Covestro Develops Innovative Process for Recycling Polycarbonate

Covestro has developed an innovative process for recycling polycarbonate, i.e., polychain plastics. In this process, plastics are converted back into their monomers, a precursor of plastics, so that they can be fed back into the production process as alternative raw materials.

At Covestro in Leverkusen, the technical implementation of chemical recycling is now beginning on a pilot scale. On the way to industrial scale, the process is still being optimized and is undergoing further development stages.

Recyclate Serve as Raw Materials for Future Plastics

"As a manufacturer of plastics such as polycarbonate, we naturally have a responsibility in dealing with these important materials, including at the end of their product life. Our advantage is: we know how our products are designed and can therefore conduct targeted research into recycling solutions," says Dr. Thorsten Dreier, Covestro's chief technology officer. "The chemical recycling of polycarbonate is another example with which our colleagues in development show that closed cycles are possible in the future. We need to use end-of-life plastics as a resource and reuse them as alternative raw materials to close the loop."

The return of plastics through recycling replaces primary fossil raw materials in production. Comprehensive recycling thus contributes to climate neutrality and the protection of natural resources and the environment. Mechanical recycling of polycarbonate is already an important component of Covestro's recycling strategy. The mechanical recycling process is used whenever waste streams are sufficiently pure and the recycled polycarbonate meets the requirements profile of the future application.

Chemical recycling works in a complementary way to mechanical recycling - it converts plastic building blocks back into monomers, i.e. their individual building blocks. These can be separated and serve as raw materials for future plastic. Chemical recycling can therefore make larger waste streams that are unsuitable for mechanical processes in particular accessible for recycling; it allows the production of plastics that meet the highest quality requirements. Covestro is therefore actively developing chemical recycling.

Chemolysis Process Adapted to Polycarbonate

The newly developed process, which was driven by an international team, is a specific chemolysis process adapted to polycarbonate. "Pre-sorted waste streams containing a product content of more than 50% polycarbonate can be recycled this way. This has been successfully demonstrated with various polycarbonate-containing plastic waste streams," explains Markus Dugal, head of Process Technology at Covestro. "With the help of this chemolysis, the cycle can be closed to a direct precursor of polycarbonate. This makes the recycling process very sustainable."

The recycled product, a precursor of polycarbonate, can be mass-balanced and reused as a raw material for the production of polycarbonate without further processing. "Such high-quality recycled raw materials are needed for applications that require top quality. These include, for example, applications in the automotive sector with special requirements in terms of safety, optical transparency or aesthetics, and products in our everyday lives such as consumer electronics," says Lily Wang, head of the Engineering Plastics Business Entity.

Pilot Plant for Further Expansion to Industrial Scale

Following successful development in the laboratory, the next stage of development, the technical implementation of a continuous process, has already started. A pilot plant, which is currently in the planning stage, will be used to gather the experience needed for further expansion to industrial scale. Millions of euros will be invested in this over the next few years. The pilot plant will be built in Leverkusen, Germany.

At the same time, Covestro is driving forward further processes for innovative recycling of polycarbonate in its research laboratories. These include chemolytic alternatives, recycling with enzymes that break down the plastic, and smart pyrolysis. Promising alternatives can also be tested with the pilot plant.

Plastics are key to sustainable growth and a green future. To ensure that plastic products do not become waste at the end of their life, they must be reused as alternative raw materials. Innovative recycling is one of the four fields Covestro is actively driving forward on the road to a circular economy. Covestro is therefore stepping up its research into recycling methods, with an open approach to technology, and promoting innovative approaches such as chemical recycling.

Source: Covestro

Today's KNOWLEDGE Share: 𝐅𝐮𝐧 𝐟𝐚𝐜𝐭𝐬 𝐚𝐛𝐨𝐮𝐭 𝐭𝐡𝐞 𝐔𝐒 𝐌𝐚𝐧𝐮𝐟𝐚𝐜𝐭𝐮𝐫𝐢𝐧𝐠 𝐒𝐞𝐜𝐭𝐨𝐫::

 Today's KNOWLEDGE Share:

𝐅𝐮𝐧 𝐟𝐚𝐜𝐭𝐬 𝐚𝐛𝐨𝐮𝐭 𝐭𝐡𝐞 𝐔𝐒 𝐌𝐚𝐧𝐮𝐟𝐚𝐜𝐭𝐮𝐫𝐢𝐧𝐠 𝐒𝐞𝐜𝐭𝐨𝐫::

• Roughly 12.8 million people are employed in manufacturing, making it the 5th largest employer (Source: https://lnkd.in/eNSDg2T2)

• Of the 271,705 identified exporters in 2020, 25% were manufacturers (Source: https://lnkd.in/enyrG-gC)

• 292,825 factories in the United States. The vast majority (268,000) have less than 99 employees. There are 846 factories that employee 1,000 or more employees (Source: https://lnkd.in/enEQzYxM)

• The sector contributes $2.3 Trillion to the U.S. GDP, amounting to 10.8% of total GDP (Source: https://lnkd.in/enSZs6wd.)

