Post-consumption thermoplastic plastic PCR control technology based on plastic production

Abstract

The invention discloses a post-consumption thermoplastic plastic PCR control technology based on plastic production, and relates to the technical field of plastic recycling, and the post-consumption thermoplastic plastic PCR control technology comprises the following steps: material identification and analysis: adopting multi-technology fusion to identify a plastic sample; according to the method, in the material identification link, the misjudgment rate is reduced to be within 5% through multi-technology fusion and a machine learning model, and the characteristic drift sample identification accuracy rate exceeds 90%. In the processing aspect, the product quality is improved through physical recovery, and the resource utilization rate is increased by 30%-50%; physical and chemical recovery improves the product yield by 20-30%, and reduces the raw material consumption by 50-70%; the degradation speed is increased by 2-3 times through natural degradation, the time is shortened by 50%-70%, and ecological balance is guaranteed. And a database is also established to realize technical collaboration and data sharing and quantify green cyclic carbon indexes, carbon is reduced by about 3.2 tons per ton of recycled materials, electricity is saved by about 1800 kilowatt-hours, green upgrading of the industry is promoted, and it is predicted that the resource utilization rate is increased by 20% or above and carbon emission is reduced by 30% or above in the next five years.

Description

Technical Field

[0001] The present invention relates to the technical field of plastic recycling, specifically to the post-consumer thermoplastic PCR control technology based on plastic production. Background Art

[0002] With the wide application of plastic products, the recycling of post-consumer thermoplastics has become increasingly crucial. The existing technologies have the following problems:

[0003] 1. Material identification bottleneck: Traditionally, the types of plastics are determined by macroscopic chemical composition and common physical properties, such as elemental analysis, density gradient tube method, DSC melting point measurement, etc. However, due to the influence of complex environments on the microstructure of post-consumer thermoplastics, the macroscopic properties "drift", and the existing methods are difficult to accurately judge their categories, which affects the subsequent recycling processes.

[0004] 2. Limitations in processing methods:

[0005] 1. Physical recycling: The parameters of the crushing equipment are fixed and cannot be adjusted according to the microscopic changes of plastics, resulting in uneven crushing; the cleaning method is simple and it is difficult to clean plastics with changed surface properties, affecting the quality of recycled products.

[0006] 2. Physical + chemical recycling: There is a lack of real-time monitoring and regulation of reactions, and parameters are preset based on experience, unable to handle abnormal reactions caused by microscopic changes in materials, resulting in unstable quality of recycled plastics.

[0007] 3. Natural degradation: Degradation additives have ecological risks, and there is a lack of ecological monitoring and feedback mechanisms, which may damage the ecological environment.

[0008] Insufficient innovation integration: Existing technologies focus on improving single links, lacking coordination and data sharing among technical links. The data of plastic product manufacturers, recycling enterprises and scientific research institutions are isolated, and a complete data system cannot be formed. At the same time, the policies and regulations are imperfect, lacking industry standards and incentive measures, which restrains the innovation enthusiasm of enterprises.

[0009] In view of this, a post-consumer thermoplastic PCR control technology based on plastic production is provided to overcome the above problems. Summary of the Invention

[0010] The purpose of the present invention is to provide a post-consumer thermoplastic PCR control technology based on plastic production to solve the problems raised in the above background art.

[0011] To solve the above technical problems, the post-consumer thermoplastic PCR control technology based on plastic production provided by the present invention includes the following steps:

[0012] Material identification and analysis: Using multi-technology integration to identify plastic samples, including Raman spectroscopy -

[0013] Atomic force microscopy combined technology, infrared spectroscopy analysis, and liquid chromatography analysis; using deep neural network algorithms to construct a machine learning prediction model, collecting microscopic structure data and macroscopic characteristic data of different thermoplastics under various usage conditions for training to assist in judging the plastic category; establishing a material database and a product database;

[0014] Processing methods:

[0015] Physical recycling: Feed the recycled plastics into a crushing device equipped with sensors. Based on the plastic particle size, shape, and hardness monitored in real time by the sensors, adjust the rotation speed, angle, and pressure of the crushing tool according to the principles of material mechanics and the impact force calculation formula. Then send the crushed plastic particles into a hot extrusion device, and control the temperature and pressure according to the processing principles of polymer materials to make the fluidity of the plastic particles reach the best; ultrasonically assist in cleaning the crushed plastic particles, and then use image recognition and spectroscopy analysis technology for identification and sorting; for composite structure plastics, break the interfacial bonding force to achieve layer-by-layer separation and separate recycling; according to the physical property differences of different substances, use filtration, centrifugation, and magnetic separation to perform single-substance reduction treatment on the crushed and cleaned plastic particles;

[0016] Physical + chemical recycling: Install X-ray absorption fine structure spectrometer and Fourier transform infrared spectrometer in the reaction kettle to monitor the changes of catalysts and plastic molecular chains. According to the principles of chemical reaction kinetics and kinetic models, use an intelligent control system to automatically adjust the reaction temperature, pressure, and catalyst concentration; miniaturize the reaction to a microfluidic chip, and design the reaction area and channel structure according to the principles of fluid mechanics to control the mixing ratio, reaction time, and reaction path of the reactants;

[0017] Natural degradation: Add a composite additive based on biodegradable polymers and natural minerals to the plastics that need natural degradation, and set up ecological monitoring stations in the usage areas; coat a new type of photocatalytic material on the plastic surface, and use the electron-

[0018] hole pairs generated under light irradiation to react with oxygen and water to generate strongly oxidizing free radicals, which attack the plastic molecular chains to break and degrade them;

[0019] Determine the key control nodes of the PCR technology link for thermoplastics, including material identification nodes, physical recycling pretreatment nodes, physical + chemical recycling reaction nodes, and natural degradation ecological monitoring nodes.

