Processing and production of recycled polymer materials

Abstract

Methods and compositions for processing polyolefin reclaim, including but not limited to polyethylene and polypropylene, are provided. The polyolefin reclaim feedstock can be visbroken to improve processing properties and / or devolatilized to remove waste by-products to produce processed polyolefin reclaim. The processed polyolefin reclaim can be blended with pre-consumer polyolefins to produce blend compositions with acceptable or improved processing properties. Such pre-consumer polyolefins can also be visbroken to further tailor the processing properties of such polymer blends. Extruders and / or extruder zone combinations can be used in the same or different locations for visbreaking and / or blending of both the polyolefin reclaim and / or the pre-consumer polyolefin.

Description

[Technical field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application was made under the Patent Cooperation Treaty and claims priority to U.S. Provisional Application No. 63 / 213,429, filed June 22, 2021, and entitled "Processing and Products From Polymer Recycled Materials," and U.S. Provisional Application No. 63 / 238,655, filed August 30, 2021, and entitled "Processing and Products From Polymer Recycled Materials," the contents of which are incorporated herein by reference in their entireties.

[0002] The present disclosure relates to the use of an extrusion process to improve the processing properties of polyolefin reclaim, either alone or in combination with other polyolefins. The present invention also relates to compositions produced by such a process. [Background technology]

[0003] Polyolefins, including polyethylene and polypropylene, can be used in many applications, including packaging of food and other commodities, electronic devices, automotive parts, and various products. Waste plastic materials can be obtained from various sources, including the separate collection of municipal plastic waste, consisting of flexible packaging (cast films, blown films, BOPP films), rigid packaging, blown bottles, and injection molded containers. Generally, the two main polyolefin fractions are obtained by separation processes from other polymers such as PVC, PET, or PS, namely, polyethylene (including HDPE, LDPE, LLDPE) and polypropylene (including homopolymer, random copolymer, and multiphase copolymer).

[0004] The multicomponent properties of the recovered polyolefin or polyolefin fraction may result in poor mechanical and optical properties of the prepared article or polyolefin formulation with a portion of the virgin polyolefin replaced with the recovered polymer. Unpredictable mechanical and / or optical properties may result from variations in one or more properties of the recycled polyolefin, including but not limited to melt index, high load melt index, melt elasticity, complex viscosity, or combinations thereof. In addition, the recycled polyolefin or polyolefin fraction may contain contamination with impurities or other components. In addition, the molecular weight, molecular weight distribution, and / or comonomer content of the recycled polyolefin or polyolefin fraction may limit the range of virgin polyolefins into which the recycled polyolefin can be incorporated. Another limitation in using recycled polyolefins is the presence of unpleasant odors from volatile organic compounds that may be absorbed by these polymers during use. Summary of the Invention [Problem to be solved by the invention]

[0005] The polyethylene waste is desirably split into one or more fractions of primarily HDPE, MDPE, LDPE, LLDPE or polypropylene. A method for producing a polyolefin composition, including recycled polyolefins, having a useful combination of performance properties is provided. The disclosed method is highly flexible and can be carried out with common equipment and familiar techniques to produce a wide variety of products.

[0006] Generally, the present disclosure relates to a method of processing polyolefin reclaim, particularly one or more high density polyethylene ("HDPE") reclaims, one or more medium density polyethylene ("MDPE") reclaims, one or more low density polyethylene ("LDPE") reclaims, one or more low density polyethylene ("LDPE") reclaims, one or more polypropylene ("PP") reclaims, or combinations thereof, which includes implementing visbreaking conditions in an extruder to render the polyolefin reclaim into a visbroken polyolefin reclaim having a reduced weight average molecular weight. In some embodiments, the polyolefin reclaim is subjected to devolatilization conditions to convert the polyolefin reclaim into a visbroken polyolefin reclaim having a reduced weight average molecular weight and reduced volatile organic compound ("VOC") content.

[0007] Visbreaking conditions include thermal visbreaking and / or peroxide visbreaking. Thermal visbreaking includes sufficient temperature, pressure and mechanical shear to cause polymer chain breaking beyond polymer chain branching or crosslinking. Peroxide visbreaking can occur when a peroxide is added to the polymer melt in the extruder and then thermally decomposed to produce radicals that react with the polymer chains to break them. In some embodiments, the visbreaking conditions include thermal visbreaking in the absence or substantially absence of oxygen at a temperature at least 180° C. above the melting point of the polyolefin.

[0008] Devolatilization conditions may include reduction of VOCs in the polyolefin by a portion of the extruder having an intensive mixing device and a devolatilization section that allows for the removal of VOCs at high temperatures. Devolatilization conditions may be further enhanced by injection of gas into the extruder, distribution of gas into the polymer melt to remove VOC components, and extraction of the gas and removed VOC components by evacuation and / or vacuum.

[0009] In some embodiments, the processed polyolefin reclaim may be pelletized as a product while exiting the extruder. In other embodiments, the processed polyolefin reclaim may be fed to a second extruder and compounded or blended with virgin polyolefin. In other embodiments, in yet other embodiments, the virgin polyolefin may be a polyolefin powder product from the polymerization unit, a pelletized polyolefin, or a polyolefin melt that is the product of a third extruder. In any of the embodiments in this paragraph, the virgin polyolefin may have been subjected to a visbreaking process prior to addition to the second reactor.

[0010] In some embodiments, virgin polyolefin is fed to a third extruder and the polymer melt from the third extruder is co-fed to a second extruder along with the processed polyolefin reclaim melt.

[0011] In some embodiments, compositions are provided that are or include a polymer blend of 5% to 90% by weight recycled polyolefin and 10% to 95% by weight virgin polyolefin. The weight percentages are based on the total weight of the polymer blend, and one or both of the recycled polyolefin feedstock and the virgin polyolefin are visbroken. The visbreaking may be thermal visbreaking and / or peroxide visbreaking.

[0012] The foregoing has outlined rather broadly the features and technical advantages of the present invention in order that the following detailed description of the invention may be better understood. Additional features and advantages of the invention will be described below which form the subject of the claims of the invention. It should be appreciated by those skilled in the art that the conception and specific embodiments disclosed may be readily utilized as a basis for modifying or designing other membrane structures and / or processes for carrying out the same purposes of the invention. Those skilled in the art will also realize that such equivalent structures do not depart from the spirit and scope of the invention as set forth in the appended claims. The novel features of the invention, including its structure and method of manufacture, as well as other objects and advantages, will be better understood from the following description. [Brief description of the drawings]

[0013] The claimed subject matter can be understood by reference to the following description in conjunction with the accompanying drawings, in which like reference numbers indicate like elements and in which: [Figure 1] FIG. 1 is a simplified flow diagram of a process for obtaining processed polyolefin reclaim according to an embodiment of the present invention. [Diagram 2] FIG. 2 is a simplified flow diagram of a process for obtaining a blend of processed polyolefin reclaim and virgin polyolefin using two extruders according to an embodiment of the present invention. [Diagram 3] Figure 3 is a simplified flow diagram of a process for obtaining a blend of processed polyolefin reclaim and virgin polyolefin using three extruders according to an embodiment of the present invention. While the disclosed method and composition are susceptible to various modifications and alternative forms, the accompanying drawings show specific embodiments that are illustratively described in detail herein. However, it should be understood that the description of specific embodiments herein is not intended to limit the invention to the particular forms disclosed, but rather to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the appended claims. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0014] Exemplary embodiments of the claimed subject matter below will now be disclosed. For purposes of clarity, some features of an actual implementation may not be described herein. It should be understood that in developing such an actual embodiment, many implementation-specific decisions must be made to achieve the developer's particular goals, including complying with system-related and business-related constraints that vary from implementation to implementation. Moreover, it should be understood that such development efforts, even if complex and time-consuming, would be routine for those of ordinary skill in the art having the benefit of this disclosure.

[0015] The words and phrases used herein should be understood and interpreted as having a meaning consistent with the understanding of those words and phrases by those of ordinary skill in the art. A special definition of a term or phrase, i.e., a definition that is different from the common and customary meaning as understood by those of ordinary skill in the art, is not intended to be implied by the consistent use of the term or phrase herein. To some extent, a term or phrase is intended to have a special meaning, i.e., a meaning other than the broadest meaning as understood by those of ordinary skill in the art, and such special or distinct definition is expressly described in the definition method of the specification to provide a special or distinct definition of the term or phrase. It should also be noted that, as used in the specification and claims, the singular forms "a," "an," and "the" include plural references unless otherwise specified.

