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Page no; 4 CONTENTS Series Preface ix Preface xi About the Author xxi Acknowledgements xxii 1 Sorting and Separation Techniques 1 2 Size Reduction of Recycled Plastics 63 3 Melt Filtration of Contamination in Recycled Polymers 101 4 Recycling of PET 119 5 Recycling of Polyolefins 183 6 Recycling of PVC 219 7 Polystyrene Recycling 271 8 Nylon Recycling 287 9 Recycling of Engineering Thermoplastics 303 10 Recycling of Polyurethanes 339 11 Recycling of Polymer Composites 379 12 Rubber Tyre Recycling 411

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Page no; 4 CONTENTSSeries Preface ixPreface xiAbout the Author xxiAcknowledgements xxii1Sorting and Separation Techniques12Size Reduction of Recycled Plastics633Melt Filtration of Contamination in Recycled Polymers1014Recycling of PET1195Recycling of Polyolefins1836Recycling of PVC2197Polystyrene Recycling2718Nylon Recycling2879Recycling of Engineering Thermoplastics30310Recycling of Polyurethanes33911Recycling of Polymer Composites37912Rubber Tyre Recycling41113Feedstock RecyclingPyrolysis, Hydrogenation and Gasification45914Incineration of Plastic Waste with Energy Recovery50715Plastics Lumber Based on Recycled Polymers537Index 573

SORTING AND SEPARATION TECHNIQUES1Introduction22Manual Sorting33Density-based Sorting Methods33.1 Float-Sink Methods (Wet Separation) 43.2 Dry Separation 53.3 Centrifugal Sorting 53.4 Sorting with Near-Critical and Super-Critical Fluids 93.5 Float-Sink by Preferential Solvent Absorption 133.6 Float-Sink by Hydrophobicity 133.7 Froth Flotation 134Optical Sorting154.1 Operation of Colour Sorters 154.2 Commercial Models 185Advanced Spectroscopic-Based Sorting Methods205.1 Mid-Infra-Red (MIR) Spectroscopy 205.2 Near-Infra-Red (NIR) Spectroscopy 235.3 Laser Acoustic Sensing 355.4 Raman Spectroscopy 365.5 Sorting by Laser-Induced Emission Spectral Analysis 375.6 Sorting by Plasma Emission Spectroscopy 375.7 Miscellaneous Spectroscopic Techniques 415.7.1 Polarized Light 415.7.2 Phase Contrast Illumination 415.7.3 UV Light 415.7.4 Fluorescent Tagging 416X-ray Fluorescence for Sorting PVC426.1 XRF-Based PVC Bottle Sorting Systems 436.2 XRF-Based PVC Flake Sorting Systems 457Electrostatic Sorting Techniques477.1 Triboelectric Pen 477.2 Continuous Separation of Plastic by Frictional Electrification 487.2.1 Introduction 487.2.2 Triboelectric Drum Separator 497.2.3 Corona Charging Belt Separator 52Sorting by Melting (Softening) Temperature549Sorting by Selective Dissolution5510Sorting by Size Reduction-classification5811Sorting of Metal Contaminants by Eddy Current Separators58Acknowledgements 58References 59

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2SIZE REDUCTION OF RECYCLED PLASTICS1Introduction 642Cutting Processes 642.1 Shredders 642.2 Rotary Grinders 682.3 Rotary Knife Cutters (Granulators) 682.3.1 Wet Size Reduction 722.4 Slicers 732.5 Screw Cutters 742.6 Laminate Separation by Size Reduction 743Densification Processes763.1 Agglomerators 763.1.1 Agglomeration by Densifying Discs 763.1.2 Agglomeration by Compression 783.1.3 Agglomeration by Agitation 813.1.4 Agglomeration As Part of the Erema Size Reduction Process 813.1.4.1 Erema Cutter-Compactor 833.1.4.2 Erema Vacuum Shredder Drum 843.1.4.3 Compaction of EPS Foam 843.1.5 Agglomeration-Assisted Sorting 853.2 Densification/Compaction of Film 863.3 Roller Die Compaction 894Pulverization Processes894.1 Introduction 894.2 Disc Pulverisers 904.3 Turbo Rotor Pulverization 924.4 Hammer Mills 924.5 Cryogenic Pulverization 944.6 Solid State Shear Extrusion (SSSE) 944.6.1 Equipment for SSSE Pulverization 975Chemical Size Reduction98Acknowledgements 98References 98< previous page page_63 next page >