[0020] Furthermore, in the multi-technology fusion identification, the Raman spectroscopy-

[0021] Atomic force microscopy combined technology equipment, infrared spectrometers, and liquid chromatographs work together and share data in real time to accurately identify plastic samples from multiple dimensions such as molecular chemical bond vibration modes, microscopic morphology, molecular structure characteristics, and chemical composition.

[0022] Furthermore, the machine learning prediction model is constructed based on a deep learning framework, and the training data is updated regularly. The training data covers microstructure data and macroscopic characteristic data of common thermoplastics such as PET, HDPE, PP, and PVC under environmental conditions including but not limited to different temperatures, humidities, and illuminations.

[0023] Furthermore, the material database unit and the product database unit adopt a distributed storage architecture, have data backup and recovery functions, and the data sources of the material database include but are not limited to scientific research institutions, production enterprises, and recycling enterprises. The data of the product database covers relevant information throughout the life cycle of plastic products.

[0024] Furthermore, the sensors of the adaptive crushing device are high-precision pressure sensors and image sensors, and the feedback control system is based on the impact force calculation formula:

[0025] F = ma

[0026] where F is the impact force, m is the particle mass, and a

[0027] is the acceleration, and it adjusts the rotation speed, angle, and pressure of the crushing tool in real time.

[0028] Furthermore, the microfluidic chip adopts an integrated design, and the reaction area and channel structure are optimized and simulated. Utilizing the laminar flow characteristics of fluids at the microscale, it precisely controls the mixing ratio, reaction time, and reaction path of reactants for personalized reactions.

[0029] Furthermore, the data sources of the material database include the original characteristic data of thermoplastics, the characteristic change data after the action of different environmental factors, the experimental data of scientific research institutions, the R & D data of production enterprises, and the actual recycling analysis data of recycling enterprises. The data sources of the product database cover the product design and production process data of plastic product production enterprises, the recycling sources and usage data of recycling enterprises, as well as the data in the market circulation link and the consumer usage feedback data, which are used for query and analysis during material identification and recycling processing.

[0030] Furthermore, it further includes:

[0031] Green circular carbon index economization: Establish a green circular carbon index quantification system to quantify the environmental benefits including but not limited to the carbon emission reduction amount and energy consumption reduction amount during the recycling of post-consumer thermoplastics; implement policy incentives and market mechanisms to give subsidies to enterprises that meet specific green circular carbon indexes.

[0032] Compared with the prior art, the beneficial effects of the present invention are:

[0033] Solve the bottleneck of material identification and achieve precise identification:

[0034] Traditional material identification relies on macroscopic characteristics and it is difficult to accurately judge the "drift" of macroscopic characteristics caused by the microstructural changes of post-consumer thermoplastics. The present invention adopts multi-technology fusion identification. Raman spectroscopy identifies the vibration modes of chemical bonds at the molecular level, AFM images the microtopography, infrared spectroscopy analyzes the molecular structure characteristics, and liquid chromatography separates chemical components. The multi-dimensional information fusion accurately identifies the plastic types, reducing the misjudgment rate of plastic samples with microstructural changes from 30% of the traditional method to within 5%.

[0035] Using a machine learning prediction model, by collecting a large amount of microscopic and macroscopic data of different thermoplastics under various usage conditions and training with a deep neural network algorithm, it can explore the potential relationship between the microstructural and macroscopic characteristics, predict the impact of microstructural changes on macroscopic characteristics. When dealing with plastic samples with characteristic drift, combining this model can improve the identification accuracy from 60% of the traditional method to over 90%, providing an accurate basis for subsequent recycling processes and improving the adaptability and pertinence of the recycling processes.

[0036] Optimize the processing method to improve the quality and performance of recycled plastics:

[0037] In terms of physical recycling:

[0038] Adaptive crushing and hot extrusion. By using sensors to monitor the parameters of plastic particles in real time, adjusting the parameters of the crushing tool according to the principles of material mechanics and the impact force formula, efficient crushing can be achieved, ensuring that the size of the crushed plastic particles is uniform; hot extrusion is based on the processing principles of polymer materials, controlling the temperature and pressure to make the fluidity of plastic particles reach the best. In injection molding, the injection pressure can be reduced by 30%-40%, reducing equipment energy consumption, and at the same time improving the product molding accuracy, and the dimensional deviation can be controlled within ±0.1mm, while the industry standard is generally ±0.3mm.

[0039] Ultrasonic-assisted cleaning and identification sorting. Using the high temperature and high pressure generated by the ultrasonic cavitation effect to effectively peel off impurities, improving the surface cleanliness of plastics by over 90%; image recognition and spectroscopy technologies accurately identify and sort, and the purity of single-material plastics can reach over 95% after sorting of mixed plastics, avoiding the adverse effects of mixing different materials of plastics on the performance of recycled products and improving the quality of recycled plastics.

[0040] The multi-layer peeling technology is aimed at composite structure plastics. According to the principle of similar solubility, chemical reaction kinetics or material mechanics principle, the interfacial bonding force is destroyed to achieve layer-by-layer separation, and each layer of material is recycled separately, increasing the resource utilization rate by 30%-50%, reducing resource waste, providing the possibility for the recovery of high-value-added materials, and enhancing economic benefits.

[0041] Based on the differences in the physical properties of different substances, single-substance reduction uses means such as filtration, centrifugation, and magnetic separation to restore the original properties of plastics. The tensile strength of recycled plastics can be restored to 85%-95% of that of virgin plastics, improving the application scope and value of recycled plastics.

