Safe landfill material, biological assimilation and conversion method and formula

Abstract

Disclosed herein are methods, compositions, formulations, and closed loop systems for delaying biological assimilation of a product constructed from at least one plastic-based material component and buried within a biological environment to prevent premature release of biogas while also enhancing a subsequent biogas capture period after triggering a biological assimilation period. The final result of biological assimilation of plastic materials constructed according to the principles of the present invention in landfills is biogas that can be safely captured, small amounts of water vapor, and biomass released onto the earth. This is a real carbon neutral closed loop, and synthetic plastics starting from natural gas can be converted into renewable natural gas with almost no loss, possibly no loss.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Application No. 63 / 314,026, filed on February 25, 2022, entitled Safe Landfill Material Degradation Methodologies and Formulae, and this U.S. Application is hereby incorporated by reference in its entirety. background 1. Technical Field

[0002] The present disclosure generally relates to materials, processes and systems for the manufacture and sale of various disposable and durable products, with a primary focus on non-recyclable plastics (referring to traditional hand sorting and mechanical recycling systems), which are primarily synthetic (some may contain biocomponents), all of which can be safely bioassimilated in a closed-loop recycling system and converted into one or more biogases. 2. Background technology

[0003] All products, whether they are disposable, short-term durable goods or long-term durable goods, have a desired end of life (DEOL). In other words, all products eventually reach the end of their usable lifespan-and in the United States of America, most products end up in landfills regulated by the EPA. In this article, DEOL is considered to be the time range from the product manufacturing date to the last use of the product before disposal in a landfill regulated by the EPA, many of which have engineered biodigester environments to capture biogas from organic waste and send it to a neighboring biogas plant for additional treatment. Current methods and material formulae cannot correctly cope with the landfill recycling standards of DEOL and EPA supervision. When products are disposed of as waste, even products made of paper and cellulose may fail in this regard. Compostable products such as most bioplastics are used for composting and are not discarded in waste streams. Moreover, most of the accelerated degradation additives (biodegradable or mineral degradation) used in plastics do not have specific, safe degradation characteristics for EPA landfills. Further complicating the issue, some of these accelerated degradation products are falsely labeled as recyclable, which is inconsistent with federal, state (such as California) laws, and standards and guidelines established by the Federal Trade Commission (FTC), the Sustainable Plastics Alliance (SPA), the American Plastics Recyclers (APR), the BioPlastics Institute (BPI), and others.

[0004] Unfortunately, suppliers of degradation additives and their plastic film and plastic bag manufacturing customers apply a guesstimate approach to the amount of additive used, which is usually as a percentage of the overall plastic raw material or materials. Obviously, due to the complexity associated with the DEOL of the product and the basic requirements of the US Clean Air Act of 1970 to prevent the release of greenhouse gases (GHG) (including but not limited to methane) in EPA-regulated landfills, there is no one-size-fits-all additive or formulation. A technique using mineral salts and attempting to calculate the amount on an end-of-life basis is disclosed in U.S. Patent No. 9,617,397 to Tandio et al. However, the '397 Tandio patent only partially addresses the degradation problem. The '397 Tandio patent lacks the specific application, limitations and degradation duration based on the EPA landfill standards authorized in 1970. Similarly, the '397 Tandio patent only partially addresses the traditional manufacturer, distributor and user methods, including storage, use and their related time ranges.

[0005] Oxidatively degradable materials manufactured by companies such as EPI and Symphony have no specific DEOL considerations except for the possible approximate time ranges governed by their cadmium-based technologies. This is an attempt to provide a one-size-fits-all approach. What is provided is the general time range in which plastic products can be partially or completely degraded, without accurately considering their DEOL or EPA's landfill standards and complex environments. For this, one reason is that their cadmium additive degradation agents are known to work as generally short-term oxidative degradation agents (less than 3-4 years) and have uneven, unreliable results over a longer time range. In other words, for longer DEOLs, the function of cadmium salts is inconsistent, resulting in partial degradation of some parts of plastics, complete degradation of other parts, and non-degradation of other parts. The use of these oxygen-containing salts and other biological or mineral salts together with enzyme additives for initiating degradation is typically adopted in an all-in-one approach, which neither meets the requirements of a large number of market segments using non-recyclable plastics nor the requirements of landfills regulated by the EPA. It is also important to note that it is during these rapid degradation time periods that plastics deteriorate, produce microplastic fragments and release greenhouse gases (GhG).

[0006] In business in general, there is also a serious disconnect between the opinions and judgments of consumers, users, retailers, plastic manufacturers, additive suppliers, and environmentalists and landfill operators. It is important to note that the landfills regulated by the U.S. EPA are divided into two categories. The first category, conventional landfills, are covered to try to stop degradation and also prevent the release of GhG under the authority of the Clean Air Act of 1970; and the second category, LMOP landfills, which largely prevent degradation and help prevent the premature release of GhG under their cover, and then drill wells to trigger the biological assimilation of organic matter, thereby producing biogas, which can then be converted into energy. Although LMOP landfills account for about 30%-35% of EPA landfills, they tend to be located in more populated areas and handle much more garbage than non-LMOP landfills.

[0007] The commercial disconnect also includes what should or should not be recycled in established recycling systems. For example, a vest bag returned to a supermarket is being actively recycled by a large recycler for other subsequent uses, which is not a true closed loop. Similarly, PET bottles carrying sediment have been actively recycled for many years. For products that are not currently recycled by conventional means - called "non-recyclable products", there are few standards. In the United States, many non-recyclable plastics used in commerce are contaminated with bacteria (common in food service and restaurants), laminated to paper (such as frozen product packaging), or laminated with different materials (i.e., common bag manufacturing for retail products).

[0008] Most of the disposable products (such as garbage bags, food containers and food service products, such as sandwich packaging, containers, etc.) contaminated by bacteria are considered to be non-recyclable. The DEOL of such disposable products of single use may be 6 months to 2 years, including the time period before they are even used by consumers, then used by consumers and then placed in garbage. Although most of the disposable products of single use are used in a relatively short time frame, other products may be stored in dealer warehouses for a longer time period, or stored in the user's inventory, so the DEOL time range of 2 years may be more appropriate. DEOL is also applicable to packaging, such as disposable plastic pet food bags, potato chip bags and meat packaging, where DEOL is most likely less than 2 years. After all, in any case, the food products contained therein are likely to deteriorate in a longer time frame. Therefore, most of the film products of single use are either contaminated by bacteria (food packaging), or have chemical pollution (such as cement bags, building membranes, etc.), and contain dirt and oil when thrown into the trash cans frequently used. They are considered to be non-recyclable. However, most single-use plastic vest bags are considered recyclable and can be effectively recycled, which is actually "downcycling" the plastic into a product of inferior strength and hygienic qualities.

[0009] Short-term durable goods typically have a DEOL of 2 years to as long as 8-10 years. For example, cheap reusable food containers and some multi-layer retail bags used in the home may have a DEOL of 2 to 4 years. Cheap plastic utility buckets used for painting or gardening around the home may have a life span of 5-7 years. Plastic utility tarps can be maintained outdoors for up to 5 years and are usually highly contaminated (oil, tree sap, dirt, dead insects, etc.) and deteriorate due to sun or light exposure. The DEOL of these durable goods may vary between 2-10 years, depending on thickness, blockers (such as UV-proof additives), frequency of use, and the location (e.g., indoors or outdoors) where they are used. Multi-layer bags and durable films used to package and wrap various foods and durable goods (paint, motor oil, etc.) may preferably have a DEOL of at least 5-8 years. This category of plastic products does not meet today's recycling requirements.

[0010] Long-term durable goods may have a DEOL of 10 to 20 years. This can include lawn chairs that may have a DEOL of 10-15 years, or the plastic used in some garden ornaments that may have a DEOL of 15-20 years. Designed to be reused over a number of years, they will eventually lose their functionality (memory) and may no longer seal hermetically after about 5-10 years.

[0011] Long-term durable synthetic materials over 25 years or so can include plastic fences, pipes and synthetic wood substitutes, such as wood, pallets and benches. For such products, it would be desirable not to have DEOL. These products can be recycled after extensive use, wherein their physical properties are partially restored in the re-granulation process with new polymers, and then reused in new products again. It should be noted that many of these long-term durables are made of recycled plastics, such as grocery bags. Another group of products with long DEOL over 25 years include heritage films and containers for encapsulating and preserving antiquities (such as coins, antique carpets and museum artifacts). These heritage items are usually stored indoors and resist UV light or are exposed to natural forces (elements).

[0012] Based on their normal degradation characteristics in biodigesters such as landfills, most standard plastics (such as polyethylene, PET, BOPP) and other synthetic materials are estimated to have a lifespan of 100 to 150 years. In the case of compostable plastics, they may only be decomposed into smaller fragments in 90-180 days in industrial composting equipment. When degradation occurs, both synthetic plastics and compostable plastics do not meet EPA LMOP landfill requirements, and both produce unwanted greenhouse gases (methane, CO2, etc.). Obviously, the 250-year lifespan of plastic items buried in landfills actually causes greenhouse gases to be slowly released over a very long period of time. In sharp contrast, compostable plastics immediately release greenhouse gases into the environment, and may affect the premature degradation and release of GhG in the surrounding garbage in the EPA LMOP landfill. From an environmental perspective, the emission of GhG is the main cause of climate change, and these two extreme cases are problematic contributing factors.