< previous page page_101 next page >3MELT FILTRATION OF CONTAMINATION IN RECYCLED POLYMERS1Introduction1012Discontinuous Screen Changers1033Continuous Flow Screen Changers1043.1 Continuous Filter Ribbon Screen Changer 1043.2 Backflushing Melt Filtration Systems 1053.2.1 Piston-Type Continuous Screen Changers 1063.2.1.1 Single Piston Screen Changers 1063.2.1.2 Dual Piston Screen Changers 1073.2.2 Self-Purging Melt Filter Wheel 1123.2.3 Laser Filters 1144Filtration Requirements for Different Recycled Polymers116Acknowledgements 116References 117

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4RECYCLING OF PET1Introduction1211.1 Barriers to PET recycling 1232Contamination Problems1242.1 Acid Precursors 1242.2 Moisture Contamination 1272.3 Labels 1282.4 Label Adhesives 1292.5 Colour Contamination 1292.6 Ink Contamination 1292.7 Particulate Impurities 1292.8 Trace Metal Interaction 1302.9 Adventitious Contamination 1302.10 Acetaldehyde 1303PET Separation and Washing Processes1313.1 Float-Sink Separation 1313.2 Washing 1313.2.1 Water Washing 1323.2.2 Solvent Washing 1333.3 Purification by Dissolution and Precipitation 1334Melt Reprocessing1354.1 Reduction of Intrinsic Viscosity 1354.2 Advantages 1364.3 Disadvantages 1364.4 Long-term Degradation 1364.5 Strategies for Maintaining Intrinsic Viscosity During Reprocessing 1374.5.1 Intensive Drying 1374.5.2 Reprocessing with Degassing Vacuum 1384.5.3 Chain Extension 1384.5.4 Melt Strength Enhancement 1414.5.5 Phosphites 1415Properties of Mechanically Recycled PET1435.1 Extractables 1435.2 Processability 1455.3 Hydrolysis 1455.4 Mechanical Properties 1456Applications for Mechanically Recycled PET145< previous page page_119 next page >

6.1 Fibre Applications 1466.1.1 Staple Fibre 1466.1.2 Filament 1466.1.3 Non-Wovens 1476.1.4 Fibre-Fill 1476.2 Carpets 1486.3 Strapping 1496.4 Sheet 1496.5 Films 1496.6 CoextrusionMultilayer Films 1496.7 Non-Food Contact Containers 1496.8 Injection Mouldings 1496.9 Large Mouldings 1506.10 Engineering Resins 1507Food Contact Applications for Recycled PET1517.1 Introduction 1517.2 Food Contact Issues 1527.3 Diffusion Coefficients of Contaminants 1527.4 Testing (Simulated Contamination) 1537.5 Processes That Enable Recycled PET to Be Used in Food Contact Applications 1537.5.1 Multilayer Process 1547.5.1.1 Advantages 1567.5.1.2 Disadvantages 1567.5.2 SuperCycleWashing Process 1567.5.2.1 Advantage of SuperCycleProcess 1577.5.2.2 Disadvantage 1578Chemical Recycling (Chemolysis)1578.1 Introduction 1578.1 Introduction 1578.1.1 Disadvantages of Chemolysis 1598.2 Glycolysis 1608.2.1 Advantages 1608.2.2 Disadvantages 1628.3 Methanolysis 1628.3.1 Advantages 1638.3.2 Disadvantages 1638.4 Hydrolysis 1648.4.1 Advantages 1648.4.2 Disadvantages 1648.4.3 Base-Catalyzed Hydrolysis Processes 1658.4.3.1 Sodium Hydroxide 1658.4.3.2 Oxidation of Ethylene Glycol 1668.4.4 Acid-Catalyzed Hydrolysis Processes 1668.4.4.1 Sulphuric Acid Process 1668.4.4.2 Nitric Acid Process 1668.4.5 Neutral Hydrolysis Processes 1678.4.6 Hydrolysis by Reactive Extrusion 1678.5 Hybrid Processes (Glycolysis-Hydrolysis) 1678.5.1 Embrittlement 1688.5.2 Crushing and Sizing 1698.5.3 Glycolysis-Hydrolysis 1698.5.4 Advantages of Hybrid Chemolysis 1708.6 Diolysis of PET Scrap to Give PBT 1728.7 Polyol Production 1728.7.1 Polyurethanes 1728.7.2 Unsaturated Polyesters 1738.7.2.1 Polymer Concrete and Polymer Mortar 1748.7.2.2 Automotive SMC 1748.7.3 Surface Coatings 1769Energy Recovery176Acknowledgements 179References 180Glossary of Abbreviations 182< previous page page_120 next page >

