COMPOSITIONS OBTAINED FROM RECYCLED POLYOLEFINS

Description

FIELD OF THE INVENTION

[0001] The present disclosure relates to compositions containing recycled polypropylene that can be advantageously used for the production of blow molding articles.BACKGROUND OF THE INVENTION

[0002] Polyolefins, in particular polypropylene, are increasingly consumed in large amounts for many applications, including packaging for food and other goods, fibers, automotive components, and a great variety of manufactured articles. However, the said massive use of polyolefins is creating a concern as regards the environmental impact of the waste materials generated after the first use.

[0003] In fact, large amounts of waste plastic materials are presently coming from differential recovery of municipal plastic wastes, mainly constituted of flexible packaging (cast film, blown film and BOPP film), rigid packaging, blow moulded bottles and injection moulded containers. Through a step of separation from other polymers, such as PVC, PET or PS, two main polyolefinic fractions are obtained, namely polyethylenes (in particular HDPE LDPE, LLDPE) and polypropylenes (homopolymers, random copolymers, heterophasic copolymers).

[0004] However due to the poor mechanical and physical feature of these recovered fraction it is difficult to reuse them in the industrial processes. In particular for processes such as blow molding that requires high mechanical properties. WO2019224129 and WO2019091885 disclose recycled polypropylene compositions for blow molding. However, WO2019224129 discloses a composition based on polypropylene post-consumer resin that his mixed with only one further polypropylene resin while WO2019091885 uses a high ethylene content ethylene-propylene copolymer with more than 70 wt% ethylene instead.

[0005] It has now been found that it is possible to use recycled polypropylene in blow molding industrial processes by compounding the recycled polypropylene with other polypropylene polymers so that to achieve the desired mechanical properties and compatibility.SUMMARY OF THE INVENTION

[0006] The present disclosure relates to a polypropylene compositions comprising: T1) 35-65wt%, of a recycled polypropylene mixture containing at least 80 wt% of rigid polypropylene items and having a purity of at least 90 wt% the remaining 10 wt% comprising other polymers, paper, cardboard carton aluminized plastic and textiles; the recycled polypropylene mixture having a melt flow rate (ISO 1133 230°C / 2.16 kg) ranging between 2 and 30 g / 10 min and a melting point measured by DSC ranging from 148°C to 162°C; T2) 20-50 wt% of a an ethylene propylene copolymer wherein: i) the content of ethylene derived units is comprised between 1.0 wt% and 8.0 wt%; (ii) the melting temperature ranges from 135° C to 155° C; (iii) the melt flow rate (230°C / 5 kg.. ISO 1133) ranging from 0.2 g / 10min to 3.5 (iv) the xylene solubles at 25°C ranges from 10.0 wt% to 4.0wt%; T3) 5-20 wt% of a propylene, ethylene copolymer having the intrinsic viscosity on the xylene soluble fraction measured at 25°C ranging from 2.5 dl / g to 4.5 dl / g and comprising: a) from 12 wt% to 52 wt% of a propylene homopolymer or a propylene / ethylene copolymer having a content of ethylene derived units ranging from 0.1 wt% to 4.5 wt%; and having a xylene soluble content measured at 25°C lower than 10 wt%; b) from 48 wt% to 88 wt% of a propylene ethylene copolymer having a content of ethylene derived units ranging from 15 wt% to 42 wt%; wherein the propylene composition has a melt flow rate (ISO 1133 230°C / 2.16 kg) ranging from 0.5 to 20 g / 10 min; the sum of the amount of a) and b), being referred to the total weight %of a), and b) being 100 wt%. the sum of the amount of T1), T2) and T3), being referred to the total weight %of T1), T2), and T3) being 100 wt%. DETAILED DESCRIPTION OF THE INVENTION