[0013] The Environmental Protection Agency (EPA) reports that the third largest manufacturing source of greenhouse gas production in the United States comes from its landfills. This is caused by organic waste that degrades and releases GhG primarily in the form of methane and CO2, which are commonly referred to as landfill gas (LFG). To prevent the premature release of the gas, EPA landfills are covered in layers as the waste accumulates. However, biodegradable products that are discarded and reach the upper layers of open landfills may immediately trigger degradation, thereby releasing GhG prematurely.

[0014] In order to try to reduce the generation of greenhouse gases in landfills, the EPA launched the LMOP program in 1994. In short, the federal EPA sponsors landfill operators to safely capture the escaping LFG greenhouse gases and convert them into electricity, fuel or some other form of energy. It is conceivable that they can even use machinery to directly convert the gas back to the original plastic as expected in the future. The GhG extraction process is carried out by using a biogas extractor, such as drilling a LFG well, implanting a series of pipelines under the landfill garbage, thereby initiating aerobic biological assimilation of organic matter. After about two years, the organic content that is being degraded begins anaerobic biological assimilation and releases LFG, and the methane gas produced is captured and pumped to a power generation facility through a pipeline, or can be stored to be used as a fuel, or cleaned and converted into renewable natural gas (RNG). The production period of these wells is often about 30 years, so ordinary synthetic plastics are not helpful for the capture and use of LFG. The materials that promote degradation are mainly paper, wood, cotton fabrics, food materials, etc., which degrade during the 30-year usable life of the LMOP landfill.

[0015] It is interesting to note that at the beginning of the LMOP program, greenhouse gas emissions from landfills were the second largest manufacturing source. From 1994 to 2013, approximately 30%+ of the 2122 EPA landfills have been converted to LMOP landfills, with the positive impact being a reduction in fugitive landfill gas, and thus becoming the third largest manufacturing source. With the ultimate conversion of all EPA landfills to capture LFG to convert it into some form of energy (or other), LFG emissions from landfills may become a negligible source of greenhouse gases escaping to the atmosphere in the coming years, which is a major step in preventing global warming. Drilling LFG wells is becoming the preferred means of landfill disposal systems because the process not only captures GhG safely and generates profits, but such processes help the landfill to settle properly, thereby hopefully avoiding slides that could cause collapse. In addition, some countries that have been promoting the use of oxidatively degradable materials that emit GhG are now preparing to convert their landfills to the U.S. LMOP model in the future and convert the extracted GhG into usable energy or RNG.

[0016] In the U.S. landfill and many other landfills around the world, landfill garbage is compacted by heavy equipment bulldozers. Obviously, this is to minimize space requirements and also help avoid its contents sliding over time. Water, erosion and other land movement factors may contribute to landslides, which may have devastating consequences if the landfill is near a populated area or a river. Compacted garbage is regularly covered with plastic sheets, which significantly prevents air and moisture from contacting the garbage, and helps prevent the premature degradation of the upper layer of the landfill garbage and the undesirable release of GhG. Landfill operators want to prevent all degradation according to the EPA authorization under the Clean Air Act of 1970, and make the contents only safely degraded after drilling LFG wells. However, a significant problem caused by covering practice is that the garbage that has begun to degrade prematurely in the upper layer is also covered. Then more garbage is filled on the top of the first cover layer, compacted, and then covered again, so repeatedly multiple layers (lasting several years), all of which may have some prematurely degraded garbage. In this process, and with the help of aerobic and anaerobic digestion from certain plastic products (i.e., from the rapid degradation of ASTM D5511 plastic products, and possibly oxidatively and enzymatically degradable materials), GhG is being forced to be released laterally prematurely. In other words, the pressure from the LFG gas under the blanket created by the premature degradation of the garbage is forcing the GhG to escape laterally, contaminating adjacent land and then upward into the atmosphere.

[0017] In LMOP landfills, there are three potential (and major) ways of premature release of GhG to avoid safe capture. First, before the landfill is refilled with garbage and covered again, garbage near the upper surface (but not most plastics) may trigger degradation in each compacted and covered layer. It must be noted that the covering and stratification of garbage in LMOP landfills lasts for many years. Typically, LFG wells can only be drilled four years after the garbage is deposited in the lower layer of the first cover. The surface garbage that has triggered degradation consists of most organic matter and compostable materials (including bioplastics, etc.), paper products, food materials and food residues and moisture, etc., and releases GhG prematurely. Second, if anaerobic agents are blended with plastic materials deposited in the garbage stream, such agents can also trigger premature degradation, thereby releasing greenhouse gases. An example of the anaerobic additive is Neo Plastics (Aripack), which is reported to start anaerobic degradation when it arrives at the landfill, which leads to the premature release of GhG. Premature degradation also results in lower expected methane production later in the biogas production process at the LMOP landfill. Third, unstable oxidatively degradable additives blended with synthetic plastics may also lead to premature degradation and premature release of greenhouse gases. These degradation means, together with other less used degradation accelerators, lead to lateral escape of GhG through adjacent land. Once degradation begins, migration to other materials that would not otherwise trigger premature degradation in the covering environment may also occur. These three common landfill conditions that lead to premature release of GhG pursue the foolish assumption that all materials must become biodegradable quickly.

[0018] Another result of the degradation of various organic materials and synthetic materials and plastics in landfills is the potential release of toxins. For example, compostable plastics are mainly made of genetically modified (GM) substances, and include genetically modified organisms (GMOs). Some health organizations believe that these are contributing factors to cancer. Compostable plastics also contain "genetic herbicides", which have unknown effects to a large extent, except that they are reported to cause watershed pollution, soil pollution and promote the production of super weeds. GM corn stalks may also be contaminated by commercial harmful biological agents or irrigated with contaminated water. Oxidatively degradable additives and anaerobic additives may also contain heavy metals such as cadmium, which are considered to be highly toxic at higher concentrations. Finally, printing inks have a certain degree of toxicity, even in the case of water-based. In general, paper products use more ink than plastic products, thereby causing greater toxicity of the degraded contents, and eventually enter the soil and possibly the air together with the fugitive GhG. Regardless of the source of the potential toxins released in the landfill, it is desirable to minimize their impact.

[0019] One example of a company seeking to reduce these problems is ECM Biofilms. Plastic products made with its ECM MasterBatch Pellet are reported to biodegrade in a "bioactive" environment (such as might occur in a landfill) in a time frame beginning after one year. Such a product may degrade due to aerobic digestion and anaerobic digestion, and may promote degradation when in close contact with other degrading contents. Unfortunately, this means that the additive cannot be controlled in the landfill because at least some early biodegradation occurs, especially in the upper layers. Therefore, this approach also promotes premature degradation and premature release of GhG. This further promotes early degradation of nearby contents that would otherwise remain dormant until a LFG well is drilled. Since no DEOL based on product use, storage, etc. is taken into account, nor is the four-year time period before a LFG well is drilled in an EPA LMOP-regulated landfill (except perhaps in the final last layer), this approach promotes premature degradation and release of fugitive GhG while contributing little, if any, to the subsequent extraction of the desired biogas.

[0020] The various plastic materials deposited in U.S. landfills present a hodgepodge of degradation characteristics, life spans, contamination issues, and toxicity. Beyond those standards outlined by the APR, there is little consistency in the standards adopted by the plastics industry for non-recyclable plastics, and few manufacturers are able to apply them. Worse, no consideration is given to the degradation characteristics of plastic products sold and used in over a hundred major market segments. The durability and performance of plastic products in various market segments may be considered, but no consideration is given to the safe degradation of products disposed of in landfills (primarily US EPA-regulated LMOP landfills).

[0021] Since the enactment of the Clean Air Act in the United States in 1970 and the implementation of LMOP in 1994, it has become apparent that many well-intentioned entities have been pursuing (in many cases incorrectly) degradation issues that actually increase the release of GhG rather than prevent it, and increase the release of toxins rather than reduce them. Too many technologies can only partially address the GhG and toxin issues at best. Many additives, various types of plastics, and performance requirements in many market segments only complicate the issue of safely capturing greenhouse gases in landfills as authorized by the EPA. Understandably, 50 years after the passage of the Clean Air Act and 25 years after the establishment of the LMOP recycling system, current methods are inadequate, and sometimes dangerous, even self-defeating, including compostables and bioplastics. The public's lack of knowledge about what to do and what to buy adds to the impact of misleading methods. Consumers are at best exposed to an incomplete picture of the true impact of various types of degradable technologies on the environment, not to mention what actually happens in landfills. In fact, degradable plastic suppliers and manufacturers completely avoid LFG applications and premature greenhouse gas issues. In most cases, they have no idea what is going on in the landfills, let alone the EPA or EPA LMOP landfills. These issues (issue / problem) are of long-term and high concern to EPA landfill operators, federal and state governments, and humans.

[0022] The core of the problems created in EPA LMOP landfills is obviously the obsession of the plastics industry and environmentalists to make plastics degrade quickly, which is obviously undesirable in landfills. Another huge problem is that the plastics industry has not taken into account the complex LMOP landfill engineering. Plastic scientists rarely have a background in landfill environments (LMOP or otherwise). If they have a background, such a background is often incomplete. They do not consider the compaction and covering of the first four years and the aerobic digestion of the following two years. The obsession with "reducing plastics to soil" is a wrong concept. Most plastics in the United States come from natural gas feedstocks - different from bioplastics (grown in soil), and why it should become "mud" instead of valuable biogas for generating energy or better RNG. In order to have a true closed loop on synthetic plastics, bio-assimilation should result in conversion back to natural gas. In other words, renewable natural gas (RNG) is the desired end product of the bio-assimilation process. All other attempts at recycling are at best downgraded to other plastic products of poorer quality.