[0016] For example, the following description includes a non-exhaustive list of definitions of some specific terms used in this disclosure (other terms may be defined or clarified elsewhere in this specification). These definitions are intended to clarify the meaning of the terms used herein. Although it is believed that these terms are used in a manner consistent with their common meaning, the definitions are still specified here for clarity. definition

[0017] As used here, "antioxidants" are compounds that inhibit oxidation, which is a chemical reaction that produces radicals or chain reactions.

[0018] As used herein, "compounding conditions" refers to the conditions of temperature, pressure, and shear effected in an extruder to intimately mix two or more polymers and optional additives to produce a substantially homogenous polymer product.

[0019] As used herein, "devolatilization conditions" refers to subjecting the polymer melt in the extruder to injection and discharge of sweep gas, addition of heat, physical mixing, reduced pressure by application of venting or vacuum, or a combination thereof. Devolatilization conditions implemented in the extruder are sufficient to reduce the VOC of the polymer fed to the extruder at a predetermined rate and / or to a predetermined VOC target of the polymer exiting the extruder. Devolatilization conditions are intended to reduce the VOC in the polyolefin by a portion of the extruder having an intensive mixing device and a devolatilization section that allows for the removal of VOC at high temperatures. Devolatilization conditions can be further improved by injecting gas into the extruder, distributing the gas in the polymer melt to remove VOC components, and removing the gas and removed VOC components by venting or vacuum.

[0020] As used herein, "devolatilized polyolefin reclaim" means the product obtained by subjecting a polyolefin reclaim feedstock to the devolatilization conditions described herein.

[0021] As used herein, within the context of "first extruder," "second extruder," and "third extruder," "extruder" refers in some embodiments to separate extrusion apparatuses and in other embodiments to separate sections within a single extrusion apparatus. In some embodiments, the first extruder and the second extruder are separate machines. In some embodiments, the first extruder and the second extruder are separate parts of a single machine. In some embodiments, the second extruder and the third extruder are separate machines. In some embodiments, the second extruder and the third extruder are separate parts of a single machine. In some embodiments, the first extruder, the second extruder, and the third extruder are separate machines. In some embodiments, the first extruder, the second extruder, and the third extruder are separate parts of a single machine. As used herein, "extruder" includes any equipment or combination of equipment capable of continuously processing one or more polyolefins under visbreaking, compounding, melting, or devolatilizing conditions, including, but not limited to, a Farrel continuous mixer (FCM® mixer, available from Farrel Corporation, Ansonia, Connecticut).

[0022] As used herein, "HDPE" refers to ethylene homopolymers and copolymers produced by gas phase and / or slurry phase polymerization and having a density of 0.940 g / cm 3 ~0.970g / cm 3 This refers to ethylene copolymers in the range.

[0023] As used herein, "polyolefin recycle feedstock" means polyolefin recycle feedstock after collection and sorting, but before being subjected to the processes disclosed herein.

[0024] As used herein, "polyolefin reclaim" refers to post-consumer recycled ("PCR") polyolefins and / or post-industrial recycled ("PIR") polyolefins. Polyolefin reclaim is from end products that have completed their life cycle as consumer goods, or from plastic waste that would otherwise be discarded as waste (such as polyethylene bottles) or generated as waste in industrial processes. Post-consumer polyolefins include polyolefins collected in commercial and household recycling programs, such as flexible packaging (cast film, blown film, BOPP film), rigid packaging, blown bottles, injection molded containers, etc. Generally, the process of separation from other polymers such as PVC, PET or PS results in two main polyolefin fractions: polyethylene reclaim (including HDPE, MDPE, LDPE and LLDPE) and polypropylene reclaim (including homopolymers, random copolymers and multiphase copolymers). The polyethylene reclaim may be further separated to recover the polyolefin-based fraction. In addition to contamination from various polymers, polyolefin recycled materials contain many impurities such as PMMA, PC, wood, paper, textile products, cellulose, food and other organic wastes, many of which cause the polyolefin recycled materials to produce unpleasant odors before and after normal processing.

[0025] As used herein, "LDPE" refers to a polyethylene produced by high pressure radical polymerization and having a density of 0.910 g / cm 3 ~0.940g / cm 3 This refers to ethylene homopolymers and ethylene copolymers in the range.

[0026] As used herein, "LLDPE" refers to a densified polyethylene (LLDPE) produced by gas phase and / or slurry phase polymerization and having a density of 0.910 g / cm 3 ~0.940g / cm 3 This refers to ethylene copolymers in the range.

[0027] As used herein, "MDPE" refers to a polyethylene terephthalate (PE) produced by gas phase and / or slurry phase polymerization and having a density of 0.925 g / cm 3 ~0.940g / cm 3 This refers to ethylene copolymers in the range.

[0028] As used herein, "melt conditions" refers to the conditions of temperature, pressure and shear, alone or in combination with each other, required to produce a polymer melt from a feed of polymer particles or powder.

[0029] As used herein, "processed polyolefin reclaim" refers to raw polyolefin reclaim that has been visbroken, or visbroken and then volatilized.

[0030] As used herein, a "virgin polyolefin" is a pre-consumer polyolefin. A pre-consumer polyolefin is a polyolefin product obtained directly or indirectly from a petrochemical feedstock fed to a polymerization unit. The pre-consumer polyolefin may undergo post-polymerization steps such as, but not limited to, extrusion, pelletization, visbreaking, and / or other processing that is completed before the product reaches the end-use consumer. In some embodiments, the virgin polyolefin has a single heat history. In some embodiments, the virgin polyolefin has one or more heat histories. In some embodiments, the virgin polyolefin does not contain additives. In some embodiments, the virgin polyolefin contains additives.

[0031] As used herein, "visbreaking conditions" refers to thermal visbreaking and / or peroxidic visbreaking. Thermal visbreaking includes sufficient temperature, pressure and / or mechanical shear to result in polymer chain breaking, primarily through polymer chain branching or crosslinking. Peroxidic visbreaking occurs when peroxide is added to the polymer melt in the extruder, followed by thermal decomposition of the peroxide to produce radicals that react with the polymer chains to break them. As used herein, visbroken polymers will have lower number and weight average molecular weights, narrower molecular weight distributions, higher melt indexes, and higher high-load melt indexes. In some embodiments, the visbreaking conditions consist of thermal visbreaking in the absence or substantially absence of oxygen at temperatures above 300°C, or in the range of 320°C to 400°C.

[0032] As used herein, "visbreaking" refers to n , M w and MWD(M w / M n The polymer is thermally and / or chemically processed to reduce the melt index I2 (ASTM D-1238, 2.16 kg @ 190 ° C) and high load melt index I 21 (ASTMD-1238, 21.6 kg@190°C). The application of high temperatures and / or the addition of radical sources such as peroxides to polyolefin materials results in the degradation of the polymer chains and a decrease in the average molecular weight of the polymer. At the same time, the molecular weight distribution becomes narrower. When this method is employed intentionally to alter the properties of a polymer, these methods are commonly referred to as "visbreaking".

[0033] "Visbroken polyolefin reclaim," as used herein, means the product obtained by subjecting polyolefin reclaim feedstock to the visbreaking conditions described herein. Processing of recycled polyolefin raw materials

[0034] In FIG. 1, flow diagram 100 includes a visbreaking extruder 110 having a visbreaking zone 115 and an optional devolatilization zone 120. Polyolefin regenerator feedstock 125 is added near the extruder inlet end of extruder 110. The polyolefin regenerator is drawn through extruder 110 via one or more rotating screwdrivers in the barrel of extruder 110. The length of the visbreaking extruder 110 is divided into one or more zones. Each zone may have one or more designated pitches of screwdrivers, inlets 130, 135 for injecting gas, a vent or vacuum connection 140 for exhausting gas, a means for adding or exhausting heat, an inlet 145 for injecting peroxide, and inlets for injecting additives to provide preselected process conditions including, but not limited to, pressure, temperature and / or shear.

[0035] 1 shows an embodiment having both a visbreaking zone 115 and, optionally, a devolatilization zone 120. Other embodiments may have only a visbreaking zone 115 without a devolatilization zone. The processing conditions of the visbreaking extruder 110 can be further controlled by the rotational speed of the screwdriver. Processed polyolefin regrind 150 is removed near the exit of the visbreaking extruder 110 for further processing or pelletization. -HDPE or MDPE

[0036] HDPE and / or MDPE are homopolymers and units derived from ethylene and C3-C 12 The copolymers of units derived from ethylene and one or more units derived from α-monoolefins include copolymers of units derived from ethylene and one or more units derived from α-monoolefins. 12 The α-olefins are substituted or unsubstituted C3-C6 olefins such as propylene, butene, pentene, hexene, heptene, octene, nonene, decene, undecene, dodecane and their isomers. 12Comonomers include, but are not limited to, α-olefins. When comonomers are present, they can be present at up to 20%, 15%, 10% or 5% by weight.