• Average compensation in U.S. manufacturing is 10.2% higher than that for total private industry (Source: https://lnkd.in/enSZs6wd.)

• The Boeing Everett Factory in Washington State is the largest factory in the world with a surface area of 398,000 m² (98.3 acres). (Source: https://lnkd.in/eWe2hA4F.)

• California has the most manufacturing jobs (1,541,050) and the most number of manufacturing companies (24,304), followed by Texas in both categories (Source: https://lnkd.in/eR37SQPM)

Map generated by: https://lnkd.in/eFvekxMS

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Evonik to Supply Catalyst for Röhm’s New Methyl Methacrylate Production Plant

Evonik signs an agreement to scale up and produce custom catalyst for Röhm’s new methyl methacrylate (MMA) production plant in Bay City, Texas, USA, which is due to be opened in 2024.

Methacrylate monomers and their derivatives are important precursors used in the automotive, electronic, medical and construction industries.

Catalyst with Reduced Environmental Impact

“This agreement once again, underscores our commitment and capability in custom Catalysts arena. We’re delighted to be able to work with the Röhm team to enable commercial scale production of MMA,” said Sanjeev Taneja, head of Evonik Catalysts.

Taneja continued, “These catalysts play a key role in Röhm’s newly developed LiMA (Leading in Methacrylates) technology to produce MMA with efficient resource use and reduced environmental impact. In many ways, LiMA sets new standards and is the most efficient MMA production technology to have been developed.”

Compared to other MMA processes, the LiMA technology has clear sustainability advantages, as it enables a high yield with low energy consumption and reduced wastewater volumes.

Methacrylate monomers & their derivatives are also essential precursors used in the production of PLEXIGLAS® and specialty applications such as contact lenses and adhesives.

Source: Evonik/specialchem

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Researchers to Study Atomic-level Mechanical Force for Chemical Production

Understanding the atomic-scale mysteries of "crushing" chemistry is the goal of an expanding research center with a newly awarded $20 million investment from the U.S. National Science Foundation (NSF).

Managed by Texas A&M University, NSF's Center for the Mechanical Control of Chemistry (CMCC) will conduct a rigorous exploration to know how the mechanical application of force can enable new advances in chemistry, with the potential to make industrial processes cheaper and more environmentally friendly.

Explore Mechanochemical Reactions

Mechanical chemistry, or mechanochemistry, is the crushing of chemicals to produce reactions and substances. It has long been used by chemists and nature alike — for example, diamonds are created when carbon is squeezed under enormous pressure inside the Earth. While mechanical chemistry has been used to grind out everything from pigments in Renaissance-era paintings to medicinal compounds at local pharmacy, the atomic-scale processes at the heart of such crushing transformations are not fully understood or predictable.

Moreover, while heat or light are often used to impart the energy needed to make and break bonds in chemical reactions, the use of mechanical force to impart that energy and thus drive new types of chemistry remains an underexplored frontier.

The additional funding will enable the center to become a nexus for mechanical chemistry research across the U.S. by supporting work at 11 U.S. institutions in nine states.

"Using traditional chemical methods, chemists have discovered many effective ways to create substances that have enhanced human health and prosperity — like the ammonia essential for agricultural fertilizers, which help provide the world's food supply. But such substances could potentially be produced in a more sustainable way through undiscovered techniques of mechanical chemistry," said NSF assistant director for mathematical and physical sciences Sean L. Jones. "NSF's Center for the Mechanical Control of Chemistry will focus on providing the insights necessary for innovative minds across America to scale it up."

NSF's Support for CMCC's Research Advancements

The center itself is being scaled up. The $20 million from NSF is a phase two award from its Centers for Chemical Innovation program, which supports multiple centers aimed at solving fundamental challenges in chemical research and developing subsequent innovations. CMCC received a $2 million phase one award in 2020.

Source: National Science Foundation/specialchem

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BASF to Increase Production Capacity for Polyisobutenes in Germany

BASF will increase the production capacity for its medium-molecular weight polyisobutenes, marketed under the tradename OPPANOL® B, at its site in Ludwigshafen, Germany, by 25%.

Increased Demand for PolyisobutenesBASF will increase the production capacity for its medium-molecular weight polyisobutenes, marketed under the tradename OPPANOL® B, at its site in Ludwigshafen, Germany, by 25%.

Increased Demand for Polyisobutenes

The investment comes in response to the rising global demand for high-quality medium-molecular weight polyisobutenes. The capacity expansion is expected to reach full completion by the first half of 2025.

“With this step we are further strengthening BASF’s position as a reliable supplier that strongly supports growth and the demanding requirements of customers in various industries,” said Lena Adam, senior vice president, fuel and lubricant solutions, BASF.

Suitable for Window Sealants

Medium-molecular weight polyisobutenes are essential performance components for products in a variety of industries including the automotive, construction, electronics as well as the food & packaging industry. Applications, for example, may include surface protective films, window sealants, binder material for batteries and food packaging solutions.