[0023] Plastics with DEOL profiles will be valuable to landfill operators, manufacturers, users and consumers throughout the world, overcoming numerous problems associated with prior art and subsequently degrading in a timely and controllable manner in a biodigester environment (such as a LMOP landfill) to prevent premature release of GhG, and subsequently captured by LFG-type wells and profitably converted into biogas and RNG. Materials with standardized properties specifically formulated using basic bioassimilation guidelines that meet EPA's LMOP landfill requirements are highly desirable because the waste disposed therein is converted into energy, preventing premature release of GhG and leaving minimal toxic residues. In addition, plastics using this approach will be consistent with today's recycling goals because products that end up in landfills are considered to be contaminated or non-recyclable in some way or another. When bioassimilation is safely performed during the life of an LMOP landfill, the end result is a compact, stable landfill with little or no residual minerals or toxins in the soil. Furthermore, proposals incorporating such plastics could create a true closed-loop recycling system that meets the requirements of manufacturers, users, and consumers, and could be verified through appropriate ASTM testing, as well as NGO or government chain of custody, to validate their claims of non-toxicity and meet EPA LMOP requirements. Summary of the invention

[0024] Embodiments constructed in accordance with the present invention overcome one or more of the problems associated with the prior art and effectively solve the long-standing, considerable problem of landfills with single-use plastics. Furthermore, embodiments constructed in accordance with the principles of the present invention achieve this cost-effectively, using existing infrastructure, and with significant health and environmental benefits. Little or no landfill GhG, including CO2 and methane gases, is produced until after the LFG well is drilled, and degradation of the plastic material can begin - and the resulting biogas can be safely captured and converted to energy or RNG. The end result of the bioassimilation of plastic materials in a landfill constructed in accordance with the principles of the present invention is biogas that can be safely captured, a small amount of water vapor, and biomass that returns to the earth. This is a truly carbon-neutral closed loop - synthetic plastics that start with natural gas can be converted back to renewable natural gas with little or no loss.

[0025] The best environment to utilize embodiments constructed according to the principles of the present invention is in EPA LMOP landfills, which are ideally suited for closed loop systems when used in conjunction with the embodiments described herein. In landfills that do not have a system for converting LFG to an energy source, embodiments constructed according to the principles of the present invention remain dormant with a time bomb effect until the landfill can be converted to process LFG, such as in EPA LMOP landfills in the United States.

[0026] Embodiments constructed according to the present invention are mainly used for disposable plastic products, which are not candidates for conventional recycling systems. Such embodiments are also ideal for plastics with insufficient recycling infrastructure in a given area (e.g., in most areas of California). In other words, embodiments constructed according to the present invention are non-recyclable plastic products that will enter landfills, including single-use disposables and short-term durable goods and long-term durable goods. Embodiments disclosed herein are also intended to connect the points of these products to have good environmental quality and meet U.S. EPA LMOP landfill standards. The solutions described herein combine the technology of using emerging technologies to produce unique solutions with good, clear long-term environmental results preferably in a true closed loop, and these emerging technologies produce interrelated main lines through humans, society and business. The solutions disclosed herein also utilize industrial arts, engineering and applied sciences to produce practical solutions that meet existing and expected federal, state and municipal laws and fully comply with the goals of EPA, FTC, APR, SPC, etc.

[0027] In the process, the landfill safety technology disclosed herein provides methods for determining the appropriate end of life (DEOL) of materials, most importantly plastics, which also meet the preferred EPA LMOP landfill bioassimilation requirements. The embodiments disclosed herein further provide systems and processes that use non-toxic additives, molecular modifications and blending methods that are customized for the defined use of a specific product and also meet the desired standards set forth in EPA landfills. The systems and processes disclosed herein can also include the use of additives and molecular modification methods and systems integrated into the resin manufacturing process.

[0028] One or more embodiments disclosed herein: 1) use today's standards to correctly specify the approximate DEOL of a product; 2) are typically based on established time-driven usability standards (single use, short-term and long-term durable goods); and 3) have a predetermined goal to not allow or initiate any form of degradation for a period of at least 4-5 years after the DEOL expires, thereby preventing premature release of GhG; and 4) can only begin bioassimilation under the influence of common microorganisms found in EPA landfills after the product of the present invention has been deposited and capped in the landfill and a LFG well has been drilled; and 5) substantially complete bioassimilation occurs at or before the expiration of the landfill life (preferably up to 25-30 years) of the capped and LFG well-drilled landfill, leaving almost no trace of plastic-based materials, while also producing collectible biogas in the final bioassimilation environment. By doing so, plastic products constructed according to the principles of the present invention avoid the production of GhG until after bioassimilation begins in a biodigester environment, and contribute to the production of biogas, which is used to generate energy in a nearby power generation (or fuel conversion) facility or RNG conversion facility. Additionally, the biomass and water produced during the plastic bioassimilation process become non-toxic, non-risk components of the soil.

[0029] According to the principles of the present invention, the preferred results of using the systems, processes and materials as described by one or more embodiments described herein may include the use of one or more non-toxic biological salts or mineral salts, or organic or inorganic substances, as may be preferably cited. In addition or as an alternative thereto, such systems, processes and materials may include the use of molecularly modified and embedded additives during the resin cracking process. The additives incorporated into the plastic material should also meet RoHS, TRI and DTSC toxicity standards. It is also preferred to include product markings that comply with state and federal laws for consumers, such as the do not recycle notice required by California, for example. It is also expected that plastic manufacturers and suppliers have testing procedures conducted under specific ASTM guidelines. It is also expected to have a verification system implemented by a national agency or NGO organization for continued compliance. In addition, it is expected to establish a new ASTM standard that incorporates the use of existing test methods to verify the various stages of the overall non-degradation and subsequent bio-assimilation timeline, which meet the EPA LMOP requirements and optionally the requirements of agricultural organic biogas plants.

[0030] Unlike the prior art, key aspects of embodiments constructed according to the principles of the present invention allow nature to do its work in LMOP landfills. The prior art's obsession with rapid degradation is eliminated by the ability of the embodiments disclosed herein and constructed according to the present invention to slow down, or even postpone, the bio-assimilation of plastic materials so that it can be safely converted into biogas and energy or RNG. For non-toxic biosalts and mineral salts (organic and inorganic substances) additives, the key is to use an overall uniformly distributed embedded amount, preferably with an overall smaller particle size, and these formulations match the engineering conditions of the EPA LMOP landfill. It is also important to note that the formulation concepts introduced for use in EPA LMOP landfills can be adjusted for other plastic products (e.g., agricultural films) to meet the engineering requirements of biodigesters used on farms, dairy operations, and even in waste food digesters.

[0031] Overall, the inability of the existing fossil fuel plastics industry to "connect the dots" is astonishing - and clearly demonstrated by its obsession with rapid degradation being somehow good for the planet, and its pursuit of recycling technologies that are nothing more than dirty, bacteria-ridden downcycle operations. Alternative methods, such as pyrolysis and chemical recycling, have been banned in California due to toxicity issues. In the industry, it is seen as an expensive method for converting "old plastic" into expensive gases like propane. Why? In stark contrast, the present disclosure explains systems, processes, and materials for naturally and cheaply converting plastic directly back into its original, versatile raw natural gas, which can be regenerated into RNG forever. All of this is done using existing waste management infrastructure without any health or safety issues.

[0032] The embodiments disclosed herein may support one or more of the following objectives, but are not limited to:

[0033] 1. A system for modifying the properties of plastic products for safe bioassimilation in EPA LMOP landfills.

[0034] 2. A plastic degradation system that does not release greenhouse gases prematurely when disposed of in landfills.

[0035] 3. A plastic degradation system that induces biological assimilation in a LFG landfill after being deposited, compacted and covered in the LFG well landfill for at least four years.

[0036] 4. System that fully bio-assimilates plastics before 30-year LFG landfill life.

[0037] 5. Systems and processes for making plastics and plastic products that begin to bio-assimilate in the LFG wells at a future timeframe after being deposited (e.g., four years) and are fully bio-assimilated at the end of the life of the landfill (e.g., after 30 years).

[0038] 6. Systems for making degradable plastic products that would otherwise be considered contaminants in conventional recycling streams.

[0039] 7. A system for determining an approximate DEOL based on conventional factors such as one of: A) a single use disposable product; B) a short term durable product; and C) a long term durable product.

[0040] 8. System for determining DEOL based on environmental factors (eg in cold and very hot regions).

[0041] 9. Necessary formulations for the use of biological additives and / or mineral additive substances in plastics to produce desired bioassimilation properties in plastics.

[0042] 10. Landfill safe formula that meets the standards and requirements of EPA, FDA, FTC, APR, SPA, and all other relevant laws and agencies of a particular region, state or country.

[0043] 11. Landfill safe formulations and associated processes for producing plastic materials as herein recited.

[0044] 12. A process for making plastics by compounding plastic materials that produces bioassimilation properties that meet landfill targets.

[0045] 13. A process for producing plastics by molecular modification which results in the desired bioassimilable properties as set out herein.

[0046] 14. Process for making plastics using chain extenders to extend the expected life of the product pertaining to the present invention for safe disposal in landfills.