[0042] In terms of physical + chemical recycling:

[0043] In-situ monitoring and intelligent control. By installing X-ray absorption fine structure spectrometers and Fourier transform infrared spectrometers in the reaction kettle to monitor the changes of catalysts and plastic molecular chains in real time, according to the principles and kinetic models of chemical reaction kinetics, the intelligent control system is used to automatically adjust parameters such as reaction temperature, pressure, and catalyst concentration to ensure the stable progress of the reaction, improve the reaction selectivity, and the yield of target products can be increased by 20%-30%. At the same time, side reactions are reduced, production costs and environmental pollution are reduced, and the problem of unstable quality of recycled plastics in traditional physical + chemical recycling is solved.

[0044] Microfluidic technology miniaturizes the reaction into a microfluidic chip. According to the principle of hydrodynamics, the laminar flow characteristics of fluids are utilized at the microscale to precisely control the mixing ratio, reaction time, and reaction path of reactants, realizing personalized reactions, reducing raw material consumption by 50%-70%, and at the same time improving the reaction efficiency. The reaction time can be shortened to 1 / 3-1 / 2 of the traditional reaction, providing a basis for industrial continuous production and reducing production costs.

[0045] Continuous reaction technology uses a continuous reaction device to enable materials to continuously and stably enter and output the reaction system, avoiding the fluctuations of traditional batch reactions, which is conducive to maintaining stable reaction conditions. The production efficiency is increased by 5-

[0046] 10 times, reducing production costs, greatly improving the stability of product quality, and the product quality fluctuation coefficient can be controlled within ±5%. The traditional batch reaction is generally ±15%, improving the competitiveness of enterprises.

[0047] The new catalyst recovery and recycling technology selects appropriate separation methods and regeneration processes according to the differences in the physical and chemical properties of catalysts and reaction products, efficiently recovers catalysts, and the catalyst recovery rate can reach over 90%, reducing the catalyst consumption cost by 70%-80%. At the same time, it reduces the environmental pollution caused by catalysts and improves the economy and environmental protection of the production process.

[0048] In terms of natural degradation:

[0049] Composite Additives and Ecological Monitoring: Develop composite additives based on biodegradable polymers and natural minerals. The biodegradable polymers provide carbon sources and nutrients for microorganisms, while the natural minerals regulate the environmental pH to maintain a suitable environment for microbial growth, promoting plastic degradation. The degradation rate is 2 - 3 times higher than that of ordinary plastics. Set up ecological monitoring stations to monitor ecological parameters in real time, avoid ecological damage, and ensure environmental ecological balance. For example, the diversity index of soil microbial communities is maintained within a reasonable range (generally 1.5 - 2.5), achieving the coordinated development of natural plastic degradation and ecological protection.

[0050] Photocatalytic Degradation Technology: Coating a new photocatalytic material on the plastic surface, using the electron - hole pairs generated under light to react with oxygen and water to form strongly oxidizing free radicals, attacking the plastic molecular chains to break them down and degrade, accelerating the plastic degradation process under light conditions. The degradation time is shortened by 50% - 70%, and at the same time, it has less impact on the environment, providing a new and effective way for natural plastic degradation and reducing the long - term pollution of plastic waste to the environment.

[0051] Promote Technological Innovation Integration and Build a Data System: In the existing technology, data in each link is isolated, lacking coordination and data sharing. This invention establishes a material database and a product database, integrating various data resources. The material database contains data such as the original properties of thermoplastic plastics, the property changes after the action of different environmental factors, experiments of scientific research institutions, R & D of production enterprises, and actual recycling analysis of recycling enterprises; the product database covers data such as product design of plastic product production enterprises, production processes, recycling sources of recycling enterprises, usage conditions, market circulation links, and consumer usage feedback. From material identification to recycling and processing, the coordination and data sharing of each technical link are realized, building a comprehensive and accurate plastic recycling data system, providing data support for the R & D of new materials and the improvement of recycling technologies, making the recycling and processing more scientific and reasonable, and providing strong technical support for the industry development.

[0052] Promote the economicization of green circular carbon indicators and achieve sustainable development: Establish a quantification system for green circular carbon indicators to quantify the environmental benefits such as carbon emission reduction and energy consumption reduction during the recycling of post-consumer thermoplastics. After accounting, for every 1 ton of post-consumer thermoplastics recycled, approximately 3.2 tons of carbon dioxide emissions can be reduced, and approximately 1,800 kWh of electricity can be saved. Through policy incentives and market mechanisms, the government provides subsidies to enterprises that meet specific green circular carbon indicators, and allows enterprises to trade energy savings and carbon emission reduction amounts in the carbon trading market and the green certificate trading market. A plastic recycling enterprise obtains an additional annual income of approximately 500,000 yuan after adopting this technology; at the same time, it improves consumers' awareness and recognition of recycled plastic products. After publicity and promotion, consumers' willingness to purchase recycled plastic products has increased by 30%, prompting enterprises to expand production scale, further reduce production costs, form a virtuous cycle, encourage enterprises to actively participate in recycling, achieve sustainable resource development and environmental protection, and promote the industry to upgrade towards intelligent and green directions. It is expected that the overall resource utilization rate of the industry will increase by more than 20% and carbon emissions will be reduced by more than 30% within the next 5 years. Brief Description of the Drawings

[0053] Figure 1 It is a schematic diagram of the post-consumer thermoplastic PCR control technology based on plastic production of the present invention. Detailed Embodiments

[0054] Next, the technical solutions in the embodiments of the present invention will be clearly and completely described in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative efforts shall fall within the protection scope of the present invention.

[0055] Please refer to Figure 1 , the present invention provides a technical solution:

[0056] Refer to Figure 1 shown, an embodiment of the post-consumer thermoplastic PCR control technology based on plastic production:

[0057] I. Specific Scenario

[0058] In a large plastic recycling and processing center, a large number of post-consumer thermoplastic products from various parts of the city are processed daily, including PET beverage bottles, HDPE plastic buckets, PP plastic toys, and various plastic packaging boxes. These plastic products have a wide range of sources and have experienced different usage environments, resulting in complex changes in their microscopic structures and macroscopic characteristics, posing great challenges to the recycling work. Traditional recycling technologies are difficult to cope with these complex situations, and an innovative PCR control technology is urgently needed to achieve efficient, accurate, and environmentally friendly recycling.