“The additional production capacity for our medium-molecular weight OPPANOL® B polyisobutenes will enable our customers to grow with innovative solutions that contribute to sustainable development, for example, in energy-efficient housing. Building on our backward integration into key raw materials we will be leveraging the full strength of BASF as a global leader in polyisobutene,” said Dr. Tanja Rost, vice president, global marketing and product development, fuel and lubricant solutions, BASF.

Source:BASF/Specialchem

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US Plastics Machinery Shipments Decline Almost 20% Year-on-Year

Single-screw extruders are a rare bright spot in survey, with shipments surging just over 40%.

Shipments of primary plastics machinery in North America declined 4.1% in Q2 2023 compared with the previous quarter and 19.8% from the same period in 2022, according to the Plastics Industry Association's Committee on Equipment Statistics (CES). The initial estimate for the second quarter of 2023 indicates a shipment value of $331.6 million.

Bucking the trend, shipments of single-screw extruders surged 39.3% in a quarter-over-quarter (Q/Q) analysis and exhibited an even more remarkable year-over-year (Y/Y increase of 40.9%, according to CES. By contrast, shipments of twin-screw extruders declined 15.0% Q/Q and 11.2% Y/Y.

Injection molding machinery shipments declined 6.1% Q/Q, and 23.6% Y/Y. 

Subdued manufacturing landscape

Noting that the manufacturing sector is the main customer of the plastics industry, PLASTIC’s Chief Economist Perc Pineda, PhD, commented: “Although the US economy exhibited resilience in the first half of 2023, the decline in plastics machinery shipments signifies a subdued manufacturing landscape. The upswing in personal consumption expenditures (PCE) that followed the conclusion of the COVID-19 recession reached its peak in the first quarter of 2021, subsequently maintaining a consistent trajectory. Interestingly, PCE on services commenced its recovery at a slower pace post-COVID-19 recession, and this upward trend has persevered, playing a pivotal role in driving the economic expansion in the first half of the year," said Pineda.

Plastics machinery suppliers expressed some optimism that business would improve in the months ahead. In the most recent quarterly CES survey gauging their outlook on market conditions and equipment expectations, the percentage of participants expecting conditions to either remain the same or improve in the next 12 months rose to 46.0%.

Plastics machinery exports rise:

During the second quarter, US exports of plastics machinery saw a notable uptick of 10.2%, reaching a total value of $252.8 million, reports the CES. The primary export destinations for US plastics machinery, Mexico and Canada, collectively received exports worth $126.4 million, accounting for 50% of all US plastics machinery exports. Imports, valued at $458.6 million, declined 10.5%. As a result, the trade deficit in plastics equipment shrank by 32.0%. It now stands at $205.8 million.

"As the economy readjusts, the shift between goods and services consumption is underway. However, sustaining a robust economic expansion, given a 5.5% benchmark interest rate or possibly higher in 2023, appears unlikely.

Source:Plasticstoday.com

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Sensing and controlling microscopic spin density in materials

By fine-tuning the spin density in some materials, researchers may be able to develop new quantum sensors or quantum simulations.

Electronic devices typically use the charge of electrons, but spin — their other degree of freedom — is starting to be exploited. Spin defects make crystalline materials highly useful for quantum-based devices such as ultrasensitive quantum sensors, quantum memory devices, or systems for simulating the physics of quantum effects. Varying the spin density in semiconductors can lead to new properties in a material — something researchers have long wanted to explore — but this density is usually fleeting and elusive, thus hard to measure and control locally.

Now, a team of researchers at MIT and elsewhere has found a way to tune the spin density in diamond, changing it by a factor of two, by applying an external laser or microwave beam. The finding, reported this week in the journal PNAS, could open up many new possibilities for advanced quantum devices, the authors say. The paper is a collaboration between current and former students of professors at MIT, and collaborators at Politecnico of Milano. The first author of the paper, Guoqing Wang PhD ’23, worked on his PhD thesis in Cappellaro’s lab and is now a postdoc at MIT.

A specific type of spin defect known as a nitrogen vacancy (NV) center in diamond is one of the most widely studied systems for its potential use in a wide variety of quantum applications. The spin of NV centers is sensitive to any physical, electrical, or optical disturbance, making them potentially highly sensitive detectors. “Solid-state spin defects are one of the most promising quantum platforms,” Wang says, partly because they can work under ambient, room-temperature conditions. Many other quantum systems require ultracold or other specialized environments.

“The nanoscale sensing capabilities of NV centers makes them promising for probing the dynamics in their spin environment, manifesting rich quantum many body physics yet to be understood”, Wang adds. “A major spin defect in the environment, called P1 center, can usually be 10 to 100 times more populous than the NV center and thus can have stronger interactions, making them ideal for studying many-body physics.”

But to tune their interactions, scientists need to be able to change the spin density, something that had previously seldom been achieved. With this new approach, Wang says, “We can tune the spin density so it provides a potential knob to actually tune such a system. That’s the key novelty of our work.”

Such a tunable system could provide more flexible ways of studying the quantum hydrodynamics, Wang says. More immediately, the new process can be applied to some existing nanoscale quantum-sensing devices as a way to improve their sensitivity.

Source:MIT News

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