[0047] 15. A process for manufacturing plastic products using bio-additives and mineral additives in a blended portion which are considered non-toxic when used in plastic products and which subsequently induce fragmentation and subsequent bio-assimilation after drilling a LFG well.

[0048] 16. A process for making plastics using one or more of the following minerals as additives or blending components to meet the bioassimilation requirements of the present invention, these minerals are not limited to: A) cobalt; B) iron; C) cadmium; D) calcium; E) magnesium; F) calcium oxide; G) calcium carbonate; and H) its stearate variant.

[0049] 17. Process for making plastics and plastic products using starch or any number of organic materials (growing crops, extracts, wastes, etc.) as an additive or blending component to initiate, facilitate or provide food to assist bio-assimilation to meet the desired time frame, these organic materials are for example but not limited to: A) cassava starch; B) avocado (and / or its seeds); C) sugar beets; D) sorghum; E) potato; F) agave; and G) corn.

[0050] 18. A process for making plastics using one or more of the following biopolymers as additives or blending components to meet the bioassimilation requirements of the present invention, such as, but not limited to: A) chitin; B) chitosan; or C) commercially produced biopolymers such as Ecoplas TM and Ingeo TM plastic.

[0051] 19. A process for making a plastic by a combination of one or more of the following: blending materials, introducing additives, and physically modifying the molecular structure so that it has time-sensitive bioassimilation properties as recited herein.

[0052] 20. Plastics formulated to be converted into biogas.

[0053] 21. Plastics formulated to resist biodegradation and to promote conversion to biogas by bioassimilation in a biodigester environment.

[0054] 22. A plastic product made according to the processes and methods recited herein that inhibits early degradation and release of one or more GhGs such as carbon dioxide and methane until after a LFG well is drilled and bioassimilation begins.

[0055] 23. A plastic product that degrades according to the processes and methods recited herein, which plastic product inhibits the release of one or more GhGs such as carbon dioxide and methane up to the first 4 years, which helps prevent premature degradation of adjacent landfill contents.

[0056] 24. A plastic product degraded according to the processes and methods recited herein, which plastic product helps improve the bio-assimilation of landfill contents in the final years before the end of life of a LMOP well, thereby increasing biogas production profitability.

[0057] 25. A plastic product degraded according to the processes and methods recited herein, which begins bio-assimilation at least 4 years after deposition and is then fully converted to biogas in no more than 30 years.

[0058] 26. Plastic products that degrade according to the processes and methods recited herein and that meet EPA LMOP standards, as may be changed in the future.

[0059] 27. Methods for verifying the degradation and bioassimilation (or biogas conversion) of a material such that it complies with legal standards of a given government or public agency, such as record keeping.

[0060] 28. Methods for verifying that materials degrade safely according to landfill standards so that the resulting LFG can be safely captured, such as ASTM testing.

[0061] 29. Method for verifying that a material degrades safely according to landfill standards and that the resulting LFG can be safely captured and converted to biogas in a LFG-to-energy landfill.

[0062] 30. Methods for verifying that degradation of materials leaves no or negligible amounts of toxic substances acceptable on the TRI and DTSC lists, e.g., RoHs testing.

[0063] 31. Method for verifying that the degradation of a plastic as recited herein is based on generally accepted ASTM guidelines.

[0064] 32. A compliance system that verifies the compliance of manufacturers of raw materials, additives and plastics used to make products that are part of the landfill safe technology of the present invention.

[0065] 33. Any one or more of the items on this list recited herein using a group of selected catalyst additives, but not limited thereto.

[0066] 34. Unique catalysts formulated by pyrolysis, including calcium oxide, etc.

[0067] Furthermore, the purpose of this application is to present preferred methods, processes, formulations and plastic compositions, and to broadly set forth the various ways in which the invention may be effectively employed in a variety of industries.

[0068] All embodiments summarized above are intended to be within the scope of one or more inventions disclosed herein. However, although certain embodiments are discussed herein, only the appended claims (rather than the present disclosure) are intended to limit the present invention. The summarized embodiments and other embodiments and aspects of the present invention will become apparent to those skilled in the art from the following detailed description of preferred embodiments with reference to the accompanying drawings, and the present invention is not limited to any particular embodiment or embodiments disclosed. BRIEF DESCRIPTION OF THE DRAWINGS

[0069] The accompanying drawings incorporated herein form a part of the specification, illustrate the concepts of the invention, and together with the description further serve to explain the principles of the invention and enable those skilled in the relevant art to make and use the invention.

[0070] Figure 1 is a graph illustrating the approximate long-term timeline and life span of a single-use plastic product constructed in accordance with the principles of the present invention following disposal in a LMOP landfill.

[0071] Figure 2 is a diagram illustrating the approximate short-term timeline and life span of a single-use plastic product constructed in accordance with the principles of the present invention following disposal in a LMOP landfill.

[0072] Figure 3 is an exemplary block diagram of a set of closed-loop recycling components of a safe landfill, delayed biological assimilation system constructed in accordance with the principles of the present invention.

[0073] Figure 4 is a flow chart illustrating how an exemplary plastic constructed in accordance with the principles of the present invention may be discarded at the end of its useful life and converted into biogas and energy, or RNG, in a landfill.

[0074] Figure 5 is a block diagram illustrating the requirements that may be applied to properly produce products made in accordance with the principles of the present invention. DETAILED DESCRIPTION A. Description of Exemplary Products, Methods of Use, and Processes

[0075] In general, the present disclosure relates to systems and methods for producing products incorporating plastic-based material components that can be safely bio-assimilated within a biodigester (such as a landfill regulated by the Landfill Methane Outreach Program (LMOP) of the Environmental Protection Agency (EPA)) or other related disposal systems (such as an organic bio-digester plant, such as those commonly found in the agricultural industry). In contrast to technologies that focus on rapid degradation and are obsessed with turning products into soil rather than RNG, the timing of bio-assimilation disclosed herein is preferably delayed so that it occurs in a more timely manner so as to prevent the premature release of greenhouse gases (GHGs), which can then be captured and converted into one or more biogases after the delayed production, and further converted into energy or RNG. The present disclosure also provides a public awareness labeling system that allows consumers and users to be informed of the product life expectancy before disposing of the product. In addition, the present disclosure provides methods for testing and verifying the bio-assimilation characteristics of the required materials to meet the desired EPA landfill characteristics and likewise ensure compliance with federal and local laws.

[0076] The examples used in the specific embodiments are generally used for non-recyclable (referring to the well-known mechanical sorting and recycling system) plastic products, regardless of whether they are disposable or have a long DEOL. The following word combinations should be interpreted interchangeably: A) additives and compounds; B) salts and substances; C) biological and organic; D) mineral and inorganic; and E) biogas, LFG and GhG. In addition, the term biodigester as used herein refers to LMOP landfills and other environments in which materials undergoing biological assimilation under certain conditions are disposed. As used herein, biological assimilation refers to consumption by common microorganisms found in the biodigester environment during their life span. It is important to distinguish the difference from the use of the word "biodegradable", which is often misused and misunderstood. It should be noted that FTC Part 260 lists the use of this word in conjunction with packaging, meaning "degradable in a relatively short period of time", which is not what the present invention wants. During the dormant period, there will be almost no resulting microplastics. The same is true after the biological assimilation period in the biodigester is completed. GhG can be produced as part of biological assimilation processes either aerobic or anaerobic, although the majority of the greenhouse gas methane is produced as a result of anaerobic processes.

[0077] Now refer to Figure 1 The first exemplary biogas generation and extraction scenario shown in FIG. 1 illustrates the long-term timeline and life span of a single-use, disposable plastic product constructed in accordance with the principles of the present invention, and the subsequent life span of the product in a LMOP landfill. Figure 1As shown in , the useful life of the product begins at event A (manufacture date). After manufacturing, the journey of the product includes a period of about the first year ending at event B, during which the product undergoes transportation and storage in major warehouses, and then storage in other locations (such as packaging distributors, restaurants, supermarkets, and family food storage rooms). Such a time period also includes the final use of the consumer. It should be understood that such activities during this period typically occur at "room temperature" of seventy-two degrees, but this is not meant to be limited in any way. These activities occur in the surrounding environment outside the landfill / biodigester environment. Most of this single-use plastic is contaminated with food materials and dirt (for example, sandwich packaging, fruit and vegetable bags, multi-layer lined coffee cups, etc.). The one-year period ending at event B defines the expected useful life end (DEOL) of the product. After the DEOL of the product expires, the product is discarded into the existing waste management garbage pickup stream and disposed of at the LMOP landfill supervised by the EPA. Once delivered to the landfill, the product is typically compacted and periodically covered (buried) in a cell (a specific location in the landfill) for a period of up to four years after the DEOL expires, and ends at Event C. The compaction and covering (landfilling) process in an EPA LMOP landfill is carefully designed to prevent as much GhG from escaping into the environment (atmosphere) as possible. In this example, a plastic product constructed according to the principles of the present invention can be deposited in a new cell and remain dormant at the bottom as other garbage (primarily organic content) accumulates on top for up to four years according to EPA LMOP standards. Approximately 73% of most garbage in the United States is organic and 27% is plastic. During this four-year burial dormancy stage or period, the temperature is usually cold, as low as 45 degrees up to 55-60 degrees, some warm places may be slightly higher, and colder northern climate zones may be lower. After a four year period ending at event C as measured from DEOL event B, a LFG well is drilled to place one or more biogas extractors in communication with the environment defined by the landfill (biodigester) and connected to a pipeline network. Decomposed waste that has accumulated a certain amount of biogas is released and flows into a pipeline network (not shown). It should be understood that the landfill dormancy period between event B and event C is typically 4-5 years in a LMOP landfill, but this is not meant to be limiting.