[0037] Such ethylene homopolymers and / or copolymers can be produced in suspension, solution, slurry or gas phase processes using known equipment and reaction conditions. In some embodiments, polymerization temperatures range from about 0° C. to about 300° C. at atmospheric, subatmospheric or superatmospheric pressures.

[0038] Slurry or solution polymerization systems may utilize subatmospheric or superatmospheric pressures and temperatures ranging from about 40° C. to about 300° C. An exemplary liquid phase polymerization system is described in U.S. Pat. No. 324,095, the disclosure of which is incorporated herein by reference in its entirety. A liquid phase polymerization system generally includes a reactor to which the olefin monomer and catalyst composition are added, which contains a liquid reaction medium for dissolving or suspending the polyolefin. The liquid reaction medium may consist of the bulk liquid monomer or an inert liquid hydrocarbon that is unreactive under the polymerization conditions employed. Such inert liquid hydrocarbons are not required to be used as solvents for the catalyst composition or the polymer obtained by this process, but are commonly used as solvents for the monomers used in the polymerization. Suitable inert liquid hydrocarbons for this purpose include isopentane, hexane, cyclohexane, heptane, benzene, toluene, and the like. Reactive contact between the olefin monomer and the catalyst composition should be maintained by constant stirring or agitation. The reaction medium, including the olefin polymer product and unreacted olefin monomer, is continuously removed from the reactor. The olefin polymer product is separated and the unreacted olefin monomer and liquid reaction medium are recycled to the reactor.

[0039] Gas phase polymerization systems can utilize superatmospheric pressures ranging from 1 psig (6.9 kPag) to 1000 psig (6.9 MPag), 50 psig (344 kPag) to 400 psig (2.8 MPag), or 100 psig (689 kPag) to 300 psig (2.1 MPag), and temperatures ranging from 30°C to 130°C, or 65°C to 110°C. Gas phase polymerization systems can be stirred bed or fluidized bed systems. In some embodiments, a gas phase fluidized bed process is carried out by continuously passing a stream containing one or more olefin monomers through a fluidized bed reactor under reactive conditions and in the presence of a catalyst composition at a rate sufficient to maintain a bed of solid particles in suspension. A stream containing unreacted monomer is continuously removed from the reactor, compressed, cooled, and optionally partially or completely condensed and recycled to the reactor. Product is removed from the reactor and make-up monomer is added to the regenerant stream. Depending on the temperature control needs of the polymerization system, any gas that is inert to the catalyst composition and reactants can also be present in the gas stream.

[0040] In some embodiments, a catalyst based on a Group VIB metal is used. In some embodiments, the catalyst is a chromium-based catalyst. The HDPE homopolymers and / or copolymers of the present invention have some long chain branching and a density of 0.940 g / cm 3 ~0.970g / cm 3 The MDPE copolymer has some long chain branching and a density in the range of 0.925 g / cm 3 ~0.940g / cm 3 is in the range.

[0041] In some embodiments, Ziegler-Natta (ZN) catalysts are used. Such catalysts are based on a Group IVB transition metal compound and an organoaluminum compound (cocatalyst). Such transition metals include, but are not limited to, Ti, Zr, and Hf. Non-limiting examples of zinc catalyst systems include TiCl4+Et3Al and TiCl3+AlEt2Cl. HDPE homopolymers and / or copolymers can be used with a melting point of 0.940 g / cm. 3~0.970g / cm 3 It has some long chain branching with densities in the range of 0.1 to 1.0. -LLDPE

[0042] LLDPE is a polymer made of ethylene homopolymer and units derived from ethylene and C3-C 12 The copolymers of units derived from ethylene and one or more units derived from α-monoolefins include copolymers of units derived from ethylene and one or more units derived from α-monoolefins. 12 The α-olefins are substituted or unsubstituted C3-C6 olefins such as propylene, butene, pentene, hexene, heptene, octene, nonene, decene, undecene, dodecane and their isomers. 12 The polymerization temperature ranges from about 0° C. to about 300° C. at atmospheric, subatmospheric, or superatmospheric pressures. In some embodiments, the polymerization temperature ranges from about 0° C. to about 300° C. at atmospheric, subatmospheric, or superatmospheric pressures. When comonomers are present, they can be present up to 20 wt%, 15 wt%, 10 wt%, or 5 wt%. Such ethylene homopolymers and / or copolymers can be produced in suspension, solution, slurry, or gas phase processes using known equipment and reaction conditions. In some embodiments, the polymerization temperature ranges from about 0° C. to about 300° C. at atmospheric, subatmospheric, or superatmospheric pressures.

[0043] Slurry or solution polymerization systems may utilize subatmospheric or superatmospheric pressures and temperatures ranging from about 40° C. to about 300° C. An exemplary liquid phase polymerization system is described in U.S. Pat. No. 324,095, the disclosure of which is incorporated herein by reference in its entirety. A liquid phase polymerization system generally includes a reactor to which the olefin monomer and catalyst composition are added, which contains a liquid reaction medium for dissolving or suspending the polyolefin. The liquid reaction medium may consist of the bulk liquid monomer or an inert liquid hydrocarbon that is unreactive under the polymerization conditions employed. Such inert liquid hydrocarbons are not required to be used as solvents for the catalyst composition or the polymer obtained by this process, but are commonly used as solvents for the monomers used in the polymerization. Suitable inert liquid hydrocarbons for this purpose include isopentane, hexane, cyclohexane, heptane, benzene, toluene, and the like. Reactive contact between the olefin monomer and the catalyst composition should be maintained by constant stirring or agitation. The reaction medium, including the olefin polymer product and unreacted olefin monomer, is continuously removed from the reactor. The olefin polymer product is separated and the unreacted olefin monomer and liquid reaction medium are recycled to the reactor.

[0044] Gas phase polymerization systems can utilize superatmospheric pressures ranging from 1 psig (6.9 kPag) to 1000 psig (6.9 MPag), 50 psig (344 kPag) to 400 psig (2.8 MPag), or 100 psig (689 kPag) to 300 psig (2.1 MPag), and temperatures ranging from 30°C to 130°C, or 65°C to 110°C. Gas phase polymerization systems can be stirred bed systems or fluidized bed systems. In some embodiments, gas phase fluidized bed processes are carried out by continuously passing a stream containing one or more olefin monomers through a fluidized bed reactor under reactive conditions and in the presence of a catalyst composition at a rate sufficient to maintain a bed of solid particles in suspension. A stream containing unreacted monomer is continuously removed from the reactor, compressed, cooled, and optionally partially or completely condensed and recycled to the reactor. Product is removed from the reactor and make-up monomer is added to the regenerator stream. Depending on the temperature control needs of the polymerization system, any gas that is inert to the catalyst composition and reactants can also be present in the gas stream.

[0045] In some embodiments, Ziegler-Natta (ZN) catalysts are used. Such catalysts are based on a Group IVB transition metal compound and an organoaluminum compound (cocatalyst). Such transition metals include, but are not limited to, Ti, Zr, and Hf. Non-limiting examples of zinc catalyst systems include TiCl4+Et3Al and TiCl3+AlEt2Cl. LLDPE homopolymers and / or copolymers can be used with a melting point of 0.910 g / cm. 3 ~0.940g / cm 3 It has some long chain branching with densities in the range of 0.1 to 1.0. -LDPE

[0046] LLDPE is an ethylene homopolymer, a polymer made up of units derived from ethylene and C3-C 12 These include copolymers with one or more units derived from an α-olefin, copolymers of units derived from ethylene and one or more units derived from an α-monoolefin containing a polar group, or mixtures thereof.

[0047] Such ethylene homopolymers can be produced in a high pressure radical polymerization process, for example, in one or more tubular reactors, one or more autoclave reactors, or a combination thereof. Operating conditions for the high pressure process include, but are not limited to, pressures ranging from 70 MPa to 700 MPa and temperatures ranging from 150° C. to 500° C. The homopolymers are highly long chain branched and have a density of 0.910 g / cm. 3 ~0.940g / cm 3 is in the range.

[0048] Ethylene and C3-C 12 Copolymers with α-olefins can be produced by high pressure radical polymerization processes, such as in one or more tubular reactors, one or more autoclave reactors, or a combination thereof. 12 The α-olefins are substituted or unsubstituted C3-C6 olefins such as propylene, butene, pentene, hexene, heptene, octene, nonene, decene, undecene, dodecane and their isomers. 12 The homopolymers include, but are not limited to, α-olefins. When comonomers are present, they can be present up to 15 wt%, 10 wt%, or 5 wt%. Operating conditions for the high pressure process include, but are not limited to, pressures ranging from 70 MPa to 700 MPa and temperatures ranging from 150° C. to 500° C. The homopolymers are highly long chain branched and have a density of 0.910 g / cm. 3 ~0.940g / cm 3 is in the range.