< previous page page_183 next page >5RECYCLING OF POLYOLEFINS1Introduction1842HDPE Bottle Recycling (Dairy, Juice and Household and Industrial Chemical Bottles1842.1 The Recycling Process for HDPE Bottles 1852.2 Characteristics of Recycled HDPE 1872.3 Producers of Recycled HDPE and Recycle-Tolerant Grades 1882.4 Applications for HDPE Recyclate 1902.4.1 Large Moulded Containers 1902.4.2 Blow Moulded Bottles 1922.4.3 Multilayer Blow-Moulded Containers for Food Contact Applications 1942.4.4 Bottle Crates 1942.4.5 Kayaks 1942.4.6 Pallets and Large Injection Moulded Parts 1952.4.7 Agricultural and Drainage Pipe 1952.4.8 Film Applications 1962.4.8.1 Introduction 1962.4.8.2 Grocery Sacks 1972.4.8.3 Garbage Bags 1982.4.8.4 Overwrap Film 1982.4.9 Rubber-Modified Products 1982.4.10 Structural Applications 1992.4.11 Miscellaneous Applications 2002.5 Contamination Issues for HDPE 2002.5.1 PP Contamination of HDPE 2012.5.2 Copolymer HDPE Contamination in Homopolymer HDPE 2012.5.3 PET Contamination in HDPE 2022.5.4 Adhesive Contamination in HDPE 2022.5.5 Paper Contamination 2022.5.6 Contamination by Packaging Contents 2022.5.7 Contamination by Additives 2032.5.8 Contamination by Reprocessing 2042.5.9 Purification of HDPE Recyclate 2043Recycling of HDPE Motor-Oil Containers2054Recycling of HDPE Automotive Fuel Tanks2055LDPE Recycling2075.1 Stretch Film Recycling 2075.2 Contamination Problems with LDPE Recyclate 209LLDPE Film Recycling2097Polypropylene Recycling2107.1 Battery Cases 2107.2 Automotive Bumpers 2107.3 Bale Wrap and Bulk Bags 2137.4 Recycled PP Blends 2137.5 Applications for Recycled PP 2138Recycle Design Considerations2138.1 Product Dismantling Considerations 214Acknowledgements 215References 2156RECYCLING OF PVC1Introduction2202Barriers to PVC Recycling2222.1 Contamination 2222.2 Thermal Instability of PVC 2222.3 Multicomponent Nature of PVC Applications 2232.4 Low Volumes of Scrap PVC 2233Separation Techniques for PVC and PET2233.1 Manual Sorting 2233.2 Automatic Sorting 2233.2.1 Polarized Light 2243.2.2 Softening Point 2243.2.3 Electrostatics 2243.2.4 Sorting by Density 2243.2.5 Selective Dissolution 2243.2.6 Froth Flotation 2253.2.7 X-Ray Fluorescence 2253.2.7.1 Advantages 2263.2.7.2 Disadvantages 2264Size Reduction Techniques2274.1 Ambient Grinding 2274.2 Cryogenic Grinding 2275Melt Filtration2286Mechanical Recycling Processes2326.1 PVC Bottle Recycling 2326.1.1 The Solvay Process 2326.1.2 The Geon Process 2346.2 PVC Cable Recycling 2366.2.1 Cable Insulation Cleaning and Recovery Process 2376.3 PVC Pipe Recycling 2406.4 PVC Window Frame Recycling 2426.5 Flexible PVC Film Recycling 2486.6 PVC Roofing Membrane Recycling 2496.7 PVC Automotive Composites 2516.7.1 PVC-Backed Textiles 2516.7.2 PVC-Skinned Dashboards 2536.7.3 Automotive Cable Recycling 253< previous page page_219 next page >Applications for Mechanically Recycled PVC2547.1 Co-Extruded PVC Pipes 2547.2 Co-Extruded Cladding 2567.3 Guttering 2587.4 Co-Extruded Window Frames 2597.5 PVC Plastic Wood 2597.6 Conduit for Cables 2597.7 Pipe Fittings 2607.8 Floor Coverings 2607.9 Fibres 2607.10 Non-Food Bottles 2627.11 Surface Coatings 2637.12 Sound Protection Panels 2647.13 Automotive Acoustic Insulation 2647.14 Floor Mats 2657.15 Computer Equipment 2658Chemical Recycling of PVC2659Incineration with HCl and Energy Recovery2669.1 Dioxin Formation 2669.2 HCl Formation 2669.3 Thermosplitting 2679.4 Closed-Loop Salt Cycle Process 268Acknowledgements 268References 269

