a second polymer, wherein the second polymer:
 i) is a virgin polyolefin, a polyolefin recyclate feedstock, a processed polyolefin recyclate, or a combination thereof; and 
 ii) is present in an amount in the range of from 10 wt. % to 95 wt. %; 
   wherein all weight percentages are based on the combined weight of the first and second polymers.   
     
     
         18 . The composition of  claim 17 , wherein:
 a. the virgin polyolefin comprises a virgin LDPE, a virgin LLDPE, a virgin HDPE, a virgin MDPE, a virgin polypropylene, or a combination thereof;   b. the polyolefin recyclate feedstock comprises a LDPE recyclate feedstock, a LLDPE recyclate feedstock, a HDPE recyclate feedstock, a MDPE recyclate feedstock, a polypropylene recyclate feedstock, or a combination thereof; and   c. the processed polyolefin recyclate comprises a processed LDPE recyclate, a processed LLDPE recyclate, a second processed HDPE recyclate, a processed MDPE recyclate, a processed polypropylene recyclate, or a combination thereof.   
     
     
         19 . The composition of  claim 17 , wherein processed means subjected to thermal visbreaking and optionally subjected to devolatilization. 
     
     
         20 . A blend comprising:
 a visbroken HDPE, having a first I 2 ; and   a virgin HDPE, a HDPE recyclate feedstock, a processed HDPE recyclate, or a combination thereof, having a second I 2 ;   wherein:   
       
         
           
             
               
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