[0049] Copolymers of ethylene and one or more alpha monoolefins containing polar groups can be produced in a high pressure radical polymerization process, such as one or more tubular reactors, one or more autoclave reactors, or a combination thereof. The alpha monoolefins containing polar groups include, but are not limited to, methacrylic acid, esters, nitriles, and amides, such as acrylic acid, methacrylic acid, cyclohexyl methacrylate, methyl acrylate, acrylonitrile, acrylamide, or mixtures thereof. When comonomers are present, they can be present up to 15 wt%, 10 wt%, or 5 wt%. Operating conditions for the high pressure process include, but are not limited to, pressures ranging from 70 MPa to 700 MPa and temperatures ranging from 150°C to 500°C. The homopolymers are highly long chain branched and have a density of 0.910 g / cm. 3 ~0.940g / cm 3 is in the range. -polypropylene

[0050] Polypropylene is a propylene homopolymer, a mixture of units derived from propylene, ethylene and C4-C 12 and copolymers with units derived from one or more of the α-olefins. The polypropylene may be a homopolymer, a heterophasic copolymer, a random copolymer, and combinations thereof. Polyolefin Recycled Material

[0051] In some embodiments, the polyolefin recyclate feedstock is obtained from one or more HDPE, one or more MDPE, one or more LDPE, one or more LLDPE, one or more PP, or a combination thereof. The polyolefin recyclate feedstocks described above derived from HDPE, MDPE, LLDPE, LDPE, PP, or a combination thereof may be characterized by having the following properties: i) Density is 0.900g / cm 3 ~0.970g / cm< 3 Within the range ii) Melt index (I2, 2.16 kg, 190°C) is 5.0 g / 10 min or less. iii) Molecular weight distribution (M w / M n ) must be 4.0 or higher and 5.0 or higher iv) the weight average molecular weight is greater than or equal to 85,000 daltons, greater than or equal to 100,000 daltons, greater than or equal to 150,000 daltons, greater than or equal to 200,000 daltons, greater than or equal to 250,000 daltons, and / or less than or equal to 600,000 daltons, less than or equal to 500,000 daltons, less than or equal to 400,000 daltons, or less than or equal to 300,000 daltons; v) Melt elasticity (ER) is 0.5 or more.

[0052] In some embodiments, in addition to the properties mentioned above, the polyolefin recycle feedstock may be further characterized by having one or more of the following properties: vi) 1st VOC content; vii) First High Load Melt Index (I 21 , 21.6kg, 190℃), viii) First Melt Index Ratio (MIR, I 21 / I2) ix) The first long chain branch parameter (g') is less than or equal to 1.0, 0.99, 0.98, or 0.97. x) First Total Polydispersity Ratio (PDR) xi) First complex viscosity ratio (η * 0.1 / η * 100 ), and xii) 1st intrinsic viscosity Visbreaking Extruder

[0053] The polyolefin recycle feedstock is fed to a first extruder and subjected to visbreaking and, optionally, devolatilization conditions. - Visbreaking

[0054] Visbreaking conditions are implemented in the visbreaking zone of the first extruder and are customized for the polyolefin. In some embodiments, the visbreaking conditions refer to thermal visbreaking and / or peroxide visbreaking. In some embodiments, the visbreaking conditions include thermal visbreaking, where the temperature in the visbreaking zone is 300° C. or higher and chain scission reactions are believed to prevail over long chain branching and / or crosslinking reactions. In some embodiments, the temperature in the visbreaking zone may be in the range of 320° C. to 500° C., 340° C. to 480° C., or 360° C. to 460° C. In some embodiments, the instrument at the discharge of the first extruder directly or indirectly measures rheology (I2, I 21 , viscosity, melt elasticity, complex viscosity ratio, etc.) are monitored to assist in measuring and controlling visbreaking. In some embodiments, when antioxidant addition is used in conjunction with visbreaking, the antioxidant addition point is at a location on the first extruder after a significant portion of the visbreaking reaction has occurred. In some embodiments, the visbreaking conditions include oxygen-free or substantially oxygen-free thermal visbreaking, where substantially oxygen-free means 1.0 wt.% or less, 0.10 wt.% or less, or 0.01 wt.% or less, based on the total weight of polymer in the extruder. In some embodiments, the visbreaking extruder includes one or more melt filters. -Volatilization

[0055] Devolatilization conditions can also be performed in the first extruder, with a portion of the extruder having a high density mixing arrangement devolatilization section to reduce the VOCs in the polyolefin regenerator feedstock and to allow for VOC removal at high temperatures. Devolatilization conditions can be further improved by injecting a sweep, such as nitrogen, carbon dioxide, water, or a combination thereof, into the extruder to distribute the gas in the polymer melt to remove the VOC components; and removing the gas and removed VOC components by evacuation and / or vacuum. Processed polyolefin reclaimed material

[0056] The processed polyolefin reclaim is discharged from the discharge of the visbreaking extruder, where "processed" means that the polyolefin reclaim feedstock is in a visbroken or subsequent visbroken state. As noted above, the processed polyolefin reclaim may be characterized as having the following properties: i) Density: The ratio of the density of the processed polyolefin reclaimed material to the density of the raw polyolefin reclaimed material is 1.0 or greater. ii) Melt Index: The ratio of the melt index of the processed polyolefin reclaim to the melt index of the raw polyolefin reclaim is 5.0 or more, and / or the melt index of the processed polyolefin reclaim is 5.0g / 10min or more and 10.0g / 10min or more. iii) Molecular weight distribution: the ratio of the molecular weight distribution of the processed polyolefin reclaim to the molecular weight distribution of the raw polyolefin reclaim is within the range of 0.25-0.60, 0.30-0.55, or 0.35-0.50. iv) Weight average molecular weight (“M w2 "): The ratio of the weight average molecular weight of the processed polyolefin recycled material to the weight average molecular weight of the raw polyolefin recycled material is within the range of 0.10 to 0.70, 0.15 to 0.60, or 0.20 to 0.50. Also, v) Melt Elasticity ("ER"): The ratio of processed polyolefin reclaim to ER of polyolefin reclaim feedstock is in the range of 0.10-0.45, 0.15-0.40, 0.20-0.35, and / or a second melt elasticity of 2.0 or less, 1.5 or less, 1.3 or less, and / or 0.75 or more, 0.85 or more, 0.95 or more.

[0057] In some embodiments, in addition to the properties above, the processed polyolefin reclaim is characterized by one or more of the following: vi) VOC Content: The ratio of the VOC content of the polyolefin reclaimed material to the VOC content of the processed polyolefin reclaimed material is not more than 0.9, 0.8, 0.7, 0.6 or 0.5, either alone or in any combination with a lower limit of not less than 0.1. vii) High Load Melt Index (I 21 , 21.6 kg, 190°C): the ratio of the high-load melt index of the processed polyolefin recycled material to the high-load melt index of the raw polyolefin recycled material is 2.0 or more, 3.0 or more, or 4.0 or more. viii) Melt Index Ratio (MIR, I 21 / I2): The ratio of the MIR of the processed polyolefin recycled material to the MIR of the raw polyolefin recycled material is within the range of 0.30 to 0.60. ix) Long Chain Branching Parameter (g'): The ratio of g' of the processed polyolefin recycle to g' of the raw polyolefin recycle is less than or equal to 1.0. x) The first long chain branching index ("LCBI") is greater than or equal to 0.60, with the LCBI of the processed polyolefin reclaim being less than or equal to 0.40. xi) Total Polydispersity Ratio (PDR): The ratio of PDR of processed polyolefin reclaim to PDR of raw polyolefin reclaim is less than or equal to 0.50, less than or equal to 0.45, less than or equal to 0.40. xii) Complex viscosity ratio (η * 0.1 / η * 100 ): The ratio of the complex viscosity of the processed polyolefin recycled material to the complex viscosity of the raw polyolefin recycled material is 0.50 or less, 0.40 or less, or 0.30 or less, and / or the second complex viscosity ratio is 10 or less, 8.0 or less, or 6.0 or less, and the complex viscosity at a temperature of 190°C is 0.1 rad / secη * 0.1 seconds and the complex viscosity is 100 rad / secη * 100 Seconds. xiii) Intrinsic viscosity [η]: The ratio of the intrinsic viscosity of the processed polyolefin reclaimed material to the intrinsic viscosity of the raw polyolefin reclaimed material is not more than 0.90, not more than 0.80, not more than 0.70. Blending processed polyolefin reclaim with polyolefin blend components - 2 extruders

[0058] In FIG. 2, the flow diagram 200 includes a visbreaking extruder 210 and a compounding extruder 255. As shown in FIG. 2, an embodiment of the present invention includes a visbreaking extruder 210 having a visbreaking zone 215 and a devolatilization zone 220. Polyolefin regenerator feedstock 225 is added to the visbreaking extruder 210 near the inlet end of the extruder. The polyolefin regenerator feedstock 225 is drawn through the visbreaking extruder 210 via one or more rotating screwdrivers in the barrel of the visbreaking extruder 210. The length of the visbreaking extruder 210 is divided into one or more zones. Each zone has one or more designated pitches on the screwdriver, inlets 230, 235 for injecting gas, a vent or vacuum connection 240 for exhausting gas, a means for adding or exhausting heat, an inlet 245 for injecting peroxide, and an inlet for injecting additives, and can provide preselected process conditions including, but not limited to, pressure, temperature, and shear.