< previous page page_271 next page >Page 2717POLYSTYRENE RECYCLING1Introduction2712Densification of EPS Foam2733Size Reduction of Waste EPS Foam2743.1 Applications for Size-Reduced EPS 2743.1.1 Soil Improver 2743.1.2 Composting Aid 2743.1.3 EPS-Cladded Drainage Pipe 2753.1.4 Construction Applications 2763.1.4.1 Lightweight Concrete 2763.1.4.2 EPS as a Cavity-Former in Clay Firebricks 2763.1.4.3 EPS-Modified Insulating Mortar 2763.1.4.4 EPS-Modified Plaster 2763.1.4.5 EPS-Modified Plastic Lumber 2774Mechanical Recycling of PS2774.1 General Mechanical Recycling of EPS 2774.2 Erema Process for Reprocessing of EPS 2774.3 Degradation of Recycled PS 2784.4 Grades of Mechanically Recycled PS 2795Solvent Recycling2796Applications for Recycled EPS2816.1 Packaging Foam 2816.2 Loosefill 2816.3 PS Wood Substitute 2816.4 Sorbant Polymers 2837Depolymerization of Scrap PS2838Energy Recovery from Scrap EPS285Acknowledgements 286References 286

< previous page page_287 next page >Page 2878NYLON RECYCLING1Introduction2872Carpet Recycling2882.1 Sorting and Separation of Used Carpets 2892.1.1 Carpet Identification by Melting Point 2892.1.2 Carpet Identification by Near Infra-Red 2902.1.3 Grinding and Density Separation of Carpets 2902.1.4 Solvent Separation 2913Chemical Recycling of Nylon2913.1 Acidolysis 2913.2 Hydrolysis 2933.3 Ammonolysis (or Aminolysis) 2933.4 Depolymerization in Vacuo 2964Mechanical Recycling and Applications297Acknowledgements 301References 301

< previous page page_303 next page >Page 3039RECYCLING OF ENGINEERING THERMOPLASTICS1Introduction3042Major Areas Where Engineering Polymers Are Being Recycled3062.1 Computers and Electrical Equipment Housings 3062.2 Automotive Plastics 3072.3 Compact Discs 3073Major Recyclers of Engineering Plastics3073.1 GE Polymer Recovery Process 3073.2 Bayer Engineering Plastics Recycling Program 3103.3 MRC Polymers 3114Major Engineering Polymers Being Recycled3114.1 Polycarbonate 3114.2 PC Blends and Alloys 3144.2.1 PC-PBT Resins 3144.2.2 PC-ABS Resins 3154.2.3 PC-PMMA Resins 3164.3 ABS 3174.3.1 Uses of Recycled ABS 3224.4 PPO-PS Blends 3244.4.1 Uses for Recycled PPO-PS 3254.5 Polyacetals 3264.5.1 Mechanical Recycling of Polyacetals 3264.5.2 Chemical Recycling of Polyacetals 3274.6 Styrene-Methacrylate Copolymers 3305Removal of Paints and Plating from Engineering Plastics3315.1 Hydrolysis 3325.2 Chemical Stripping 3325.3 Liquid Cyclone 3335.4 Compressed Vibration 3335.5 Melt Filtration 3335.6 Mechanical Abrasion 3335.7 Cryogenic Grinding 334< previous page page_303 next page >< previous page page_304 next page >Page 3045.8 Dry Crushing 3355.9 Roller Pressing 335Acknowledgements 337References 338

10RECYCLING OF POLYURETHANES1Introduction3402Physical Recycling3412.1 Introduction 3412.2 Rebonded Foam 3432.2.1 Rebonding of Rigid PU Foam 3432.2.2 Rebonding of Flexible PU Foam 3432.3 Regrind Recycling 3452.3.1 Regrind Recycling of PU Foam 3462.3.2 Regrind Recycling of RIM PU 3482.3.3 SRIM Recycling 3522.4 Compression Moulding 3523Chemical Recycling3543.1 Introduction 3543.2 Glycolysis of Rigid PU Foams (University of Padova) 3553.3 Commercial Chemical Recycling Processes for PU Foams 3593.3.1 Single Polyol Recovery Processes 3603.3.1.1 Getzner Alcoholysis/Glycolysis Process 3603.3.2 Double Polyol Recovery Processes (Recovery of Flexible and Rigid PolyolComponents)3643.3.2.1 Split-Phase Glycolysis (ICI) 3643.3.2.2 Tandem Chemolysis Process (Dow) 3693.4 Miscellaneous Approaches 3704Feedstock Recycling and Energy Recovery3714.1 Gasification 3734.2 Incineration with Heat Recovery 3735Recycling Considerations for PU Foams3755.1 CFC Problems 3755.2 Car Seat Design 3756Future Outlook375Acknowledgements 376References 376< previous page page_339 next page >