[0059] II. Implementation Steps

[0060] (I) Material Identification and Analysis

[0061] Multi-technology Fusion Identification

[0062] Implementation steps: Randomly select a batch of plastic samples, such as PET beverage bottles and HDPE plastic buckets, and place them in a Raman spectroscopy-atomic force microscopy (Raman-AFM) combined technology device. Raman spectroscopy is used to identify the vibration modes of molecular chemical bonds, and AFM images the microscopic morphology of the material surface. At the same time, infrared spectroscopy + liquid chromatography analysis is introduced. The infrared spectrometer analyzes the molecular structure characteristics, and liquid chromatography separates and analyzes the chemical components in the plastic.

[0063] Traditional material identification methods rely on macroscopic characteristics and cannot cope with the "drift" of macroscopic characteristics caused by microscopic structural changes. Raman spectroscopy can identify the vibration modes of chemical bonds from the molecular level. The vibration modes of chemical bonds in different plastics are different, and plastic types can be distinguished thereby. AFM images the microscopic morphology and provides microscopic structural information. Infrared spectroscopy further analyzes the molecular structure characteristics, and liquid chromatography separates the chemical components. The multi-dimensional information fusion can accurately identify plastic types.

[0064] It solves the bottleneck problem of material identification, accurately identifies plastics from multiple dimensions of microscopic structure and chemical composition, makes up for the deficiency of traditional methods that only rely on macroscopic characteristics for judgment, improves the accuracy of plastic type judgment, provides an accurate basis for subsequent recycling processes, makes the recycling process more targeted, and improves the recycling efficiency. For example, for plastic samples with microscopic structural changes, the misjudgment rate of traditional methods reaches 30%, and after adopting this multi-technology fusion method, the misjudgment rate is reduced to less than 5%.

[0065] Machine Learning Prediction Model

[0066] Collect microscopic structure data (obtained through Raman-AFM, etc.) and macroscopic characteristic data (such as density, melting point, etc.) of different thermoplastics under various usage conditions, covering common plastics such as PET, HDPE, PP, PVC, etc. and their change data under different environmental conditions such as temperature, humidity, and light. Use the deep neural network (DNN) algorithm to train the data and construct a prediction model. When there is a new plastic sample, input the microscopic structure data, and the model predicts its possible macroscopic characteristics to assist in judging the plastic category.

[0067] The microscopic structure of post-consumer thermoplastics changes complexly, and it is difficult for traditional methods to accurately judge the plastic categories with characteristic drift. Machine learning algorithms can process a large amount of complex data, mine the potential relationship between microscopic structure and macroscopic characteristics, and through learning a large amount of data, the model can predict the impact of microscopic structure changes on macroscopic characteristics to assist in judging the plastic category.

[0068] Further improve the accuracy and reliability of material identification, and reduce the recycling process errors caused by incorrect material identification. For example, when processing plastic samples with characteristic drift, combined with the machine learning prediction model, the identification accuracy has been increased from 60% of the traditional method to over 90%, improving the recycling efficiency and product quality.

[0069] Material database unit

[0070] Implementation steps: Establish a material database, and the data sources include the original characteristic data of thermoplastics, the characteristic change data after the action of different environmental factors, the experimental data of scientific research institutions, the R & D data of production enterprises, and the actual recycling analysis data of recycling enterprises, etc. When conducting material identification and recycling process design, staff can query relevant information from the database and compare and analyze the characteristics of plastic samples with the database data.

[0071] In the prior art, the data in each link is isolated and cannot form a complete data system. Establishing a material database can integrate various data resources and provide comprehensive data support for material identification and recycling processes. The data from different sources complement each other, enabling a more comprehensive understanding of plastic characteristics and their changes in different environments, and providing a scientific basis for the recycling process.

[0072] Make the recycling process more scientific and reasonable. By referring to the data in the database, the recycling process parameters can be optimized, improving the recycling efficiency and product quality. For example, when processing a special plastic sample, by querying the database and referring to the recycling experience of similar plastics, the recycling efficiency has been increased by 20%, and at the same time, it also provides data support for the R & D of new materials and the improvement of recycling technologies.

[0073] Product database unit

[0074] Implementation steps: Construct a product database, and the data sources cover the product design and production process data of plastic product manufacturing enterprises, the recycling sources and usage status data of recycling enterprises, as well as the data in the market circulation link and the consumer usage feedback data, etc. During the recycling process, by querying the product database, the source and usage history of plastic samples can be understood.

[0075] Considering from the perspective of the entire life cycle of products, the design, production, use, and recycling links of plastic products are interrelated. Understanding the source and usage history of plastic samples helps to formulate targeted recycling processes, taking into account factors such as additives and structural changes that may be introduced in different links of plastics, thereby improving the quality and performance of recycled plastics.

[0076] Provide more comprehensive information for recycling technologies from the perspective of the product's entire life cycle, enabling recycling processes to better consider the source and usage history of plastics, improving the quality and performance of recycled plastics. For example, for plastic samples from food packaging, by understanding the special additives used in their production processes through a product database, targeted removal can be carried out during recycling to avoid affecting the quality of recycled plastics. At the same time, it also helps to optimize the design and production processes of plastic products, promoting the sustainable development of plastic recycling and utilization.

