Grantee Research Project Results
Final Report: A Process for Online Quality Control of Recycled Plastic Flake
EPA Contract Number: 68D02057Title: A Process for Online Quality Control of Recycled Plastic Flake
Investigators: Sommer, Edward J.
Small Business: National Recovery Technologies Inc.
EPA Contact: Richards, April
Phase: II
Project Period: June 1, 2002 through June 1, 2004
Project Amount: $225,000
RFA: Small Business Innovation Research (SBIR) - Phase II (2002) Recipients Lists
Research Category: SBIR - Pollution Prevention , Pollution Prevention/Sustainable Development , Small Business Innovation Research (SBIR)
Description:
The objective of this research project was to develop an automated system for online monitoring of contaminant in a stream of recycled plastic in the flake form. The value of the flake is increased because contaminated flake can be diverted for further flake sorting or blending. The increased value of the product improves the economics for recovery and recycling of plastics.
Summary/Accomplishments (Outputs/Outcomes):
Based on a market analysis, National Recovery Technologies, Inc. (NRT) identified online monitoring of contamination level in the recycled plastics stream as important for increasing the value of the recycled material. Existing quality control methods rely on laboratory analyses that give results hours, or sometimes even days, after the material has been processed. Such techniques are suitable for quality monitoring but are not designed for quality control.
NRT developed spectroscopic techniques for the identification of contaminant polymers within the recycled flake stream. NRT then utilized innovative algorithms to determine the level of contamination (in parts per million) within the flake stream. Meaningful results are obtained with just 4 minutes of online analysis, allowing the processor to divert material with high contamination levels. Thus, the NRT Online Flake Analyzer is well suited to quality control applications.
The NRT Online Flake Analyzer also is useful as a quality monitoring tool. Data can be displayed for periods up to the preceding month of production. This permits the monitoring of quality trends that are useful for recognizing changes in material quality due to material input, upstream sorting changes, and other factors. Data also may be downloaded to files that are compatible with standard spreadsheet programs.
NRT also investigated methods for color analysis of the recycled plastic flake stream. Clear plastic flake has the highest value in the marketplace due to its ability to be used in more diverse applications. Online analysis of color contamination within a clear recycled plastic flake stream will allow for diversion of material contaminated with color, resulting in a more valuable flake stream.
Conclusions:
This project led to the development of two prototype systems for the online analysis of recycled plastic flake. Flake can be analyzed at rates of up to 100 lb/hr (46 kg/hr) with a high degree of accuracy. This technology is expected to be installed in plastics recycling facilities where quality control is of concern. It also is expected to have significant impact within the plastics recycling industry because it will increase the value of the recycled resin.
Supplemental Keywords:
online monitoring, quality control, plastic flake, flake stream, Online Flake Analyzer, flake analysis, recycled material, contaminant polymers, polymer analysis, color analysis, color contamination, plastics recycling, EPA, small business, SBIR,, RFA, AirSBIR Phase I:
A Process for Online Quality Control of Recycled Plastic FlakeThe perspectives, information and conclusions conveyed in research project abstracts, progress reports, final reports, journal abstracts and journal publications convey the viewpoints of the principal investigator and may not represent the views and policies of ORD and EPA. Conclusions drawn by the principal investigators have not been reviewed by the Agency.