[0078] In the next two years after the end of the five-year period starting from event C, the landfilled garbage began to bio-assimilate more quickly in a process that was mainly aerobic and partially anaerobic. When about the end of the seven-year period (event D), the bio-assimilation process mainly transitioned to an anaerobic process, which produced the methane biogas that can be used to generate energy (electricity) or converted into the desired RNG. Between the end of the seven-year period (event D) and the end of the 30-year period (event E) (i.e., a total of 23 years), due to the triggering of the bio-assimilation process after the initial delay or postponement period, the landfill converted methane profitably as needed. From the end of the 30-year period (event E) to the end of the landfill service life (event F), the generation of biogas gradually decreased until the generation eventually expired and the collection was terminated. It is interesting to note that the embodiments disclosed herein according to the present invention can indeed help extend the profitable time frame. Similarly, it improves the output and profit margin in any bio-digester environment by converting the plastics of the present invention into biogas, which was not feasible before.

[0079] exist Figure 2 In the second exemplary biogas generation and extraction scenario shown in FIG. 1 , the short-term timeline and life span of a product constructed according to the principles of the present invention in a LMOP landfill is similar to Figure 1 timeline and lifespan, where the useful life also begins at event A (date of manufacture). However, Figure 2 A very short period of time in which a product constructed in accordance with the principles of the present invention is buried and covered in a landfill is shown, as represented by the time period between the previous one year period ending at event B, where the product was first disposed of in a landfill, and another one year period ending at event C, where a well was drilled and a GhG (biogas) extraction component was installed and placed in communication with the biodigester environment. It should be understood that Figure 1 and 2 These two time ranges can be used to prepare one or more compound additives to achieve a delayed bioassimilation period as desired. Figure 1 and 2 The long time period between event D and event E shown in is about 23 years or more respectively, thus it allows sufficient flexibility in formulation.

[0080] Reference now Figure 3, which depicts a general overview of the components of a closed loop biogas recycling system, a petroleum-based feedstock or natural gas feedstock 10 provides a source of material for a product to be made, which is incorporated into a plastic-based or polymer-based material at a manufacturing plant 12. The product 14 is constructed with the plastic-based material components according to the processes and formulations described herein to have an inherent bio-assimilation dormant period or "time bomb" characteristic. The product enters a distribution and storage network 16 until the product enters actual use by a consumer / end user 18. Once the DEOL expires, the product 14 is placed at a local waste collection where waste management 20 picks up the product and transports it to a landfill 22. The product (now garbage) remains dormant in the landfill environment until a well / extractor 24 has been drilled and placed in communication with the landfill environment, thereby exposing the buried garbage to the elements and initiating a bio-digester environment 25. As the well is drilled, bio-assimilation of the product (garbage) begins and a volume of biogas 26 is produced within the newly created bio-digester environment 22 of the landfill. During the biogas collection period, the well / extractor recovers the volume of biogas. The collected biogas is transferred to a conversion plant 28 where it can be converted into energy or back into the natural gas feedstock 10.

[0081] Reference now Figure 4 In the process shown, biogas is generated and a recycle stream is extracted from a contaminated food bag 14 ( Figure 3 ) starts. In this exemplary embodiment, it should be understood that the contaminated bag 14 is manufactured on the date ( Figure 1 and 2 For example, at step 100, a food bag may be purchased by a restaurant and subsequently used to store greasy French fries at the restaurant. At step 102, the bag is initially stored for 3 months and then used by a consumer 18 ( Figure 3) and eventually discarded in the garbage, and then picked up by local garbage collectors, who transport the bags (now garbage) to the LMOP landfills supervised by the EPA. In step 104, the bag 14 is buried with other garbage for up to 4 years. During this 4-year time frame, the plastic-based materials (typically long-chain polymers) used to make contaminated food bags remain dormant and neither bio-assimilate, nor biodegrade, nor degrade in any other way, nor does it release greenhouse gases (GhG) prematurely to meet the requirements of the EPA. This refers to all plastic compositions, whether organic, mineral or chemical. It should be noted that it is the premature degradation of garbage (mainly discarded paper, cellulose and other organic and anaerobic plastic products) during this four-year period that prematurely releases GhG in the landfill. Four years later, a LFG well is drilled at step 106, releasing the accumulated gas and initiating aerobic degradation of the organic contents within the burial area of ​​the landfill, and the contaminated food bag 14 and surrounding organic materials also begin to fragment and bio-assimilate, which heats the landfill contents at step 108. At step 110, the bio-assimilation of the organic contents in the landfill can generate heat up to 130 degrees, which promotes both the bio-assimilation of the organic materials and the bio-assimilation of the plastic-based materials used to make the contaminated bag 14, and at step 110, the resulting heat and / or migration of organic components in the landfill initiates and promotes the bio-assimilation of nearby plastic materials also constructed according to the principles of the present invention. In this example, the product incorporating at least one plastic-based material and constructed according to the principles of the present invention includes additives (such as those identified herein and specifically formulated) to initiate bio-assimilation, thereby producing biogas when a warmer temperature such as 130 degrees is reached at step 112. Slightly cooler temperatures of 100 degrees and above can also induce bio-assimilation of plastics. However, this may take longer at lower temperatures. Likewise, the recipe can be adjusted to cooler temperatures, down to above 80 degrees Fahrenheit. As previously described in Figure 1 and 2 As described in the , the bio-assimilation process switches from aerobic to anaerobic two years after drilling and lasts for the remainder of the 30-year life of the EPA LMOP landfill. In step 114a, the biogas 26 ( Figure 3 ) is captured by the LMOP system and pumped to the energy generation facility. Alternatively or in addition, the biogas can be captured in step 114b and converted into fuel or into a feedstock to produce a new product 14 ( Figure 3 ).

[0082] Plastic products 14( Figure 3)This delayed initiation of bioassimilation within the landfill environment22 is the key to LMOP landfill fill safety technology: salts, bioplastics and synthetic blends, organic biopolymers (such as chitin), molecular modification methods and additives, and perhaps even enzymes are used for formulation to initiate or cause bioassimilation when the landfill heat rises to warmer temperatures. Conversely, it can also be said that bioassimilation is initiated after the cooler temperatures of the covered landfill contents that have not yet been drilled have ended. The time bomb effect after the drilling of the LFG well can be activated by any number of time-activated, chemically activated, mineral-activated, or organically activated substances that cause the breakdown of the long-chain molecular structure of the plastic-based materials to be sufficiently fragmented for bioassimilation by common landfill microorganisms. In addition, in order for plastics, which are mainly bioplastics, to degrade safely in LMOP landfills, a form of "degradation preventer" or "chain extender" may be required during the first four years in the landfill so that the product can be properly bioassimilated thereafter after the well is drilled. Various types of chemical and organic degradation preventer materials can be included in its structure, or it can be engineered into the bioplastic molecular structure before or during the compounding (resin formation) process.

[0083] Still reference Figure 4 During the heat-induced time frame (steps 108-110), the bag 14 of the present invention Figure 3 ) is ongoing and LFG gases (primarily CO2 and methane biogas) are produced at step 112. These LFG gases are similar to those emitted by organic materials. It is also during and after this stage that the formulation of the present invention allows its plastic-based materials to continue to fully fragment and break down into fine bioavailable fragments. This process of safe bioassimilation in an EPA LMOP landfill is driven by an additive (or other) formulation with an appropriate "time bomb" effect - the time bomb effect is determined by at least one year of DEOL plus an additional 4 years of biodigester dormancy period as expected in EPA landfills.

[0084] As previously in Figure 1 and 2As discussed in, the total 5-year non-degradation time period (NDTP) of the contaminated food bag 14 includes: A) the time spent before and in the manufacturing facility; B) the time frame of transportation to the distribution center and storage at the distribution center; C) the time frame of the product being transported to the restaurant of the end user and stored in the restaurant; D) the time spent before the product is used by the consumer and discarded in the restaurant garbage; and E) the time period of the garbage being transported to the landfill facility, sent to the actual landfill, compacted (with other garbage), buried and covered, which can be a few days or up to four years. Items A-D in the aforementioned list generally define the expected end of useful life (DEOL) time period, while item E defines a buried dormant time period of up to four years of burial and covering, all of which together define the NDTP. After the end of item E (where the well is drilled) is called the biodigester time period. Note that the DEOL time period and the buried and covered (buried dormant) time period that define the NDTP can also be triggered by temperature changes rather than combined time periods.

[0085] When biogas 26( Figure 3 ) is then generated and captured in the LMOP landfill at step 114a, which will be composed of the contaminated food bag 14 ( Figure 3 ) The biogas 26 released passes through the pipeline network 24 ( Figure 3 ) is sent to power plant 28( Figure 3 ). The methane gas is used as a fuel to generate electricity, to fuel automobiles or in various alternative applications, typically releasing CO2. Alternatively, the captured biogas 26 may be converted into a natural gas feedstock in step 114b to produce new products.

[0086] exist Figure 4 In the example, considering one year of DEOL, for product 14 ( Figure 3 ) is incorporated with organic additives into the formulation of plastic-based material components. However, in the case of short-term durable goods such as household containers, the DEOL may be 5 years, so the additional 4 years makes the NDTP 9 years, requiring a different formulation. Regardless of the DEOL, the formulation of the present invention is specifically formulated to have a desired NDTP, as long as it does not exceed about 20-25 years. The NDTP time allocation should include sufficient additional time to allow the product of the present invention to be fully bioassimilated in a landfill - before the end of the 30-year landfill life.