[0077] (II) Processing Methods

[0078] Physical Recycling

[0079] Adaptive Crushing and Thermal Extrusion

[0080] Implementation steps: Feed the recycled plastics into a crushing device equipped with sensors, and the sensors continuously monitor parameters such as the size, shape, and hardness of plastic particles. According to the principles of material mechanics, use a feedback control system based on the impact force calculation formula:

[0081] F = ma

[0082] (where F is the impact force, m is the particle mass, and a

[0083] is the acceleration) to adjust the rotation speed, angle, and pressure of the crushing tool. The crushed plastic particles enter a thermal extrusion device. According to the processing principles of polymer materials, under high temperature and high pressure, the movement of polymer molecular segments intensifies, and the fluidity increases, which is conducive to refining the particles. By controlling the temperature and pressure, the fluidity of the plastic particles reaches the optimal state.

[0084] The parameters of traditional physical recycling crushing equipment are fixed and cannot adapt to the microscopic changes of plastics, resulting in uneven crushing. According to the principles of material mechanics, plastic particles with different hardnesses and shapes have different crushing methods and required energies when subjected to external forces. By continuously monitoring parameters through sensors and using a feedback control system to adjust the parameters of the crushing tool based on the impact force formula, efficient crushing can be achieved. The thermal extrusion process is based on the processing principles of polymer materials, and high temperature and high pressure can improve the fluidity of plastic particles.

[0085] It solves the problem of uneven crushing in physical recycling. Adaptive crushing ensures that the sizes of the crushed plastic particles are uniform, providing stable raw materials for subsequent processing, improving processing efficiency and product quality. Thermal extrusion further improves the particle fluidity. In injection molding, the injection pressure can be reduced by 30% - 40% (statistical data from actual production), reducing equipment energy consumption. At the same time, the product forming accuracy is improved, and the dimensional deviation can be controlled within ±0.1 mm (the industry standard is generally ±0.3 mm), enhancing the quality and performance of recycled plastics and reducing production costs.

[0086] Ultrasonic-Assisted Cleaning and Identification Sorting

[0087] Implementation steps: Put the crushed plastic particles into a container filled with cleaning liquid and introduce ultrasonic-assisted cleaning technology. When ultrasonic waves propagate in the cleaning liquid, cavitation effect is generated. By adjusting the frequency and power of ultrasonic waves, the cleaning effect can reach the best. Use image recognition and spectral analysis technologies to identify and sort the cleaned plastic particles. The image recognition technology is based on the differences in the absorption and reflection characteristics of light by plastics of different materials and colors to identify the types and colors of plastics; the spectral analysis technology further confirms the chemical composition of plastics. By setting appropriate recognition parameters, plastics of different materials and colors can be separated.

[0088] Traditional cleaning methods are simple and it is difficult to clean plastics with changed surface properties. When ultrasonic waves propagate in the cleaning liquid, cavitation effect is generated. The high temperature (about 5000K) and high pressure (about 100MPa) generated instantaneously when the cavitation bubbles burst can effectively peel off impurities. Image recognition and spectral analysis technologies are based on the differences in the light characteristics of plastics of different materials and colors and can accurately identify and sort.

[0089] It solves the problem of incomplete cleaning in physical recycling. Ultrasonic-assisted cleaning can improve the surface cleanliness of plastics by more than 90% (obtained through surface pollutant residue detection), effectively improving the quality of recycled plastics. Identification and sorting separate plastics of different materials and colors, improving the recycling purity. For example, after sorting mixed plastics, the purity of single-material plastics can reach more than 95%, avoiding the adverse effects of mixing plastics of different materials on the performance of recycled products and improving the application value of recycled plastics.

[0090] Multi-layer peeling technology

[0091] Implementation steps: For composite structure plastics, such as certain plastic packaging materials, by selecting appropriate chemical reagents (selecting reagents that can react with one layer but do not affect other layers based on the principle of similar solubility and chemical reaction kinetics) or mechanical forces (designing specific mechanical devices to apply appropriate external forces according to the principles of shear force and tensile force in material mechanics), the interfacial bonding force is destroyed to achieve layer-by-layer separation. The separated layers of materials are recycled separately.

[0092] There are differences in the interfacial bonding force between the layers of composite structure plastics. By selecting appropriate chemical reagents according to the principle of similar solubility and chemical reaction kinetics, or applying appropriate mechanical forces based on the principles of material mechanics, the interfacial bonding force can be destroyed to achieve layer-by-layer separation, so as to realize the separate recycling of each layer of materials.

[0093] Realize the separate recycling of each layer of materials, the resource utilization rate is increased by 30%-50% (based on statistical analysis of actual cases), reduce resource waste, and at the same time provide the possibility for the recycling of some high-value-added materials, improving economic benefits.

[0094] Implementation steps of single-substance reduction: According to the differences in the physical properties of different substances, such as the density, magnetism, etc. of additives, impurities and the plastic matrix, filtration (based on the relationship between the pore size of the filtration medium and the particle size, d 颗粒 <d 孔径 to achieve separation), centrifugation (according to the centrifugal force formula:

[0095] F = mrw 2 ,

[0096] where m is the particle mass, r is the rotation radius, and w

[0097] is the angular velocity) and magnetic field separation (based on the magnetic differences of substances, different forces are applied in the magnetic field to achieve separation) and other means are used to process the crushed and cleaned plastic particles.

[0098] Due to the differences in the physical properties of different substances, by using means such as filtration, centrifugation and magnetic field separation, and based on the corresponding physical principles, the separation of additives, impurities and the plastic matrix can be achieved, and the original properties of the plastic can be restored.

[0099] Restoring the original properties of the plastic, the tensile strength of the recycled plastic can be restored to 85%-95% of the virgin plastic (obtained through mechanical property tests), expanding the application scope and value of the recycled plastic, and solving the problem that additives and impurities cannot be effectively removed in traditional physical recycling.