[0059] 2 shows an embodiment having a visbreaking zone 215 and a devolatilization zone 220. Other embodiments may have separate visbreaking zone 215 or devolatilization zone 220. The process conditions in the visbreaking extruder 210 can be further controlled by the rotational speed of the screwdriver. Processed polyolefin regrind 250 is removed near the exit of the visbreaking extruder 210 for further processing.

[0060] The embodiment of FIG. 2 includes a second extruder 255 having a mixing zone 260. Processed polyolefin reclaim 250 is added to compounding extruder 255 as a first blend component along with polyolefin blend component 252 and subjected to compounding conditions. Polyolefin blend component 252 includes virgin polyolefin, polyolefin reclaim feedstock, processed polyolefin reclaim, or combinations thereof. In some embodiments, the virgin polyolefin includes virgin HDPE, virgin LLDPE, virgin HDPE, virgin MDPE, virgin polypropylene, or combinations thereof. In some embodiments, the polyolefin reclaim feedstock includes LDPE reclaim feedstock, LLDPE reclaim feedstock, HDPE reclaim feedstock, MDPE reclaim feedstock, polypropylene reclaim feedstock, or combinations thereof. In some embodiments, the processed polyolefin reclaim includes processed LDPE reclaim, processed LLDPE reclaim, a second processed HDPE reclaim, a second processed MDPE reclaim, processed polypropylene reclaim, or combinations thereof. In some embodiments, the polyolefin blend component includes virgin polyolefin, polyolefin reclaim feedstock, processed polyolefin reclaim, or a combination thereof. The mixture of processed polyolefin reclaim 250 and polyolefin blend component 252 is drawn through the compounding extruder 255 by one or more rotating screwdrivers in the extruder 255 barrel. One or more additional inlets near the inlet end of the extruder are used to add antioxidants 265 and / or other ingredients 270. The length of the compounding extruder 255 can be divided into one or more zones. Each zone may have one or more specific pitches on the screwdriver, a means for adding or removing heat, and an inlet for injecting additives. It includes a vent or vacuum connection 275 for removing gas to provide preselected process conditions including, but not limited to, pressure, temperature, and shear. The blend 280 of processed polyolefin reclaim 250 and polyolefin blend component 252 is removed upon exiting the compounding extruder 255 for further processing or pelletization.

[0061] In some embodiments, the polyolefin blend component may be a polyolefin powder product from the polymerization apparatus, a granulated polyolefin or a polyolefin melt, which is the product removed from the third extruder. In some of these embodiments, the polymerization apparatus includes two, three or more polymerization reactors and / or two, three or more polymerization zones within the polymerization reactor. More specific polymerization apparatus embodiments include, but are not limited to, two or three gas-phase fluidized bed reactors connected in series, two or three slurry-phase reactors connected in series, and a gas-phase fluidized bed reactor connected in series to a multi-zone circulating reactor.

[0062] In some embodiments, the amount of a polyolefin blend component, which itself can include two or more polymers, is determined based on the logarithmic mixture rule, where the blend components satisfy the following equation:

number

[0063] The first blend component is a processed reclaim of polyolefin produced by a visbreaking extruder. The second blend component comprises virgin polyolefin, polyolefin reclaim feedstock, processed polyolefin reclaim, or a combination thereof. In some embodiments, the virgin polyolefin comprises virgin LDPE, virgin LLDPE, virgin HDPE, virgin polypropylene, or a combination thereof. In some embodiments, the polyolefin reclaim feedstock comprises LDPE reclaim feedstock, LLDPE reclaim feedstock, HDPE reclaim feedstock, polypropylene reclaim feedstock, or a combination thereof. In some embodiments, the processed polyolefin reclaim comprises processed LDPE reclaim, processed LLDPE reclaim, second processed polyolefin reclaim, processed polypropylene reclaim, or a combination thereof. In some embodiments, the polyolefin blend component comprises virgin polyolefin, polyolefin reclaim feedstock, processed polyolefin reclaim, or a combination thereof. When processed polyolefin recycle is blended with other processed polyolefin recycles, the first polyolefin recycle has at least one parameter that distinguishes it from the second processed polyolefin recycle. -Virgin polyolefin

[0064] In some embodiments, virgin polyolefins are ethylene homopolymers, units derived from ethylene and one or more C-C 12 copolymers of units derived from ethylene and units derived from one or more α-monoolefins, and copolymers of units derived from ethylene and units derived from one or more α-monoolefins. 12 The α-olefins are substituted or unsubstituted C3-C6 olefins such as propylene, butene, pentene, hexene, heptene, octene, nonene, decene, undecene, dodecane and their isomers. 12Including, but not limited to, α-olefins. When comonomers are present, they can be present up to 20 wt%, 15 wt%, 10 wt%, or 5 wt%. Virgin polyolefins can be derived as a portion of post-consumer recycled polyolefins and / or post-industrial recycled polyolefins, which are primarily comprised of polyolefin reclaim, meaning 80 wt% or more, 85 wt% or more, 90 wt% or more, 95 wt% or more based on the total weight of virgin polyolefins.

[0065] Such ethylene homopolymers and / or copolymers can be produced in suspension, solution, slurry or gas phase processes using known equipment and reaction conditions. In some embodiments, polymerization temperatures range from about 0° C. to about 300° C. at atmospheric, subatmospheric or superatmospheric pressures.

[0066] Slurry or solution polymerization systems may utilize subatmospheric or superatmospheric pressures and temperatures ranging from about 40° C. to about 300° C. An exemplary liquid phase polymerization system is described in U.S. Pat. No. 324,095, the disclosure of which is incorporated herein by reference in its entirety. The liquid phase polymerization system of the present invention generally comprises a reactor to which the olefin monomer and catalyst composition are added, the reactor containing a liquid reaction medium for dissolving or suspending the polyolefin. The liquid reaction medium may consist of the bulk liquid monomer or an inert liquid hydrocarbon that is unreactive under the polymerization conditions employed. Such inert liquid hydrocarbons are not required to be used as solvents for the catalyst composition or the polymer obtained by this process, but are commonly used as solvents for the monomers used in the polymerization. Suitable inert liquid hydrocarbons for this purpose include isopentane, hexane, cyclohexane, heptane, benzene, toluene, and the like. Reactive contact between the olefin monomer and the catalyst composition should be maintained by constant stirring or agitation. The reaction medium, including the olefin polymer product and unreacted olefin monomer, is continuously removed from the reactor. The olefin polymer product is separated and the unreacted olefin monomer and liquid reaction medium are recycled to the reactor.

[0067] Gas phase polymerization systems can utilize superatmospheric pressures ranging from 1 psig (6.9 kPag) to 1000 psig (6.9 MPag), 50 psig (344 kPag) to 400 psig (2.8 MPag), or 100 psig (689 kPag) to 300 psig (2.1 MPag), and temperatures ranging from 30°C to 130°C, or 65°C to 110°C. Gas phase polymerization systems can be stirred bed systems or fluidized bed systems. In some embodiments, gas phase fluidized bed processes are carried out by continuously passing a stream containing one or more olefin monomers through a fluidized bed reactor under reactive conditions and in the presence of a catalyst composition at a rate sufficient to maintain a bed of solid particles in suspension. A stream containing unreacted monomer is continuously removed from the reactor, compressed, cooled, and optionally partially or completely condensed and recycled to the reactor. Product is removed from the reactor and make-up monomer is added to the regenerator stream. Any gas inert to the catalyst composition and reactants may also be present in the gas stream as necessary for temperature control of the polymerization system.