[0007] The present disclosure relates to polypropylene compositions comprising: T1) 35-65wt%; preferably from 40-60 wt%; more preferably from 45-55 wt% of a recycled polypropylene mixture containing at least 80 wt% preferably at least 85 wt% more preferably at least 90 wt% of rigid polypropylene items and having a purity of at least 90 wt%; prefererably at least 92 wt% more preferably at least 94 wt% the remaining 10 wt%; preferably 8 wt%; more preferably 6 wt% comprising: other polymers, paper, cardboard carton aluminized plastic and textiles; the recycled polypropylene mixture having a melt flow rate (ISO 1133 230°C / 2.16 kg) ranging between 2 and 30 g / 10 min; preferably ranging between 3 and 25 g / 10 min; more preferably ranging between 5 and 20 g / 10 min and a melting point measured by DSC ranging from 148°C to 162°C; T2) 20-50 wt% preferably 25-45 wt%; more preferably 32-42 wt% of a an ethylene propylene copolymer wherein: i) the content of ethylene derived units is comprised between 1.0 wt% and 8.0 wt%; preferably from 2.0 wt% to 6.0 wt% ; more preferably from 3.0 wt% to 5.0 wt% (ii) the melting temperature ranges from 135° C to 155° C; (iii) the melt flow rate (230°C / 5 kg.. ISO 1133) ranging from 0.2 g / 10min to 3.5 g / 10min; preferably from 0.6 g / 10min to 2.0 g / 10min; (iv) the xylene solubles at 25°C ranges from 10.0 wt% to 4.0wt%; preferably from 9.0 wt% to 6.0 wt%; T3) 5-20 wt%; preferably 7-15 wt% more preferably 8-13 wt% of a propylene, ethylene copolymer having the intrinsic viscosity on the xylene soluble fraction measured at 25°C ranges from 2.5 dl / g to 4.5 dl / g; preferably from 2.8 dl / g to 4.0 dl / g.; wherein T3 comprises a) from 12 wt% to 52 wt%; preferably from 15 wt% to 43 wt%; more preferably from 20 wt% to 33 wt% of a propylene homopolymer or a propylene / ethylene copolymer having a content of ethylene derived units ranging from 0.1 wt% to 4.5 wt% preferably from 1.5 wt% to 4.0 wt%; and having a xylene soluble content measured at 25°C lower than 10 wt%; preferably lower than 8 wt% ; more preferably lower than 7 wt%; b) from 48 wt% to 88 wt% preferably from 57 wt% to 85 wt%; more preferably from 67 wt% to 80 wt% of a propylene ethylene copolymer having a content of ethylene derived units ranging from 15 wt% to 42 wt%; preferably from 21.0 wt% to 35 wt% wherein the propylene composition has a melt flow rate (ISO 1133 230°C / 2.16 kg) ranging from 0.5 to 20.0 g / 10 min; preferably from 1.0 to 10.0 g / 10 min; more preferably from 1.3 to 5.0 g / 10 min the sum of the amount of a) and b), being referred to the total weight %of a), and b) being 100 wt%; the sum of the amount of T1), T2) and T3), being referred to the total weight %of T1), T2), and T3) being 100 wt%.

[0008] The rigid polypropylene items of T1) are items having a volume lower or equal to 5 liters such as bottles, cups and trays including secondary components such as lids and labels.

[0009] Components T1) can be found in the market of recycled polypropylene such as grade sold by Lyondellbasell under the tradename Moplen QCP300P.

[0010] Component T2) is a polypropylene random copolymer obtained by using Ziegler Natta catalyst than can be found in the market such as Hostalen H5416 sold by Lyondellbasell.

[0011] Component T3) is propylene, ethylene copolymer composition being heterophasic obtained by sequential polymerization by using Ziegler Natta catalyst that can be found in the market such as Adflex Q100F sold by Lyondellbasell.

[0012] By using the polypropylene composition disclosed in the present disclosure it si possible to achieve blow molding articles containing recycled polypropylene having improved mechanical features. Allowing in this way to use recycled polypropylene in the production of blow molding articles.

[0013] Thus a further object of the present disclosure is blow molding articles comprising the polypropylene composition of the present disclosure.

[0014] Blow molding articles can be obtained with a processes common know in the art for this kind of articles.

[0015] Blow molding articles in particular are bottles, tanks.

[0016] The following examples are given in order to illustrate, but not limit the present disclosure.EXAMPLES CHARACTERIZATIONS Xylene-soluble (XS) Fraction at 25 °C

[0017] Solubility in xylene: Determined as follows: 2.5 g of polymer and 250 ml of xylene are introduced in a glass flask equipped with a refrigerator and a magnetic stirrer. The temperature is raised in 30 minutes up to the boiling point of the solvent. The resulting clear solution is then kept under reflux and stirred for 30 minutes. The closed flask is then kept for 30 minutes in a bath of ice and water, then in a thermostatic water bath at 25 °C for 30 minutes. The resulting solid is filtered on quick filtering paper. 100 ml of the filtered liquid is poured in a previously weighed aluminum container, which is heated on a heating plate under nitrogen flow to remove the solvent by evaporation. The container is then kept on an oven at 80 °C under vacuum until a constant weight is obtained. The weight percentage of polymer soluble in xylene at room temperature is then calculated.