[0087] There are four major methods by which successful bioassimilation of plastics, most importantly fossil fuel plastics, can be accomplished in EPA-regulated LMOP landfills. They are: 1) the use of a catalyst (mineral or organic) to break down the long molecular chains so that they can be bioassimilated along with the organic contents of the landfill; 2) the use of a catalyst (mineral or organic) along with an organic component to break down the long molecular chains, which provides food for microorganisms to initiate bioassimilation; 3) the use of an organic additive for initiating bioassimilation; and 4) the use of an organic additive that can also serve as a catalyst and subsequently serve as food for bioassimilation. In the case of incorporation of a food source, the amount is between .25% and 3% of the total molecular weight or volume of the modified product composition. The amount of mineral catalyst can be between .1% and 1% of the total molecular weight or volume of the modified product composition. These methods are used to modify the composition of the product and / or product 14( Figure 3 )'s plastic-based material components are modified.

[0088] An important consideration is to disperse the additive widely in the fossil fuel plastic so as to have overall bio-assimilation, which is different from the corrosive nature of oxygenates (oxos) such as cadmium and cobalt. Particle sizes below 2 microns are preferred and nanoparticles are excellent. As listed in U.S. Patent Application No. US2020 / 0339784 ('784 Application) by Dr. Joseph Greene and Bradforn LaPray, nanoparticle dispersion is preferred for bio-assimilation of plastics. Another benefit of using a smaller particle size is that it reduces the amount of catalyst or food or both required to initiate and complete the bio-assimilation of plastics. Therefore, it reduces costs. But this lower amount / cost phenomenon only applies to plastics disposed of in LMOP landfills. As listed in the '784 application and as generally pursued in the plastics industry by oxygenates or otherwise for forced degradation (or biodegradation, as the case may be), higher amounts are usually used to make a "biodegradable" claim (reference FTC Environmental Marketing Statement-Section 260-also known as the requirements of the Green Marketing Statement). Biodegradation is precisely what is undesirable in the present invention.

[0089] On the other hand, it is preferred to convert plastics into biogas, which can be further processed into energy or RNG. As opposed to aggressive biodegradation over a short period of time - the environment in an EPA LMOP landfill has up to 30 years for bio-assimilation. This is a considerable period of time, a period of time that is completely ignored in the plastics industry - again, the plastics industry seeks rapid degradation within weeks or months. This long time frame significantly reduces the amount of catalyst required (if any) and the amount of organic food to help initiate bio-assimilation.

[0090] The significant reduction in the amount of catalyst plays a very important role in the bioassimilation delay method described herein. The reduction in the amount of catalyst can overcome the short-term degradation problems during the first 5 years and the premature release of GhG in the LMOP landfill. Very little catalyst is required, if any. This is especially true during the first four years, because the contents in the landfill are compacted in a colder and cold environment, thereby further helping to prevent (facilitate) the premature degradation release of GhG. In comparison, unless a higher ratio is used, the oxygen-containing compound used at its typical 3% ratio produces uneven rapid degradation of plastics; while the ratio of plastics made according to the principles of the present invention can be .1% to 1% of the total molecular weight or volume of the modified product composition. Obviously, there are a lot of cost savings for plastic manufacturers who produce products made according to the principles of the present invention, and by completing true closed-loop recycling at the EPA LMOP landfill, there are more superior results. In addition, it does this by simply using existing waste management infrastructure.

[0091] Additionally, plastics and paper / poly laminates with food contamination that has not been cleaned are preferred, and paper laminates provide food for future bio-assimilation of the present invention in EPA landfills. Therefore, such products may require lower portions of additives to initiate and complete bio-assimilation. The overall NDTP and subsequent bio-assimilation period greatly depends on the initial use of the product, the performance of the product during the early landfill stage, and then facilitates anaerobic bio-assimilation after a two-year aerobic digestion period. Although there are 100+ market segments for plastics, each market segment and application requires initial DEOL use and preferably food contamination levels.

[0092] It should be noted that this same DEOL principle can be applied to films with sun exposure such as mulch films, for example, and other films used to protect from frost such as grapevines at a winery. Solar degradation, which triggers the breakdown of plastic molecules, precedes other degradations, requiring lesser amounts of catalysts or additives.

[0093] Generally speaking, additives with high starch content (such as sorghum, potato, cassava, agave, etc.) are preferred and can more easily calculate the appropriate formulation percentage depending on the plastic and application. Corn starch processing requires additional processing steps and may affect food prices, so it is less attractive, however it can also be used.

[0094] In short, plastics constructed according to the principles of the present invention can use various catalysts and heat replacement to produce the breakdown of long molecular chains, making them more easily bioassimilated by common landfill microorganisms. Likewise, certain types of organic additives can also be formulated without the need for catalysts. This is especially true considering the longer 30-year life of LMOP landfills that produce biogas. More common is the following combination: 1) a catalyst, and 2) an organic component - used as food for the microorganisms.

[0095] Now turn to Figure 5 , depicting a set of requirements for products constructed according to the principles of the present invention, including formulation, testing, labeling and verification processes. The exemplary seedling container 30 constructed according to the principles of the present invention has a 2-year DEOL and is one container in a larger production run of thousands of containers. The production run typically uses existing plastic manufacturing processes and machinery. Before the production run, the desired bio-assimilation characteristics 32 of the seedling container 30 have been determined based on a 6-year NDTP (2-year DEOL and 4-year LMOP non-degradation period). If the DEOL of the seedling container 30 is used to grow plants in a longer time range on the farm, perhaps a 7-year NDTP is preferred. Calculating a longer NDTP is usually safer than a shorter NDTP. For the seedling container 30, a compatible plastic material 34 using a 6-year NDTP formula is selected. In this case, a material formula 36 includes a synthetic polypropylene material with a dark green colorant, and a mineral, and a biological additive, and the material formula gives a 6-year time bomb effect. The material formula 36 can also consider whether the container is used to grow plants outdoors or indoors. In cases where plants are grown outdoors for extended periods of time, the formulation may include chain extenders or UV inhibitors.

[0096] During the manufacture of the seedling container 30, the seedling container or its outer packaging has a printed product label 38 in the form of a legal notice, which states: A) Do not recycle; and B) It is safe to dispose in the EPALMOP landfill that converts decomposing garbage into energy. Or any similar words that are easy for the user to understand. It can also include a "use by" similar to those used for food, such as "sell by 7-14-22", which is typically the end of the DEOL. These types of notices can also include the ASTM number, manufacturer's name, relevant state laws and country of origin. If the product manufacturer is required to verify whether the formula used is correctly applied, they should also keep all manufacturing records 40. Government agencies or optional third-party NGOs 42 can also be used to confirm that the manufacturer complies with all formulas, early non-degradable characteristics, and late landfill bio-assimilation characteristics within the allocated time range of the established life of the EPA LMOP landfill. As previously mentioned, the EPA LMOP landfill has a maximum life of thirty years after drilling and gas extraction begins, and profitability declines after twenty-five years. The purpose of the present invention is to make the product completely bioassimilated about 25 years after drilling. B. Description of formulation, components and related processes

[0097] It is obvious that the amount of catalyst and organic compound incorporated during the manufacturing process to modify the plastic-based material component used to produce the product constructed according to the principles of the present invention depends on several time-sensitive factors. Likewise, the properties of the compound depend on other factors, such as particle size, molecular structure, and the type of organic or inorganic substance used to make them. For catalysts and organic food sources, particle sizes less than 2 microns are preferred, with superior results in the nanoparticle range. The smaller the particle size, the more uniform the dispersion, and the easier it is for microorganisms to "eat" plastics in their natural quest to bioassimilate the material. The more uniform the dispersion, the more complete the molecular decomposition and subsequent bioassimilation. Although particle sizes greater than 2 microns can work for the present invention, it may cause uneven bioassimilation. However, in the case of a long-term goal of 25 years in an existing LMOP landfill, this may not matter anyway. Migration often also plays a role in spreading catalyst properties throughout the plastic. Iron, especially iron stearate, has nanoparticle properties, which is advantageous for several reasons. It is generally regarded as a non-toxic mineral and can be found everywhere in the soil. Likewise, it is abundant in North America due to its huge market. While cobalt can also work well, it is not abundant in the U.S. and is controlled by countries outside the U.S. Being banned in some states makes it less desirable, regardless of whether the ban is scientifically justified. The obvious cost is also a factor.

[0098] One very promising catalyst that could be used is calcium oxide (CaO). It can be made cheaply by pyrolysis of calcium carbonate (CaCO3) at 700 degrees Fahrenheit. CaCO3 is abundant throughout the world, usually mined from limestone, but can also be derived from shells (such as clams and oysters), is very cheap, and is popular with the public.

[0099] Organic substances can be given catalytic properties, but most organic catalysts on the market today tend to have at least a small mineral content to initiate oxidation and decomposition of the molecular chains. For the purposes of the present invention, it makes no difference whether the proposed organic catalyst compound is completely or partially organic, as long as it provides safe biological assimilation as required.