[0068] In some embodiments, a Group VIB metal based catalyst is used. In some embodiments, the catalyst is a chromium based catalyst. Such HDPE homopolymers and / or copolymers have a viscosity of 0.940 g / cm 3 ~0.970g / cm 3 The HDPE homopolymers and / or copolymers of the present invention have some long chain branching with densities in the range of 0.925 g / cm 3 ~0.940g / cm 3 It has some long chain branching with densities in the range of 0.1 to 1.0.

[0069] Virgin HDPE may be characterized as having the following properties: i) Density is 0.940g / cm 3 ~0.970g / cm 3 Within the range of ii) the melt index (I2, 2.16 kg, 190°C) is within the range of 1.0 g / 10 min to 100 g / 10 min, 2.0 g / 10 min to 80 g / 10 min, or 3.0 g / 10 min to 50 g / 10 min; iii) Molecular weight distribution (M w / M n ) is 15 or more, iv) The weight average molecular weight is 250,000 daltons or less, 200,000 daltons or less, 150,000 daltons or less, or 100,000 daltons or less.

[0070] The virgin MDPE may be characterized as having the following properties: i) Density is 0.925g / cm 3 from 0.940 g / cm 3 Within the range of ii) the melt index (I2, 2.16 kg, 190°C) is within the range of 1.0 g / 10 min to 100 g / 10 min, 2.0 g / 10 min to 80 g / 10 min, or 3.0 g / 10 min to 50 g / 10 min; iii) Molecular weight distribution (M w / M n ) is 15 or more, iv) The weight average molecular weight is 250,000 daltons or less, 200,000 daltons or less, 150,000 daltons or less, or 100,000 daltons or less. Polyolefin Recycled Material

[0071] In some embodiments, the polyolefin recyclate feedstock is obtained from one or more HDPE, one or more MDPE, one or more LDPE, one or more LLDPE, one or more PP, or a combination thereof. The polyolefin recyclate feedstocks described above derived from HDPE, MDPE, LLDPE, LDPE, PP, or a combination thereof may be characterized by having the following properties: i) Density is 0.900g / cm 3 ~0.970g / cm 3 Within the range of ii) Melt index (I2, 2.16 kg, 190°C) is 5.0 g / 10 min or less; iii) Molecular weight distribution (M w / M n ) is greater than 4.0 or greater than 5.0, iv) the weight average molecular weight is greater than or equal to 85,000 daltons, greater than or equal to 100,000 daltons, greater than or equal to 150,000 daltons, greater than or equal to 200,000 daltons, greater than or equal to 250,000 daltons, and / or less than or equal to 600,000 daltons, less than or equal to 500,000 daltons, less than or equal to 400,000 daltons, or less than or equal to 300,000 daltons; v) Melt elasticity (ER) is 0.5 or more.

[0072] In some embodiments, in addition to the properties mentioned above, the polyolefin reclaimed feedstock may be characterized by having one or more of the following properties: vi) 1st VOC content; vii) First High Load Melt Index (I 21 , 21.6kg, 190℃), viii) First Melt Index Ratio (MIR, I 21 / I2) ix) The first long chain branch parameter (g') is less than or equal to 1.0, 0.99, 0.98, or 0.97. x) the first total polydispersity ratio (PDR), xi) First complex viscosity ratio (η * 0.1 / η * 100 ), and xii) 1st intrinsic viscosity -Processed polyolefin recycled material

[0073] The processed polyolefin reclaim is taken from the discharge of a visbreaking extruder. By "processed" it is meant that the polyolefin reclaim feedstock has been subjected to visbreaking conditions, or visbreaking conditions followed by devolatilization conditions. As noted above, the processed polyolefin reclaim may be characterized as having the following properties: i) Density: The ratio of the density of the processed polyolefin reclaim to the density of the raw polyolefin reclaim shall be greater than or equal to 1.0. ii) Melt Index: The ratio of the melt index of the processed polyolefin reclaim to the melt index of the raw polyolefin reclaim is greater than or equal to 5.0. iii) Molecular Weight Distribution: The ratio of the molecular weight distribution of the processed polyolefin reclaim to the molecular weight distribution of the raw polyolefin reclaim is not more than 0.99, not more than 0.95, and not more than 0.80. iv) Weight average molecular weight (“M w2 "): The ratio of the weight average molecular weight of the processed polyolefin recycled material to the weight average molecular weight of the raw polyolefin recycled material is 0.99 or less, 0.95 or less, 0.80 or less, or 0.70 or less. Also, v) Melt Elasticity (“ER”): The ratio of the ER of the processed polyolefin reclaim to the ER of the Feed Polyolefin Reclaim is less than or equal to 0.90, less than or equal to 0.70, and less than or equal to 0.50.

[0074] In some embodiments, in addition to the properties listed above, the processed polyolefin reclaim may be further characterized by having one or more of the following properties: vi) VOC Content: The ratio of the VOC content of the polyolefin reclaimed material to the VOC content of the processed polyolefin reclaimed material is less than or equal to 0.9, 0.8, 0.7, 0.6 or 0.5, either alone or in any combination with a lower limit of not less than 0.1. vii) High Load Melt Index (I 21 , 21.6 kg, 190°C): the ratio of the high-load melt index of the processed polyolefin recycled material to the high-load melt index of the raw polyolefin recycled material is 2.0 or more, 3.0 or more, 4.0 or more, or 5.0 or more. viii) Melt Index Ratio (MIR, I 21 / I2): The MIR of the processed polyolefin recycled material relative to the MIR of the raw polyolefin recycled material is 0.90 or less, 0.85 or less, 0.80 or less, and 0.75 or less. ix) Total Polydispersity Ratio (PDR): The ratio of PDR of processed polyolefin reclaim to PDR of raw polyolefin reclaim is 0.90 or less, 0.80 or less, 0.70 or less, 0.50 or less. x) Complex viscosity ratio (η * 0.1 / η * 100 ): The ratio of the complex viscosity ratio of the processed polyolefin recycled material to the complex viscosity ratio of the raw polyolefin recycled material is 0.70 or less, 0.60 or less, 0.50 or less, and 0.40 or less. xi) Intrinsic viscosity [η]: The ratio of the intrinsic viscosity of the processed polyolefin recycled raw material to the intrinsic viscosity of the polyolefin recycled raw material is not more than 0.90, not more than 0.80, not more than 0.70, not more than 0.50. Compounding Extruder

[0075] The processed polyolefin reclaim and polyolefin blend components are fed to a second extruder or mixer, where the blend is subjected to compounding conditions. The mixing conditions are implemented in the mixing zone of the second extruder or mixer and are customized for a particular polyolefin and optional additive mixture. The temperature, pressure and shear conditions implemented in the second extruder or mixer are sufficient to provide intimate mixing of the virgin polyolefin and, optionally, additives to produce a substantially homogenous polymer blend of the processed polyolefin reclaim and virgin polyolefin. In some embodiments, the mixing conditions include a temperature in the mixing zone of 300° C. or less, 250° C. or less, or 200° C. or less. In some embodiments, the temperature in the mixing zone may be within the range of 125° C. to 195° C., 130° C. to 180° C., or 135° C. to 165° C. Blending processed polyolefin reclaim with polyolefin blend components

[0076] In some embodiments, the blends comprise 5% to 90%, 10% to 80%, 15% to 70%, 20% to 60%, or 25% to 50% by weight of processed polyolefin regrind and 10% to 95%, 20% to 90%, 30% to 85%, 40% to 80%, or 50% to 75% by weight of polyolefin blend components, respectively, all weight percentages based on the total weight of the polymer blend. In some embodiments, the virgin polyolefin is visbroken. Visbreaking of such virgin polyolefins may be thermal visbreaking and / or peroxide visbreaking. In some embodiments, such visbreaking conditions for virgin polyolefins include thermal visbreaking in the absence or substantially absence of oxygen at a temperature above the melting point of the polyolefin and at or above 300° C., or in the range of 320° C. to 400° C.