[0018] The content of the xylene-soluble fraction is expressed as a percentage of the original 2.5 grams and then, by the difference (complementary to 100%), the xylene insoluble percentage (%); XS of components B) and C) have been calculated by using the formula: XStot = WaXSA + WbXSB + WcXSC wherein Wa, Wb and Wc are the relative amount of components A, B and C, respectively, and (A+B+C=1).Melt Flow Rate (MFR)

[0019] Measured according to ISO 1133 at 230 °C with a load of 2.16 kg, unless otherwise specified.Intrinsic Viscosity (IV)

[0020] The sample is dissolved in tetrahydronaphthalene at 135 °C and then poured into a capillary viscometer. The viscometer tube (Ubbelohde type) is surrounded by a cylindrical glass jacket; this setup allows for temperature control with a circulating thermostatic liquid. The downward passage of the meniscus is timed by a photoelectric device.

[0021] The passage of the meniscus in front of the upper lamp starts the counter which has a quartz crystal oscillator. The meniscus stops the counter as it passes the lower lamp and the efflux time is registered: this is converted into a value of intrinsic viscosity through Huggins' equation (Huggins, M.L., J. Am. Chem. Soc., 1942, 64, 2716) provided that the flow time of the pure solvent is known at the same experimental conditions (same viscometer and same temperature). One single polymer solution is used to determine [ η ].Ethylene (C2) content 13< C NMR of propylene / ethylene copolymers

[0022] 13< C NMR spectra were acquired on a Bruker AV-600 spectrometer equipped with cryoprobe, operating at 160.91 MHz in the Fourier transform mode at 120°C.

[0023] The peak of the S ββ carbon (nomenclature according to "Monomer Sequence Distribution in Ethylene-Propylene Rubber Measured by 13C NMR. 3. Use of Reaction Probability Mode " C. J. Carman, R. A. Harrington and C. E. Wilkes, Macromolecules, 1977, 10, 536) was used as internal reference at 29.9 ppm. The samples were dissolved in 1,1,2,2-tetrachloroethane-d2 at 120°C with a 8 % wt / v concentration. Each spectrum was acquired with a 90° pulse, 15 seconds of delay between pulses and CPD to remove 1H-13C coupling. 512 transients were stored in 32K data points using a spectral window of 9000 Hz.

[0024] The assignments of the spectra, the evaluation of triad distribution and the composition were made according to Kakugo ("Carbon-13 NMR determination of monomer sequence distribution in ethylene-propylene copolymers prepared with δ-titanium trichloride-diethylaluminum chloride" M. Kakugo, Y. Naito, K. Mizunuma and T. Miyatake, Macromolecules, 1982, 15, 1150) using the following equations: PPP = 100 T ββ / S PPE = 100 T βδ / S EPE = 100 T δδ / S PEP = 100 S ββ / S PEE = 100 S βδ / S EEE = 100 0 . 25 S γδ + 0.5 S δδ / S S = T ββ + T βδ + T δδ + S ββ + S βδ + 0.25 S γδ + 0.5 S δδ

[0025] The molar percentage of ethylene content was evaluated using the following equation: E% mol = 100 * [PEP+PEE+EEE]The weight percentage of ethylene content was evaluated using the following equation: E % wt . = 100 * E % mol * MW E E % mol * MW E + P % mol * MW P where P% mol is the molar percentage of propylene content, while MW E and MW P are the molecular weights of ethylene and propylene, respectively.

[0026] The product of reactivity ratio r 1 r 2 was calculated according to Carman (C.J. Carman, R.A. Harrington and C.E. Wilkes, Macromolecules, 1977; 10, 536) as: r 1 r 2 = 1 + EEE + PEE PEP + 1 − P E + 1 EEE + PEE PEP + 1 0.5

[0027] The tacticity of Propylene sequences was calculated as mm content from the ratio of the PPP mmT ββ (28.90-29.65 ppm) and the whole T ββ (29.80-28.37 ppm).

[0028] Ethylene C2 content of component b2 has been measured by measuring the C2 content on component B) and then calculated by using the formula C2tot=Xb1C2b1+Xb2C2b2 wherein Xb1 and Xb2 are the amounts of components b1 and b2 in the composition.