[0100] Organic matter used as food to aid bio-assimilation is also affected by particle size. Like catalysts, the smaller the particle size, the better the particle dispersion and subsequent bio-assimilation. It is important to note that if the organic particle size is small enough and blended into the plastic in typically larger amounts (e.g., 10% or more), no catalyst will be needed. Likewise, even smaller percentages may be sufficient over a 25 year bio-assimilation time period in an EPA LMOP landfill, as small as .25% if it is a more bio-active plastic like PETG.

[0101] The actual amount or catalyst or organic food component used in a product constructed according to the principles of the present invention depends on the plastic type, product, etc. and may be as low as 1 / 10 of one percent. th (.25%) or up to 1%. The percentages are further complicated by the carrier (plastic raw material) used in the compound and the percentage of that carrier. Compound carriers typically range from 25% to 60%, with a maximum of about 50%. Thus, a compound with 25% carrier contains about 70% catalytic material, and 5% wax, and other surfactant materials. Up to 60% carrier would contain about 35% catalytic material and 5% wax, etc. The ideal situation in the industry would be to have nanoparticle catalysts and / or organic food materials in the same compound with as little carrier as possible. C. Variants

[0102] In this article, a slightly complex, yet specific and unique method for producing plastic products has been disclosed that can be efficiently manufactured and used and also meet the requirements of the U.S. EPALMOP when disposed of in a landfill. The non-degradable and bio-assimilation properties required in plastics and products constructed according to the principles disclosed herein can be achieved in several ways, many of which are not shown herein; and many of which will be discovered in the future. Almost invariably, the main material components in plastics and products constructed according to the principles disclosed herein are common synthetics, such as polyethylene, polypropylene, ABS, PET, etc., or sometimes bio-based plastics are used. Synthetic materials and / or bio-based materials can be prepared with or without recycled content or virgin content or a combination thereof, manufactured using various types of processes on various types of machinery, and have substantially the same results that meet EPA LMOP landfill requirements.

[0103] The principles listed herein can also be applied to some energy from waste (EFW) applications and essentially all agricultural biogas plants. The main difference is that faster bio-assimilation periods are preferred. This is accomplished by adjusting the catalyst and organic components as needed. In such applications, it may be preferred not to use any organic components, since it is actually processed in an "organic bath" of agricultural waste in the facility.

[0104] It should also be noted that when adopted in, for example, Indonesia and other countries and continents in Asia (outside the United States), they may have a shorter non-degradation time frame of 2 or 3 years in their LFG landfills. Most of the garbage sent to U.S. landfills takes only a few days to arrive, so the shorter time frame has little or no effect on the calculation results used herein, but in some foreign countries, it may take longer to arrive at the landfill and should therefore be taken into account. In addition, landfills around the world contain varying amounts of pure garbage, which is not present in U.S. landfills. The formulation of the present invention is used to: 1) manage the initial non-degradation time frame (typically 4 years in the United States); 2) create a time bomb effect to safely trigger bio-assimilation and start aerobic bio-assimilation when drilling after the initial non-degradation time frame; 3) continue bio-assimilation during the anaerobic stage; and 4) the desired result is that no toxic waste or microplastics are left. This feasible goal can be effectively achieved by using various blended or homogenized resins, biological salts or mineral salts, processing aids, and other technologies as listed herein. Optional color additives and processing aids may also be incorporated. Large resin manufacturers may incorporate additives and / or molecular modifiers into their plastic reactor processes and subsequent processes that have a catalytic effect that later ends up in a landfill environment.

[0105] An alternative process is to use: A) a controlled non-toxic mineral additive such as cobalt; and B) a processing aid such as CaCO3 (mined or extracted from seawater such as oyster and clam shells, which is crushed into a powder); and then C) mixed in an organic component, such as any amount of organic material already compounded into a bioplastic. Other additives that can replace the organic component are chitin and chitosan, also known as biopolymers. Likewise, a preferred process for mass production can be produced without the use of any additives but only pre-embedded molecular modifiers into the plastic resin. The use of chitin can be derived from marine shells, which are typically about 95% CaCO3 and 5% chitin. Grinded and used in the desired amount in the formulation of the present invention, it can be used as a CaCO3 processing component and a biopolymer bioassimilation enhancing component. Chitin and other mineral salts and biological salts can also be included in color additives or other processing aids to achieve the desired results.

[0106] Manufacturers of these types of additives, processing aids, and molecular modification technologies keep closely guarded trade secrets, both individually and in combination, and so do users and manufacturers. This includes proprietary raw material suppliers, mineral grinding technologies, biological raw materials, and compounding processes thereof, etc. They can include specific usage percentages in any given formulation based on DEOL and NDTP. There is simply no one-size-fits-all approach like that adopted by many suppliers of oxygen-containing salts of cadmium or other minerals, or suppliers of degraders and promoters using bio-based and enzyme additives. In many cases, the cost of the additives listed herein only increases the cost of the final product sales price by 2%-4%.

[0107] Other variations for modifying the product composition of products constructed according to the principles of the present invention may be to include greater amounts of CaCO3 to help avoid recycling and cleaning operations in current recycling plants. For example, polyethylene floats below 12% CaCO3 and sinks at higher ratios. During the initial washing process of the polyethylene film during the recycling process, the non-recyclable polyethylene product of the present invention may be caused to sink and be discarded. Likewise, it is preferred to label all such products with a "Do Not Recycle" notice, however if it happens to slip through and be deposited in a recycling bucket, it can also be easily removed later.

[0108] It will be appreciated that applicants have invented new and useful methods to determine: 1) the end of a product's useful life; 2) safe bioassimilation in EPA-regulated landfills without premature release of greenhouse gases (GhG); 3) capture and conversion of both methane and GhG gases into energy or renewable product feedstocks; and 4) creation of a closed loop recovery method (i.e., recycling). The present invention also includes methods for manufacturers and users to produce and use products constructed according to the principles of the present invention and methods for verifying proper use.

[0109] The spirit of the invention provides a broad scope including all methods of manufacture, formulation and use.Any variations of the subject matter and methods not described herein that achieve the same results are deemed to be within the scope of the invention.

[0110] Certain objects and advantages of the present invention are described herein. Of course, it should be understood that not all such objects or advantages may be achieved according to any particular embodiment of the present invention. Thus, for example, those skilled in the art will recognize that the present invention may be embodied or performed in a manner that achieves or optimizes one advantage or a group of advantages as taught herein, without necessarily achieving other objects or advantages as may be taught or suggested herein.

[0111] Although the present invention has been disclosed in the context of certain preferred embodiments and examples, it will be understood by those skilled in the art that the present invention extends beyond the specifically disclosed embodiments to other alternative embodiments and / or uses of the present invention and obvious modifications and equivalents thereof. In addition, although various variations of the present invention have been shown and described in detail, other modifications within the scope of the present invention will be apparent to those skilled in the art based on this disclosure. However, in particular Figure 1 and 2 The key teachings in are ideal for creating test protocols that are used to validate and / or create a new ASTM standard that uses multiple test points to chart the bioassimilation of the plastics of the present invention, using: 1) ASTM D5296 and D882 to establish DEOL properties; 2) ASTM D5338 to validate aerobic bioassimilation activity; and 3) D5511 or D5526 to test anaerobic bioassimilation and biogas production.

[0112] It is also contemplated that various combinations or sub-combinations may be made to the specific features and aspects of the embodiments, but still fall within the scope of the present invention. Accordingly, it should be understood that the various features and aspects of the disclosed embodiments may be combined with or substituted for each other to form different modes of the disclosed invention. Therefore, it is intended that the scope of the invention disclosed herein should not be limited by the specific disclosed embodiments described above.

Claims

1. A method of producing one or more biogases in a biodigester environment, the method comprising: Determining a non-degradation time period for a selected product to be manufactured and used with at least one plastic-based material component; as well as The product composition of the selected product is modified during the manufacturing process to trigger bioassimilation of the plastic-based material components of the selected product, and subsequent production of at least one biogas, after the product is disposed of within the biodigester environment and the non-degradation time period expires.

2. The method of claim 1, wherein: This biodigester environment was created within the LMOP landfill.

3. The method of claim 1, wherein: The bio-assimilation of the plastic product within the bio-digester environment is caused by both aerobic and anaerobic processes.

4. The method of claim 1, wherein: The manufacturing process of the product is selected from the group consisting of one of the following machines: a blown film extruder, a blow molding machine, a thermoforming machine, a cast film machine, a compression compounder, and an injection molding machine.

5. The method of claim 1, wherein: The product composition modifier used to modify the product composition of the selected product is selected from the group consisting of at least one of salts, organic catalysts, mineral catalysts, bioplastics and synthetic blends, organic biopolymers, molecular modifiers, and enzymes.

6. The method of claim 1, wherein: The selected product is classified as non-recyclable.

7. The method of claim 1, wherein: The selected product is contaminated with an amount of organic material prior to placement within the biodigester environment.

8. The method of claim 1, wherein: The selected products are constructed from different materials.

9. The method of claim 1, wherein: The selected product is selected from the group of expected end of useful life duration consisting of: single use disposable products, short term durable products, and long term durable products.

10. The method of claim 1, wherein: The end of the non-degradation time period is determined by a transition from a predetermined lower temperature to a predetermined higher temperature within the bio-digester environment to trigger the production of the at least one biogas within the bio-digester environment.

11. The method of claim 1, wherein: The selected product is composed of a bioplastic including a chain extender to meet the non-degradation time period.

12. The method of claim 1, wherein: The non-degradation time period is determined by calculating an expected end of useful life time period for the selected product and a landfill dormancy time period, wherein the product is placed in a landfill environment prior to transitioning to the biodigester environment.