[0077] In some embodiments, blends of processed polyolefin reclaim with polyolefin blend components, in combination with or independently of the preceding blend ratios, include bimodal polymers, and the processed polyolefin reclaim product has a weight average molecular weight ("M w3 "), and the polyolefin blend component has a weight average molecular weight ("M w4 "). And M w3 / M w4 is less than or equal to 0.9, 0.8, 0.7, 0.6 or 0.5, or is greater than or equal to 1.1, 1.25, 1.5, 1.75 or 2.0. Blending Processed Polyolefin Recycled with Polyolefin Blend Components - 3 Extruders

[0078] In FIG. 3, flow diagram 300 includes a visbreaking extruder 310, a melt extruder 357, and a compounding extruder 355. The embodiment of the invention shown in FIG. 3 includes a visbreaking extruder 310 having a visbreaking zone 315 and a devolatilization zone 320. Polyolefin regrind feedstock 325 is added to the visbreaking extruder 310 near the inlet end of the extruder. The polyolefin regrind feedstock 325 is drawn through the visbreaking extruder 310 via one or more rotating screwdrivers in the barrel of the visbreaking extruder 310. The length of the visbreaking extruder 310 is divided into one or more zones. Each zone may have one or more designated pitches on the screwdriver, inlets 330, 335 for injecting gas, a vent or vacuum connection 340 for removing gas, a means for adding or removing heat, an inlet 345 for injecting peroxide, and inlets for injecting additives to provide preselected process conditions including, but not limited to, pressure, temperature, and shear.

[0079] 3 shows an embodiment having a visbreaking zone 315 and a devolatilization zone 320. Other embodiments may have separate visbreaking zone 315 or devolatilization zone 320. The processing conditions in the visbreaking extruder 310 can be further controlled by the rotational speed of the screwdriver. Processed polyolefin regrind 350 is removed near the exit of the visbreaking extruder 310 for further processing.

[0080] The embodiment of FIG. 3 includes a second extruder 355 having a mixing zone 360 ​​and a third extruder 357 having a melt zone 362. A third blend component 383 is added to the melt extruder near the inlet end of extruder 357 along with an antioxidant 365 and other ingredients 370. The polyolefin blend component 352 includes virgin polyolefin, polyolefin reclaim feedstock, processed polyolefin reclaim, or combinations thereof. In some embodiments, the virgin polyolefin includes virgin LDPE, virgin LLDPE, virgin HDPE, virgin MDPE, virgin polypropylene, or combinations thereof. In some embodiments, the polyolefin reclaim feedstock includes LDPE reclaim feedstock, LLDPE reclaim feedstock, HDPE reclaim feedstock, MDPE reclaim feedstock, polypropylene reclaim feedstock, or combinations thereof. In some embodiments, the processed polyolefin reclaim includes processed LDPE reclaim, processed LLDPE reclaim, second processed HDPE reclaim, second processed MDPE reclaim, processed polypropylene reclaim, or combinations thereof. In some embodiments, the polyolefin blend component includes virgin polyolefin, polyolefin reclaim feedstock, processed polyolefin reclaim, or combinations thereof. The mixture of the third blend component 352 and optional antioxidant 365 and / or other components 370 is drawn through the melt extruder 357 via one or more rotating screwdrivers in the barrel of the melt extruder 357. The length 357 of the melt extruder can be divided into one or more zones. Each zone may have one or more designated pitches on the screwdrivers, means for adding or removing heat, inlets for injecting additives, and vents or vacuum connections for removing gases to provide preselected process conditions including, but not limited to, pressure, temperature, and shear. The melt of polyolefin blend component 352 is removed near the discharge outlet of melt extruder 357 for further processing or granulation.

[0081] The processed polyolefin reclaim 350 is added to the compounding extruder 355 near the inlet end of the extruder along with the melt of the polyolefin blend component 352. The mixture of processed polyolefin reclaim 350 and polyolefin blend component 352 is drawn by the compounding extruder 355 through one or more rotating screwdrivers in the barrel of the compounding extruder 355, and the mixture is compounded. The length of the compounding extruder 355 can be divided into one or more zones. Each zone may have one or more specific pitches on the screwdrivers to provide preselected process conditions, including but not limited to pressure, temperature, and shear, means for adding or removing heat, inlets for injecting additives, and vent and / or vacuum connections 375 for removing gases. The blend 380 of processed polyolefin reclaim 350 and melt of the polyolefin blend component 352 is removed as it exits the compounding extruder 355 for further processing or pelletization.

[0082] In some embodiments, the polyolefin blend component may be a polyolefin powder product from the polymerization apparatus, a granulated polyolefin or a polyolefin melt, which is the product removed from the third extruder. In some of these embodiments, the polymerization apparatus includes two, three or more polymerization reactors and / or two, three or more polymerization zones within the polymerization reactor. More specific polymerization apparatus embodiments include, but are not limited to, two or three gas-phase fluidized bed reactors connected in series, two or three slurry-phase reactors connected in series, and a gas-phase fluidized bed reactor connected in series to a multi-zone circulating reactor.

[0083] In some embodiments, the amount of a polyolefin blend component, which itself can include two or more polymers, is determined based on the logarithmic mixture rule, where the blend components satisfy the following equation:

number

[0084] The first blend component is a processed reclaim of polyolefin produced in a visbreaking extruder. The second blend component comprises virgin polyolefin, polyolefin reclaim feedstock, processed polyolefin reclaim, or a combination thereof. In some embodiments, the virgin polyolefin comprises virgin LDPE, virgin LLDPE, virgin HDPE, virgin MDPE, virgin polypropylene, or a combination thereof. In some embodiments, the polyolefin reclaim feedstock comprises LDPE reclaim feedstock, LLDPE reclaim feedstock, HDPE reclaim feedstock, MDPE reclaim feedstock, polypropylene reclaim feedstock, or a combination thereof. In some embodiments, the processed polyolefin reclaim comprises processed LDPE reclaim, processed LLDPE reclaim, second processed HDPE reclaim, second processed MDPE reclaim, processed polypropylene reclaim, or a combination thereof. In some embodiments, the second blend component comprises virgin polyolefin, polyolefin reclaim feedstock, processed polyolefin reclaim, or a combination thereof. When processed polyolefin recycle is blended with other processed polyolefin recycles, the first polyolefin recycle has at least one parameter that distinguishes it from the second processed polyolefin recycle. -Virgin polyolefin

[0085] In some embodiments, the polyolefin regenerator feedstock is an ethylene homopolymer, a polymer that is a mixture of units derived from ethylene and one or more C3-C 12 copolymers of units derived from ethylene and units derived from one or more α-monoolefins, and copolymers of units derived from ethylene and units derived from one or more α-monoolefins.12 The α-olefins are substituted or unsubstituted C3-C6 olefins such as propylene, butene, pentene, hexene, heptene, octene, nonene, decene, undecene, dodecane and their isomers. 12 Including, but not limited to, α-olefins. When comonomers are present, they can be present up to 20 wt%, 15 wt%, 10 wt%, or 5 wt%. The polyolefin reclaim feedstock can be derived as a portion of post-consumer recycled polyolefins and / or post-industrial recycled polyolefins, which is primarily polyolefin reclaimed, meaning 80 wt% or more, 85 wt% or more, 90 wt% or more, 95 wt% or more based on the total weight of the polyolefin reclaim feedstock.

[0086] Such ethylene homopolymers and / or copolymers can be produced in suspension, solution, slurry or gas phase processes using known equipment and reaction conditions. In some embodiments, polymerization temperatures range from about 0° C. to about 300° C. at atmospheric, subatmospheric or superatmospheric pressures.

[0087] Slurry or solution polymerization systems may utilize subatmospheric or superatmospheric pressures and temperatures ranging from about 40° C. to about 300° C. An exemplary liquid phase polymerization system is described in U.S. Pat. No. 324,095, the disclosure of which is incorporated herein by reference in its entirety. The liquid phase polymerization system of the present invention generally comprises a reactor to which the olefin monomer and catalyst composition are added, the reactor containing a liquid reaction medium for dissolving or suspending the polyolefin. The liquid reaction medium may consist of the bulk liquid monomer or an inert liquid hydrocarbon that is unreactive under the polymerization conditions employed. Such inert liquid hydrocarbons are not required to be used as solvents for the catalyst composition or the polymer obtained by this process, but are commonly used as solvents for the monomers used in the polymerization. Suitable inert liquid hydrocarbons for this purpose include isopentane, hexane, cyclohexane, heptane, benzene, toluene, and the like. Reactive contact between the olefin monomer and the catalyst composition should be maintained by constant stirring or agitation. The reaction medium, including the olefin polymer product and unreacted olefin monomer, is continuously removed from the reactor. The olefin polymer product is separated and the unreacted olefin monomer and liquid reaction medium are recycled to the reactor.