[0029] Charpy impact test measured according to according to ISO 179-1eA, e ISO 1873-2

[0030] Elongation at yield: measured according to ISO 527. Elongation at break: measured according To ISO 527 Stress at break: measured according to ISO 527. Impact test: ISO 180-1A Samples for the mechanical analysis Samples have been obtained according to ISO 1873-2:2007 excepting for the flexural modulus for which ISO 3167 has been used. Flexural Modulus

[0031] Determined according to ISO 178.Melting point a and crystallization point

[0032] The melting point has been measured by using a DSC instrument according to ISO 11357-3, at scanning rate of 20C / min both in cooling and heating, on a sample of weight between 5 and 7 mg., under inert N2 flow. Instrument calibration made with Indium.T1 component

[0033] T1 component is a recycled polypropylene sold by QCP with the tradename QCP300P

[0034] T1 contains residue-drained, rigid, system-compatible items made of polypropylene, volume ≤ 5 litres, e.g. bottles, bottles, cups and trays, incl. secondary components such as lids, labels etc.

[0035] Purity is at least 94 wt%, metallic and mineral impurities with a unit weight of > 100 g and cartridges for sealants are not permitted!

[0036] Impurities Other metal items< 0.5 % by massRigid PE items< 1 % by massExpanded plastics incl. EPS items< 0.5 % by massPlastic films< 2 % by massOther residues< 3 % by mass

[0037] Examples of other residues are: Glass Paper, Board, Cardboard Composite paper / cardboard materials (e.g. liquid packaging boards) Aluminized plastics Other materials (e.g. rubber, stones, wood, textiles, nappies) Compostable waste (e.g. food, garden waste)

[0038] The Melt flow rate (230 °C / 2.16 kg) of T1 is 16 g / 10 min and the melting point is 150°CT2 component

[0039] T2 component is commercial grade Hostalen H5416 sold by LyondellBasell

[0040] The properties of the copolymer have been reported in table 1: Table 1MFR 5 Kg / 230°Cg / 10min1.3Ethylene derived unitswt%4.0Polydispersity (PI)4.9X.S.%8.7ISO CharacterizationFlexural modulus 24hMPa870Tensile modulus 24hMPa850IZOD 0°C 24hkJ / m219Stress at yield%27Elongation at breakkJ / m2482Tm°C140 T3 component

[0041] Components T3) is an heterophasic copolymer obtained by sequential gas phase polymerization sold by Lyondellbasell under the tradename Adflex Q100F , the features of the copolymer are reported on table 2 Table 2ComponentBComponent aSplit%wt32C2%wt3.2Xylene solubles at 25°C%wt<6.5Component bSplit%wt68C2%wt27.0intrinsic viscosity of the xylene soluble fraction at 25°Cdl / g3.2* C2= ethylene derived units

[0042] Components T1, T2 and T3 have been blended together, the characterization of the blend is reported in table 3 Table 3Ex1Comp ex 2Comp ex 3T2wt%5050T1wt%4050T3wt%10MFRg / 10min2,92.71,8Charpy 23°C 48hKJ / M24612.334Charpy 0°C 48hKJ / M25.93.55Tmdeg_C155,2155.9143Tcdeg_C121,8122.51081l bottles Drop testsm (J)4.5 (47.7)1.7 (18)4.0 (41.1)

[0043] Comparative example 3 is RB307MO a propylene ethylene random copolymer sold by Borealis

[0044] The composition of example 1 shows improved value of charpy impact on samples and drop tests on bottle.

[0045] 1 liter Bottles with a weight of 30 grams have been produced on a Krupp-Kautex KEB 4 single head machine using a one cavity bottle mould with the following conditions:

[0046] Melt temperature 190°C; mould temperature 12°C; screw speed, rpm 18; die gap 650; cycle time, sec 13.5; air pressure, bar 6.5; water pressure, bar 3.

[0047] Drop test was measured on the sample bottles filled with water ⅞ full. After conditioning for 2 hours at the temperature of the test (23° C) the bottles were left falling from increasing height The parameter reported in table 2 is the height at which 50% of the bottles breaks and the energy (20 bottles have been tested for each grade).