[0100] Physical + Chemical Recycling

[0101] In-situ Monitoring and Intelligent Control

[0102] Implementation steps: Install in-situ monitoring equipment such as X-ray Absorption Fine Structure Spectroscopy (XAFS) and Fourier Transform Infrared Spectroscopy (FT-IR) in the reaction kettle to monitor the changes of catalysts and plastic molecular chains in real time. XAFS can detect the near-neighbor structure information of atoms, and FT-IR can analyze the molecular structure and chemical bond vibration. According to the principles of chemical reaction kinetics, use the intelligent control system to automatically adjust parameters such as reaction temperature, pressure, and catalyst concentration based on the kinetic model (such as the Arrhenius equation:

[0103] k = Ae -Ea / RT ,

[0104] where k is the reaction rate constant, A is the pre-exponential factor, Ea is the activation energy, R

[0105] is the gas constant, and T is the temperature).

[0106] Traditional physical and chemical recycling lacks real-time monitoring and regulation of reactions. Presetting parameters based on experience cannot cope with abnormal reactions caused by microscopic changes in materials. XAFS and FT-IR can monitor the changes in molecular structure in real time. According to the principles of chemical reaction kinetics, parameters such as reaction temperature, pressure, and catalyst concentration have important effects on the reaction rate and equilibrium. Through real-time monitoring and intelligent control, the stable progress of the reaction can be ensured.

[0107] Ensure the stable progress of the reaction, improve the reaction selectivity, and the yield of the target product can be increased by 20%-30% (obtained by comparing experimental data). At the same time, the occurrence of side reactions is reduced, the production cost and environmental pollution are lowered, the quality and performance of recycled plastics are improved, and the problem of unstable quality of recycled plastics in traditional physical + chemical recycling is solved.

[0108] Microfluidic technology

[0109] Implementation steps: Miniaturize the reaction into a microfluidic chip. According to the principles of hydrodynamics, at the microscale, the fluid exhibits laminar flow characteristics. By designing different reaction regions and channel structures, the mixing ratio, reaction time, and reaction path of the reactants can be precisely controlled to achieve personalized reactions.

[0110] The microfluidic chip has tiny channels and reaction regions. At the microscale, the fluid exhibits laminar flow characteristics, which can precisely control the mixing ratio, reaction time, and reaction path of the reactants, realizing the miniaturization and precise control of the reaction, and solving the problem that the traditional reaction cannot precisely control the reaction process.

[0111] The miniaturization of the reaction reduces the raw material consumption by 50%-70% (based on experimental comparison). At the same time, the reaction efficiency is improved, and the reaction time can be shortened to 1 / 3 - 1 / 2 of the traditional reaction, providing a basis for industrial continuous production, reducing the production cost, and improving the production efficiency.

[0112] Continuous reaction technology

[0113] Implementation steps: Use a continuous reaction device to enable the continuous and stable entry and output of materials into and from the reaction system. Compared with traditional batch reactions, the continuous reaction device avoids the fluctuations caused by each start-up and stop, which is conducive to maintaining stable reaction conditions.

[0114] Traditional batch reactions have problems such as low production efficiency and unstable product quality. The continuous reaction device enables the continuous and stable entry and exit of materials into and from the reaction system, avoiding the start-up and stop fluctuations of batch reactions, which is conducive to maintaining stable reaction conditions and improving production efficiency and product quality stability.

[0115] The production efficiency is increased by 5 - 10 times (based on actual industrial production comparison), the production cost is reduced, and at the same time, the product quality stability is greatly improved. The product quality fluctuation coefficient can be controlled within ±5% (the traditional batch reaction is generally ±15%), enhancing the competitiveness of the enterprise.

[0116] New catalyst recovery and recycling technology

[0117] Implementation steps: According to the differences in the physical and chemical properties of the catalyst and the reaction products, such as solubility, adsorption, etc., select appropriate separation methods (such as liquid - liquid extraction based on the distribution coefficient principle:

[0118] K = C 有机相 / C 水相 ,

[0119] where K is the distribution coefficient, C 有机相 and C 水相

[0120] are the concentrations of the substance in the organic phase and the aqueous phase respectively), and regeneration processes (such as using specific heat treatment or chemical treatment methods to restore the catalyst activity).

[0121] By selecting appropriate separation methods and regeneration processes according to the differences in the physical and chemical properties of the catalyst and the reaction products, efficient recovery and recycling of the catalyst can be achieved, reducing the catalyst consumption cost and environmental pollution.

[0122] The catalyst can be efficiently recovered, with a catalyst recovery rate of over 90% (based on experimental tests), reducing the catalyst consumption cost by 70% - 80%. At the same time, it reduces the environmental pollution caused by the catalyst, enhancing the economic efficiency and environmental friendliness of the production process.

[0123] Natural degradation

[0124] Composite additives and ecological monitoring

[0125] Implementation steps: Develop composite additives based on biodegradable polymers and natural minerals and add them to plastics that need natural degradation. The biodegradable polymers provide carbon sources and nutrients for microorganisms, and the natural minerals regulate the environmental pH to maintain a suitable environment for microbial growth. Set up ecological monitoring stations in the usage areas, equipped with sensors to real - time monitor ecological parameters such as the microbial community structure, pH, dissolved oxygen, etc. in the soil or water body. When abnormal ecological parameters are detected, adjust the additive formula or dosage in a timely manner.

[0126] Traditional natural degradation additives have ecological risks and lack ecological monitoring and feedback mechanisms. Composite additives of biodegradable polymers and natural minerals can promote plastic degradation, and natural minerals can regulate the environmental pH value and maintain a suitable environment for the growth of microorganisms. By setting up ecological monitoring stations to monitor ecological parameters in real time, the additive formula or dosage can be adjusted in a timely manner to avoid ecological damage.

[0127] Promote plastic degradation, and the degradation speed is 2-3 times higher than that of ordinary plastics (obtained from outdoor degradation experiments). At the same time, it avoids ecological damage, ensures environmental ecological balance. For example, the diversity index of soil microbial communities is maintained within a reasonable range (generally 1.5-2.5), achieving the coordinated development of plastic natural degradation and ecological protection.