< previous page page_379 next page >Page 37911RECYCLING OF POLYMER COMPOSITES1Introduction3802Recycling of Thermoset Composites3812.1 Introduction 3812.2 Simple Grinding of SMC (for Re-use As a Filler) 3842.2.1 Regrind Processes 3862.3 Advanced Grinding Processes for SMC 3872.3.1 ERCOM Controlled Comminution Process 3872.3.1.1 Details of the ERCOM Process 3892.3.1.2 ERCOM Grades 3912.3.1.3 Telephone Booth Applications 3912.3.1.4 Automotive and Other Applications 3942.3.1.5 Economics of ERCOM Recycling Process 3952.3.2 Phoenix Fibreglass Recycling Process 3952.4 Selective Chemical Degradation of SMC Scrap 3962.5 Solvent Recycling of Uncured SMC 3982.6 Pyrolysis of SMC Scrap 3982.6.1 High-Temperature Pyrolysis 3992.6.2 Controlled Pyrolysis with Recovery of Pyrolytic Oil 3992.6.3 Modified Pyrolysis Process 4002.6.4 Low-Temperature Pyrolysis 4002.6.4.1 Advantages of Catalyzed Low-Temperature Pyrolysis 4012.7 Reverse Gasification of SMC Scrap 4022.8 Energy Recovery from SM Scrap 4042.8.1 Introduction 4042.8.2 Co-Combustion of SMC Scrap with Coal 4052.8.3 SMC Waste As a Fuel for Cement Kilns 4063Recycling of Thermoplastic Composites4063.1 Short-Fibre Thermoplastic Composites 4063.2 Carbon-Fibre PEEK Composites 4073.3 Aramid-Based Thermoplastic Composites 408Acknowledgements 409References 409

12RUBBER TYRE RECYCLING1Introduction4122Tyre Size Reduction4152.1 Tyre Shredding 4152.1.1 Mobile Tyre Shredders 4162.2 Mechanical Grinding 4172.3 Cryogenic Grinding 4182.4 Quality of Crumb Rubber 4193Ground Rubber Crumb Applications4203.1 Filler Applications 4203.1.1 Automotive Tyres 4213.2 Bound Rubber Products 4223.2.1 Mats 4243.2.2 Playground Mats and Pavers 4243.2.3 Skid Resistant Mats 4253.2.4 Athletic Tracks 4253.2.5 Carpet Underlay 4263.3 Rubber Crumb with a Thermoplastic Binder 4263.3.1 Soaker Hose 4263.3.2 Drainage Systems 4273.3.3 Mulch Mats 4273.3.4 Sound Proofing Barriers 4273.3.5 Interlocking Rubber Tiles 4273.3.6 Livestock Stall Mats 4284Civil Engineering Applications4284.1 Artificial Reefs 4284.2 Dock Systems 4284.3 Playground Cover 4294.4 Turf Top Dressing 4294.5 Slope Stabilization and Road Fill 4294.6 Rubberized Asphalt 4304.7 Rubber Modified Concrete 4315Reclaiming and Devulcanization4315.1 Pan Process 4325.2 Digestor Process 4335.3 Chemical Devulcanization 434< previous page page_411 next page >5.3.1 Advantages of Chemical Devulcanization 4365.3.2 Limitations of Chemical Devulcanization 4365.4 Ultrasonic Devulcanization 4365.5 Microbial Devulcanization 4376Surface Treatment4376.1 Latex Surface Treatment 4376.2 The TirecycleTM Process 4416.2.1 Grades of Tirecycle 4426.3 Crumb with Dessicant Coating 4426.4 Reactive Gas Treatment 4436.4.1 Improved Wet Traction 4436.4.2 Toughening of Epoxy Resins 4446.5 Plasma Treated Rubber 4457Composites of Recycled Tyre Crumb and Thermoplastics4468Tyre-Derived Fuel (TDF)4478.1 Fuel for Cement Kilns 4498.2 Iron Foundries 4508.3 Energy Generation 4518.4 Limitations of TDF 4519Pyrolysis4529.1 Upgraded Pyrolysis Char 4539.2 Microwave Pyrolysis 454Acknowledgements 455References 455