Claims

1. A polypropylene compositions comprising: T1) 35-65wt%, of a recycled polypropylene mixture containing at least 80 wt% of polypropylene items and having a purity of at least 90 wt% the remaining 10 wt% comprising other polymers, paper, cardboard carton aluminized plastic and textiles; the recycled polypropylene mixture having a melt flow rate (ISO 1133 230°C / 2.16 kg) ranging between 2 and 30 g / 10 min and a melting point measured by DSC ranging from 148°C to 162°C; T2) 20-50 wt% of an ethylene propylene copolymer wherein: i) the content of ethylene derived units is comprised between 1.0 wt% and 8.0 wt%; (ii) the melting temperature ranges from 135° C to 155° C; (iii) the melt flow rate (ISO 1133 230°C / 5 kg.. ISO 1133) ranging from 0.2 g / 10min to 3.5 (iv) the xylene solubles at 25°C ranges from 10.0 wt% to 4.0wt%; T3) 5-20 wt% of a propylene, ethylene heterophasic copolymer composition having the intrinsic viscosity on the xylene soluble fraction measured at 25°C ranges from 2.5 dl / g to 4.5 dl / g; comprising: a) from 12 wt% to 52 wt% of a propylene homopolymer or a propylene / ethylene copolymer having a content of ethylene derived units ranging from 0.1 wt% to 4.5 wt%; and having a xylene soluble content measured at 25°C lower than 10 wt%; b) from 48 wt% to 88 wt% of a propylene ethylene copolymer having a content of ethylene derived units ranging from 15 wt% to 42 wt%; wherein the propylene composition has a melt flow rate (ISO 1133 230°C / 2.16 kg) ranging from 0.5 to 20 g / 10 min; the sum of the amount of a) and b), being referred to the total weight %of a), and b) being 100 wt%. the sum of the amount of T1), T2) and T3), being referred to the total weight %of T1), T2), and T3) being 100 wt%.

2. The polypropylene compositions according to claim 1 wherein: component T1 ranges from 40 % by weight to 60 % by weight; component T2 ranges from 25 % by weight to 45 % by weight; component T3 ranges from 7 % by weight to 15 % by weight;3. The polypropylene compositions according to claims 1 or 2 wherein Component T1 ranges from 45 % by weight to 55 % by weight; Component T2 ranges from 32 % by weight to 42 % by weight; and Component T3 ranges from 8 % by weight to 13 % by weight.

4. The polypropylene compositions according to anyone of claims 1-3 wherein component T1 contains at least 85 wt% of rigid polypropylene items and having a purity of at least 92 wt% the remaining 8 wt% comprising: other polymers, paper, cardboard carton aluminized plastic and textiles;.

5. The polypropylene compositions according to anyone of claims 1-4 wherein in component T1 contains at least 90 wt% of rigid polypropylene items and having a purity of at least 94 wt% the remaining 6 wt% comprising: other polymers, paper, cardboard carton aluminized plastic and textiles.

6. The polypropylene compositions according to anyone of claims 1-5 wherein component T2 is a copolymer of ethylene and propylene containing from 2.0% to 6.0% by weight of ethylene units.

7. The polypropylene compositions according to anyone of claims 1-6 wherein component T2 is a copolymer of ethylene and propylene containing from 3.0% to 5.0% by weight of ethylene units.;8. The polypropylene compositions according to anyone of claims 1-7 wherein in component T2 the xylene solubles at 25°C ranges from 9.0 wt% to 6.0 wt%.

9. The polypropylene compositions according to anyone of claims 1-8 wherein component T2 has a melt flow rate (230°C / 5 kg.. ISO 1133) comprised between 0.6 to 2.0 g / 10m;10. The polypropylene compositions according to anyone of claims 1-9 wherein in component T3 component a) ranges from 15 wt% to 43 wt% and component b) ranges from 57 wt % to 85 wt%.

11. The polypropylene compositions according to anyone of claims 1- 10 wherein in component T3) component a) is a propylene ethylene copolymer having an ethylene content ranging from 1.5 wt% to 4.0 wt%.

12. The polypropylene compositions according to anyone of claims 1-11 wherein in component T3) component b) has ethylene derived units content content ranging from 21.0 wt% to 35.0 wt%..

13. The polypropylene compositions according to anyone of claims 1-12 having a melt flow rate (ISO 1133 230°C / 2.16 kg) ranging from 1.0 to 10.0 g / 10 min.

14. A blow molding article comprising the polypropylene compositions of claims 1-13.

15. A bottle according to claim 14.