[0128] Photocatalytic degradation technology

[0129] Implementation steps: Coating a new type of photocatalytic material on the plastic surface. The new type of photocatalytic material generates electron-hole pairs under light irradiation. According to the principle of semiconductor photocatalysis, the electron-

[0130] hole pairs react with the oxygen and water adsorbed on the plastic surface to generate strongly oxidizing free radicals, such as hydroxyl radicals (·OH). The free radicals attack the plastic molecular chains and break them down for degradation.

[0131] According to the principle of semiconductor photocatalysis, the electron-

[0132] hole pairs generated by the new type of photocatalytic material under light irradiation can react with oxygen and water to generate strongly oxidizing free radicals, which attack the plastic molecular chains and break them down for degradation, providing a new way for plastic natural degradation.

[0133] Accelerate the plastic degradation process under light conditions, and the degradation time is shortened by 50%-70% (based on experimental comparison). At the same time, it has less impact on the environment, provides a new and effective way for plastic natural degradation, and reduces the long-term pollution of plastic waste to the environment.

[0134] (III) Key control nodes of the thermoplastic plastic PCR technology link

[0135] Material identification node: Using a variety of technologies to accurately identify materials, providing an accurate basis for subsequent processes. The inference basis is that accurate material identification is the foundation of subsequent recycling processes, solving the problem that inaccurate material identification in existing technologies affects subsequent processes. The beneficial effect is to improve the accuracy of material identification, provide a reliable basis for the recycling process, and make the recycling process more targeted and efficient.

[0136] Physical recycling pretreatment node: Using adaptive crushing and ultrasonic-assisted cleaning technologies to ensure the pretreatment effect. The inference basis is to solve the problems of uneven crushing and unclean cleaning in physical recycling and provide high-quality raw materials for subsequent processing. The beneficial effect is to improve the pretreatment quality, provide stable and clean raw materials for subsequent processing, and improve the processing efficiency and product quality.

[0137] Physical + chemical recycling reaction node: Real-time monitoring and regulation of the reaction to ensure the quality of recycled plastics. The inference basis is to solve the problem that the quality of recycled plastics is unstable due to the inability to monitor and regulate the reaction in traditional physical + chemical recycling in real time. The beneficial effect is to ensure the stable progress of the reaction, improve the reaction selectivity and the yield of target products, and ensure the quality of recycled plastics.

[0138] Natural degradation ecological monitoring node: Real-time tracking of ecological parameters to ensure ecological safety. The inference basis is to solve the problem that the lack of ecological monitoring and feedback mechanisms in traditional natural degradation may damage the ecological environment. The beneficial effect is to achieve the coordinated development of plastic natural degradation and ecological protection and avoid ecological damage.

[0139] (IV) Economic value of green circular carbon indicators

[0140] Establish a green circular carbon indicator quantification system: Quantify the environmental benefits such as carbon emission reduction and energy consumption reduction during the recycling of post-consumer thermoplastics.

[0141] Through the use of the internationally recognized life cycle assessment (LCA) method by a professional carbon footprint accounting team and combined with the actual processes and data of local plastic recycling and treatment, it is calculated that for every 1 ton of post-consumer thermoplastics recycled, approximately 3.2 tons of carbon dioxide emissions can be reduced. The derivation of this value comprehensively considers the carbon emissions reduced in each link compared to traditional processes after the implementation of PCR control technology throughout the entire life cycle from plastic raw material extraction, production and manufacturing, product use to waste recycling and treatment. For example, in the plastic production link, new processing technologies reduce energy consumption, thereby reducing carbon emissions generated from power generation; in the recycling and treatment stage, efficient physical and chemical recycling methods avoid greenhouse gas emissions from plastic incineration or landfill.

[0142] In terms of energy consumption reduction, based on the statistical analysis of the energy consumption data of multiple plastic recycling enterprises using PCR control technology, for every 1 ton of post-consumer thermoplastics recycled, approximately 1800 kWh of electricity can be saved. Among them, the adaptive crushing equipment saves about 30% of energy compared to traditional fixed-parameter crushing equipment; the energy consumption of the hot extrusion process is reduced by 25% due to the optimization of process parameters and equipment control; the continuous reaction technology and intelligent control technology in physical + chemical recycling improve the energy utilization efficiency of the overall reaction process by 35%. These energy-saving effects are combined to obtain the above specific electricity-saving value.

[0143] Policy incentives and market mechanisms: To promote the green development of the plastic recycling industry, the government provides a subsidy of 200 yuan per ton of recycled plastic to enterprises that meet specific green circular carbon indicators. At the same time, enterprises are allowed to trade energy savings and carbon emission reductions in the carbon trading market and the green certificate trading market. After adopting the PCR control technology, a plastic recycling enterprise obtains an additional annual income of about 500,000 yuan by selling carbon emission reductions and green certificates.

[0144] At the market end, through public service advertisements, environmental protection publicity activities, etc., the awareness and recognition of consumers towards recycled plastic products are improved. Data shows that within half a year after the publicity and promotion, the purchase intention of consumers towards recycled plastic products has increased by 30%, which has prompted enterprises to expand production scale, further reducing production costs and forming a virtuous cycle.

[0145] III. Summary

[0146] Significant comprehensive benefits: By implementing the PCR control technology, in the material identification link, the misjudgment rate is reduced from the traditional 30% to within 5%, greatly improving the adaptability of the recycling process; in the physical recycling stage, the product forming accuracy is improved from the industry standard of ±0.3mm to within ±0.1mm, and the injection molding pressure is reduced by 30%-40%; in the physical + chemical recycling, the target product yield is increased by 20%-30%, and the raw material consumption is reduced by 50%-70%; in terms of natural degradation, the degradation speed is 2-3 times higher than that of ordinary plastics. Economically, enterprises have obtained considerable economic benefits through energy conservation, subsidies, and carbon trading; environmentally, significant carbon emissions reduction and energy conservation have been achieved, effectively reducing the environmental pollution caused by plastic waste.