13. The method of claim 12, wherein: The expected end of useful life time period of the selected product is defined by the time period beginning with the date of manufacture, continuing use of the product in the ambient environment other than the landfill environment, and ending with the product entering the biodigester environment; and The landfill dormancy period is defined by the initial disposition of the product within the landfill environment until one or more biogas extractors are placed in communication with the landfill environment, thereby initiating a biodigester environment.

14. The method of claim 12, wherein: The dormant period includes an initial phase in which the selected product is isolated within a landfill environment having a first temperature and inhibiting premature release of the at least one biogas, and ends during a first transition phase in which the landfill environment is sufficiently heated to promote bioassimilation of the plastic-based material of the selected product.

15. The method of claim 14, wherein: The transition to a temperature above the first temperature is triggered by placing one or more biogas extractors in communication with the landfill environment to initiate the transition to the biodigester environment.

16. The method of claim 12, further comprising: At the end of the burial dormancy period, transitioning to a temperature environment that is higher than the temperature of the burial environment, thereby causing biological assimilation of the plastic-based material by an aerobic or anaerobic process that converts the plastic-based material into a volume of at least one biogas; capturing at least a portion of the volume of biogas; as well as This captured volume of biogas is converted into energy for storage and subsequent use.

17. The method of claim 12, further comprising: A desired bio-assimilation time period is determined, during which the bio-digester environment undergoes an anaerobic process to produce a certain volume of biogas, the bio-assimilation time period occurring after the expiration of the desired buried dormancy time period and lasting until the end of an event in which useful biogas is extracted from the bio-digester environment by one or more biogas extractors placed in communication with the bio-digester environment.

18. The method of claim 12, wherein: The expected end of useful life period is one year; and The total non-degradation period is five years.

19. The method of claim 12, further comprising: determining a biogas collection time period after expiration of the landfill dormancy time period, the biogas collection time period beginning from initial placement of one or more biogas extractors placed in communication with the landfill environment until substantially completing collection of at least one biogas produced by bioassimilation of the plastic-based materials in the selected products; as well as During the biogas collection time period, a volume of biogas generated by bioassimilation of the plastic-based material component of the selected product is collected.

20. The method of claim 12, wherein: The product composition is modified by introducing an additive during the manufacturing process of the selected product, which additive has a negligible impact on the expected end of useful life time period in which the product is placed in the surrounding environment, while also delaying the production of at least one biogas caused by the bioassimilation of the plastic-based material component of the selected product until the product reaches the end of its entire useful life and is disposed of in the landfill environment and enters the biodigester environment.

21. The method of claim 20, wherein: The additive is selected from the group consisting of sorghum, potato, cassava, agave, corn starch, avocado and beet.

22. The method of claim 20, wherein: The additive is organic.

23. The method of claim 20, wherein: The additive is inorganic.

24. The method of claim 20, wherein: The additive is a biopolymer selected from the group consisting of chitin, chitosan, TM Commercially produced biopolymers sold under the trade name Ingeo TM Commercially manufactured biopolymers for sale.

25. The method of claim 20, wherein: The additive functions as both a catalyst and a digestible substance to be consumed by one or more microorganisms disposed within the bio-digester environment.

26. The method of claim 20, wherein: The additive includes at least one organic or inorganic substance that serves as a food source for common microorganisms found in landfills or biodigesters.

27. The method of claim 26, wherein: The food source is between .25% and 3% of the total molecular weight or volume of the modified product composition.

28. The method of claim 1, further comprising: A catalyst is introduced into the product composition of the selected product during the manufacturing process, the catalyst being selected to break down the long molecular chains of the plastic-based material components of the product composition within the biodigester environment.

29. The method of claim 28, wherein: The catalyst is accompanied by an organic component that provides digestible material for consumption by one or more microorganisms disposed within the bio-digester environment.

30. The method of claim 28, wherein: The catalyst causes the long molecular chains of the plastic-based material to break down when exposed to heat.

31. The method of claim 28, wherein: The catalyst is selected from the group consisting of iron, iron stearate, cobalt, cadmium, calcium, magnesium, calcium oxide and calcium carbonate.

32. The method of claim 28, wherein: The catalyst is between .1% and 1% of the total molecular weight or volume of the modified product composition.

33. A polymer for use in the manufacture of a product configured to enter a biodigester environment after a desired end of useful life period and a subsequent landfill dormancy period, the polymer comprising: at least one plastic-based material component; and An additive introduced during the manufacturing process of the product, which additive inhibits degradation of at least one plastic-based material component during the expected end of useful life period and the landfill dormancy period, and once the biodigester is heated to create the biodigester environment, the additive further enhances the bioassimilation of the plastic-based material component.

34. The polymer of claim 33, wherein: The additive includes at least one organic component.

35. The polymer of claim 33, wherein: The additive includes at least one inorganic component.

36. The polymer of claim 33, wherein: The additive consists of at least one organic catalyst.

37. The polymer of claim 33, wherein: The additive consists of at least one inorganic catalyst.

38. The polymer of claim 33, wherein: The additive includes at least one food source digestible by microorganisms present in the bio-digester.

39. A method for modifying a polymer during the manufacturing process of a product to induce bioassimilation of the product in a biodigester environment, the method comprising: Select the product to be manufactured; Select the polymer to be used in the manufacture of the product; determining a first product life cycle phase defined by use of the product in an ambient environment outside of the biodigester environment; determining a second product life cycle phase, the second product life cycle phase being defined by the product initially entering a landfill environment; and determining a third product life cycle stage defined by initiating bioassimilation of the product by an aerobic or anaerobic process within the biodigester environment; determining a fourth product life cycle stage in the biodigester environment during which an anaerobic process converts the polymer into a volume of one or more biogases; as well as The polymer is modified during the product's manufacturing process to accommodate all four life cycle stages.

40. A closed-loop biogas collection system comprising: Biodigester, which defines the biogas production environment; a plurality of products disposed within the biogas generating environment, each product having an expected end of useful life period expiring during which the product was previously used in an ambient environment outside of the biogas generating environment, the products being constructed of at least one plastic-based material and further constructed to: have a built-in bioassimilation resistance period of the product after initial disposal within the biogas generating environment, and to enter a bioassimilation period after expiration of the bioassimilation resistance period, thereby causing complete bioassimilation of the product and production of a volume of biogas; and A biogas extraction component is placed in communication with the biogas producing environment and is configured to extract a volume of biogas produced by the bioassimilation of the plastic-based material until a predetermined biogas volume capture level is achieved.

41. A polymer-based composition for delaying bioassimilation and production of biogas in a biodigester, the polymer-based composition comprising: Polymers with long molecular chain structures that are resistant to degradation and bioassimilation; as well as An additive that modifies the molecular chain structure of the polymer during the manufacturing process to produce a modified polymer, the additive being defined by an amount and type that has a negligible effect on the degradation of the modified polymer during an expected end-of-use life time period in an ambient environment, rendering the modified polymer dormant until the biodigester environment begins, and also assisting in the bioassimilation of the modified polymer and the subsequent production of a volume of biogas produced by the decomposition of the modified polymer after one or more biogas extractors are placed in communication with the biodigester.

42. A method for modifying the long-chain molecular structure of a plastic resin in a reactor, comprising: introducing a plastic resin into a reactor; as well as A heat-sensitive molecular component is added to be blended with the plastic resin in the reactor, the heat-sensitive molecular component responding to a high heat environment of at least one hundred degrees Fahrenheit to initiate decomposition of the long-chain molecular structure, thereby producing a plurality of shorter molecular chains that can be bioassimilated by common microorganisms present in the biodigester environment when the plastic resin is placed in the biodigester environment.

43. The method of claim 42, wherein: The plastic resin is compounded with one or more organic or inorganic substances shortly after being produced in the reactor.

44. A method for testing and verifying the bioassimilation of a modified polymer according to the following sequence, comprising: Testing the modified polymer during the first life cycle of use in a simulated ambient environment to verify low threshold degradation levels; Testing the modified polymer in a second life cycle stage buried in a simulated landfill environment to verify a low threshold release of a volume of biogas; Testing the modified polymer at a third life cycle stage in a simulated biodigester environment to verify bioassimilation of the modified polymer, the bioassimilation being initiated by an aerobic process; and The modified polymer is tested at a fourth life cycle stage maintained in a simulated biodigester environment to verify bioassimilation of the modified polymer by conversion into a volume of one or more biogases in an anaerobic process.

45. A method of preventing premature bioassimilation of a modified polymer prior to installation of a biogas capture device to capture one or more biogases, the method comprising: placing the modified polymer in an isolated cold environment, the isolated cold environment inhibiting premature bioassimilation of the modified polymer to prevent a volume of biogas from being released into the atmosphere; transitioning the cold environment to a higher temperature to initiate bioassimilation of the modified polymer due to the introduction of one or more biogas capture devices; as well as A transition from an aerobic process to an anaerobic process occurs within the higher temperature environment, resulting in the production of a volume of biogas as the modified polymer decomposes.

46. ​​The method of claim 45, further comprising: entering a biogas capture phase defined by collecting a volume of one or more biogases by the one or more biogas capture devices; converting the captured volume of one or more biogases into energy; as well as This energy is stored for later use.

47. The method of claim 46, further comprising: The captured volume of one or more biogases is stored as renewable natural gas.

48. The method of claim 47, wherein: At least some of the renewable natural gas is used in a plastic reactor to produce a plastic resin in a plastic reactor.

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