< previous page page_459 next page >Page 45913FEEDSTOCK RECYCLINGPYROLYSIS, HYDROGENATION AND GASIFICATION1Introduction4602Pyrolysis4622.1 Introduction 4622.2 Advantages of Pyrolysis over Incineration 4622.3 Kiln/Retort Pyrolysis Processes 4632.3.1 Introduction 4632.3.2 BASF Feedstock Recycling Process 4632.3.2.1 Benefits and limitations of the BASF Pyrolysis Process 4662.3.2.2 Economics of the BASF Process 4662.3.3 VEBA Pyrolysis Process 4672.3.4 Fuji Fixed-bed Pyrolysis of Plastic Waste 4692.4 Fluidized Bed Pyrolysis Processes 4702.4.1 Introduction 4702.4.2 The Hamburg Fluidized Bed Pyrolysis 4722.4.3 BP Fluidized Bed Cracking Process 4742.5 Examples of Applications of Pyrolysis Recycling 4782.5.1 Pyrolysis of Rubber Tyres 4782.5.2 Pyrolysis of Electronic Plastic Scrap 4792.5.3 Pyrolysis of Automotive Shredder Residue 4803Hydrogenation of Plastic Waste4803.1 Introduction 4803.2 Advantages of Hydrogenation over Incineration 4813.3 VEBA Hydrogenation Process 4813.4 Economics of Hydrogenation of Plastic Waste 4904Gasification4914.1 Introduction 4914.2 Advantages of Gasification over Incineration 4914.3 The Texaco Gasification Process 4924.4 Thermoselect Gasification Process 4934.4.1 Introduction 4934.4.2 Process Details 494< previous page page_460 next page >Page 4604.4.3 Applications of Raw Materials and Energy Recovered 4994.5 VEBA Gasification Process 5004.6 Winkler ProcessFluidized Bed Gasification 5034.7 Fixed Bed GasificationSVZ Process 5034.8 Economics of Gasification 503Acknowledgements 503References 504

< previous page page_507 next page >Page 50714INCINERATION OF PLASTIC WASTE WITH ENERGY RECOVERY1Introduction5072Incineration of Plastic Waste As Part of Municipal Solid Waste5102.1 Introduction 5102.2 Combustor Design 5122.3 Advantages and Limitations of Increasing Content of Plastic Waste for MSWIncineration5142.4 Wrzburg MSW Trials 5143Advanced Processes for Utilizing Plastic Derived Fuel (The Fuel Concept)5153.1 Introduction 5153.2 Monocombustion 5163.3 Co-Combustion 5193.3.1 Introduction 5193.3.2 Advantages of Co-Combustion of Plastics Waste 5213.3.3 Co-combustion Trials with Fluidized Bed Boilers 5213.4 Cement Kilns 5233.5 Blast Furnace Processes 5264Emissions and Solid Residues5264.1 Oxides 5264.2 Hetero-Atoms 5264.3 Dioxins 5284.4 Solid Residues 5304.5 Unburnt Carbon 5325Concluding Remarks532Acknowledgements 533References 533

< previous page page_537 next page >Page 53715PLASTICS LUMBER BASED ON RECYCLED POLYMERS1Introduction5371.1 Features of Plastic Lumber 5381.2 Limitations of Plastic Lumber 5381.3 Applications of Plastics Lumber 5392Commingled Plastic Lumber5442.1 Economics of Mixed Plastic Lumber 5483Single Stream Plastic Lumber5493.1 HDPE-Based Plastic Lumber 5493.2 Polystyrene-Based Plastic Lumber 5514Plastic Lumber with Fillers and Modifiers5524.1 Wood Fibre-Recycled Plastic Composite Lumber 5524.1.1 Introduction 5524.1.2 Compatibilizers 5524.1.3 Recycled Polyethylene-Wood Fibre Composites 5554.1.4 PS-Wood Composites 5584.1.5 PVC-Wood Composites 5584.2 Recycled Polymer-PS Lumber 5585Processes for Producing Plastic Lumber5595.1 Intrusion 5595.1.1 Product Performance 5635.2 Profile Extrusion 5675.3 Compression Moulding 5675.4 Controlled Density Injection Moulding 567Acknowledgements 571References 571