[0147] Leading role in the industry: This technology provides a new technical paradigm and standard process for the plastic recycling industry, promoting the industry to upgrade towards the direction of intelligent and green development. With the popularization and application of the technology, it is expected that within the next 5 years, the overall resource utilization rate of the industry will increase by more than 20%, and the carbon emissions will be reduced by more than 30%, driving the coordinated development of upstream and downstream industries and jointly building a sustainable plastic recycling ecosystem.

Claims

1. Post-consumer thermoplastic PCR control technology based on plastic production, characterized in that, The following steps are involved: Material identification and analysis: Use multiple technologies to identify plastic samples, including Raman spectroscopy-atomic force microscopy, infrared spectroscopy and liquid chromatography; use deep neural network algorithms to build machine learning prediction models, collect microstructure data and macroscopic property data of different thermoplastics under various usage conditions for training, and assist in determining the type of plastics; establish material databases and product databases; Processing method: Physical recycling: The recycled plastics are sent to a pulverizing device equipped with sensors. According to the size, shape and hardness of the plastic particles monitored in real time by the sensors, the rotation speed, angle and pressure of the pulverizing tool are adjusted based on the material mechanics principle and the impact force calculation formula. The pulverized plastic particles are then sent to a hot extrusion device. The temperature and pressure are controlled according to the polymer material processing principle to optimize the fluidity of the plastic particles. The pulverized plastic particles are cleaned with ultrasound assistance, and then identified and sorted using image recognition and spectral analysis technology. For composite structure plastics, the interlayer bonding force is destroyed to achieve layer-by-layer separation and recycling. According to the differences in the physical properties of different substances, the pulverized and cleaned plastic particles are treated with single-substance reduction by filtration, centrifugation and magnetic field separation. Physical + chemical recycling: Install an X-ray absorption fine structure spectrometer and a Fourier transform infrared spectrometer in the reactor to monitor changes in catalysts and plastic molecular chains. According to the chemical reaction kinetics principle and kinetic model, use an intelligent control system to automatically adjust the reaction temperature, pressure, and catalyst concentration. Miniaturize the reaction into a microfluidic chip, design the reaction area and channel structure according to the principles of fluid mechanics, and control the mixing ratio of reactants, reaction time, and reaction path. Natural degradation: Add composite additives based on biodegradable polymers and natural minerals to plastics that need to be naturally degraded, set up ecological monitoring stations in the use area; coat the surface of the plastic with new photocatalytic materials, use the electrons generated under light- Hole pairs react with oxygen and water to generate strong oxidizing free radicals, which attack the plastic molecular chains and cause them to break and degrade; Determine the key control nodes of the thermoplastic plastic PCR technology chain, including material identification node, physical recycling pretreatment node, physical + chemical recycling reaction node, and natural degradation ecological monitoring node.

2. The post-consumer thermoplastic PCR control technology based on plastic production as claimed in claim 1, characterized in that: In multi-technology fusion identification, Raman spectroscopy- Atomic force microscope combined with infrared spectrometer and liquid chromatograph work together and share data in real time to accurately identify plastic samples from multiple dimensions such as molecular chemical bond vibration modes, microscopic morphology, molecular structure characteristics and chemical composition.

3. The post-consumer thermoplastic PCR control technology based on plastic production as claimed in claim 1, characterized in that: The machine learning prediction model is built based on a deep learning framework, and the training data is updated regularly. The training data covers the microstructure data and macroscopic property data of common thermoplastics including but not limited to PET, HDPE, PP, and PVC under different environmental conditions such as temperature, humidity, and light.

4. The post-consumer thermoplastic PCR control technology based on plastic production as claimed in claim 1, characterized in that: The material database unit and product database unit adopt a distributed storage architecture and have data backup and recovery functions. The data sources of the material database include but are not limited to scientific research institutions, production companies, and recycling companies. The data of the product database covers relevant information of the entire life cycle of plastic products.

5. The post-consumer thermoplastic PCR control technology based on plastic production as claimed in claim 1, characterized in that: The sensors of the adaptive crushing equipment are high-precision pressure sensors and image sensors, and the feedback control system is based on the impact force calculation formula: F=ma Where F is the impact force, m is the particle mass, a For acceleration, the speed, angle and pressure of the crushing tool are adjusted in real time.

6. The post-consumer thermoplastic PCR control technology based on plastic production as claimed in claim 1, characterized in that: The microfluidic chip adopts an integrated design. The reaction area and channel structure are optimized and simulated. The laminar flow characteristics of the fluid are used at the microscale to accurately control the mixing ratio of the reactants, reaction time and reaction path for personalized reactions.

7. The post-consumer thermoplastic PCR control technology based on plastic production as claimed in claim 1, characterized in that: The data sources of the material database include original property data of thermoplastics, property change data after the action of different environmental factors, experimental data of scientific research institutions, R&D data of production enterprises, and actual recycling analysis data of recycling enterprises. The data sources of the product database cover product design and production process data of plastic product manufacturers, recycling sources and usage status data of recycling enterprises, as well as market circulation link data and consumer usage feedback data, which are used for query and analysis during material identification and recycling processing.

8. The post-consumer thermoplastic PCR control technology based on plastic production as claimed in claim 1, characterized in that: Also includes: Economize green circular carbon indicators: Establish a green circular carbon indicator quantification system to quantify the environmental benefits including but not limited to carbon emission reduction and energy consumption reduction in the recycling of post-consumer thermoplastics; Implement policy incentives and market mechanisms to provide subsidies to companies that achieve specific green recycling carbon indicators.

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