[0088] Gas phase polymerization systems can utilize superatmospheric pressures ranging from 1 psig (6.9 kPag) to 1000 psig (6.9 MPag), 50 psig (344 kPag) to 400 psig (2.8 MPag), or 100 psig (689 kPag) to 300 psig (2.1 MPag), and temperatures ranging from 30°C to 130°C, or 65°C to 110°C. Gas phase polymerization systems can be stirred bed systems or fluidized bed systems. In some embodiments, gas phase fluidized bed processes are carried out by continuously passing a stream containing one or more olefin monomers through a fluidized bed reactor under reactive conditions and in the presence of a catalyst composition at a rate sufficient to maintain a bed of solid particles in suspension. A stream containing unreacted monomer is continuously removed from the reactor, compressed, cooled, and optionally partially or completely condensed and recycled to the reactor. Product is removed from the reactor and make-up monomer is added to the regenerator stream. Any gas inert to the catalyst composition and reactants may also be present in the gas stream as necessary for temperature control of the polymerization system.

[0089] In some embodiments, a Group VIB metal based catalyst is used. In some embodiments, the catalyst is a chromium based catalyst. Such HDPE homopolymers and / or copolymers have a viscosity of 0.940 g / cm 3 ~0.970g / cm 3 Such MDPE copolymers have some long chain branching and have a density in the range of 0.925 g / cm. 3 ~0.940g / cm 3 is in the range.

[0090] Virgin HDPE may be characterized as having the following properties: i) Density is 0.940g / cm 3 ~0.970g / cm 3 Within the range of ii) the melt index (I2, 2.16 kg, 190°C) is within the range of 1.0 g / 10 min to 100 g / 10 min, 2.0 g / 10 min to 80 g / 10 min, or 3.0 g / 10 min to 50 g / 10 min; iii) Molecular weight distribution (M w / M n ) is 15 or more, iv) The weight average molecular weight is 250,000 daltons or less, 200,000 daltons or less, 150,000 daltons or less, or 100,000 daltons or less.

[0091] The virgin MDPE may be characterized as having the following properties: i) Density is 0.925g / cm 3 ~0.940g / cm 3 Within the range of ii) the melt index (I2, 2.16 kg, 190°C) is within the range of 1.0 g / 10 min to 100 g / 10 min, 2.0 g / 10 min to 80 g / 10 min, or 3.0 g / 10 min to 50 g / 10 min; iii) Molecular weight distribution (M w / M n ) is 15 or more, iv) The weight average molecular weight is 250,000 daltons or less, 200,000 daltons or less, 150,000 daltons or less, or 100,000 daltons or less. Polyolefin Recycled Material

[0092] In some embodiments, the polyolefin recyclate feedstock is obtained from one or more HDPE, one or more MDPE, one or more LDPE, one or more LLDPE, one or more PP, or a combination thereof. The polyolefin recyclate feedstocks described above derived from HDPE, MDPE, LLDPE, LDPE, PP, or a combination thereof may be characterized by having the following properties: i) Density is 0.900g / cm 3 ~0.970g / cm 3 Within the range of ii) Melt index (I2, 2.16 kg, 190°C) is 5.0 g / 10 min or less; iii) Molecular weight distribution (M w / M n) is greater than 4.0 or greater than 5.0, iv) the weight average molecular weight is greater than or equal to 85,000 daltons, greater than or equal to 100,000 daltons, greater than or equal to 150,000 daltons, greater than or equal to 200,000 daltons, greater than or equal to 250,000 daltons, and / or less than or equal to 600,000 daltons, less than or equal to 500,000 daltons, less than or equal to 400,000 daltons, or less than or equal to 300,000 daltons; v) Melt elasticity (ER) is 0.5 or more.

[0093] In some embodiments, in addition to the properties mentioned above, the polyolefin recycle feedstock may be further characterized by having one or more of the following properties: vi) 1st VOC content; vii) First High Load Melt Index (I 21 , 21.6kg, 190℃), viii) First Melt Index Ratio (MIR, I 21 / I2), ix) the long chain branching parameter (g') is less than or equal to 1.0, 0.99, 0.98, or 0.97; x) the first total polydispersity ratio (PDR), xi) First complex viscosity ratio (η * 0.1 / η * 100 ), xii) 1st intrinsic viscosity -Processed polyolefin recycled material

[0094] The processed polyolefin reclaim is taken from the discharge of a visbreaking extruder. By "processed" it is meant that the polyolefin reclaim feedstock has been subjected to visbreaking conditions, or visbreaking conditions followed by devolatilization conditions. As noted above, the processed polyolefin reclaim may be characterized as having the following properties: i) Density: The ratio of the density of the processed polyolefin reclaim to the density of the raw polyolefin reclaim shall be greater than or equal to 1.0. ii) Melt Index: The ratio of the melt index of the processed polyolefin reclaim to the melt index of the raw polyolefin reclaim is greater than or equal to 5.0. iii) Molecular Weight Distribution: The ratio of the molecular weight distribution of the processed polyolefin reclaim to the molecular weight distribution of the raw polyolefin reclaim is not more than 0.99, not more than 0.95, and not more than 0.80. iv) Weight average molecular weight (“M w2 "): The ratio of the weight average molecular weight of the processed polyolefin recycled material to the weight average molecular weight of the raw polyolefin recycled material is 0.99 or less, 0.95 or less, 0.80 or less, or 0.70 or less; and v) Melt Elasticity (“ER”): The ratio of the ER of the processed polyolefin reclaim to the ER of the Feed Polyolefin Reclaim is less than or equal to 0.90, less than or equal to 0.70, and less than or equal to 0.50.

[0095] In some embodiments, in addition to the properties listed above, the processed polyolefin reclaim may be further characterized by having one or more of the following properties: vi) VOC Content: The ratio of the VOC content of the polyolefin recycled material to the VOC content of the processed polyolefin recycled material is less than or equal to 0.9, 0.8, 0.7, 0.6 or 0.5, either alone or in any combination with a lower limit of not less than 0.1. vii) High Load Melt Index (I 21 , 21.6 kg, 190°C): the ratio of the high-load melt index of the processed polyolefin recycled material to the high-load melt index of the raw polyolefin recycled material is 2.0 or more, 3.0 or more, 4.0 or more, or 5.0 or more. viii) Melt Index Ratio (MIR 21 / I2): The MIR of processed polyolefin recycled materials relative to the MIR of raw polyolefin recycled materials is 0.90 or less, 0.85 or less, 0.80 or less, and 0.75 or less. ix) Total Polydispersity Ratio (PDR): The ratio of PDR of processed polyolefin reclaim to PDR of Feed Polyolefin Reclaim is less than or equal to 0.90, less than or equal to 0.80, less than or equal to 0.70, or less than or equal to 0.50. x) Complex viscosity ratio (η * 0.1 / η * 100 ): The ratio of the complex viscosity ratio of the processed polyolefin recycled material to the complex viscosity ratio of the raw polyolefin recycled material is 0.70 or less, 0.60 or less, 0.50 or less, and 0.40 or less. xi) Intrinsic viscosity [η]: The ratio of the intrinsic viscosity of the processed polyolefin recycled raw material to the intrinsic viscosity of the polyolefin recycled raw material is not more than 0.90, not more than 0.80, not more than 0.70, not more than 0.50. Melt Extruder

[0096] The polyolefin blend components and optional antioxidants and / or other ingredients are fed to a third extruder or mixer where the blend is subjected to melting conditions. The melting conditions are implemented in the melting zone of the third extruder or mixer and are customized for a particular polyolefin and optional additive mixture. Sufficient temperature, pressure and shear conditions are achieved in the second extruder or mixer to provide intimate mixing of the processed polyolefin reclaim and virgin polyolefin to produce a substantially homogenous polymer blend of the processed polyolefin reclaim and virgin polyolefin. In some embodiments, the melting conditions include a temperature in the melting zone within the range of 130°C to 250°C or 150°C to 230°C. Compounding Extruder

[0097] The processed polyolefin reclaim and polyolefin blend components are fed to a second extruder or mixer where the blend is subjected to compounding conditions. The mixing conditions are performed in a mixing zone of the second extruder or mixer and are customized for a particular polyolefin and optional additive mixture. Sufficient temperature, pressure and shear conditions are achieved in the second extruder or mixer to provide an intimate mix of the processed polyolefin reclaim and virgin polyolefin to produce a substantially homogenous polymer blend of the processed polyolefin reclaim and virgin polyolefin. In some embodiments, the mixing conditions include a temperature in the mixing zone of 300°C or less, 250°C or less, or 200°C or less. In some embodiments, the temperature in the mixing zone may be in the range of 125°C to 195°C, 130°C to 180°C, or 135°C to 165°C. Blending processed polyolefin reclaim with polyolefin blend components

[0098] In some embodiments, the blends comprise 5% to 90%, 10% to 80%, 15% to 70%, 20% to 60%, or 25% to 50% by weight of processed polyolefin regrind and 10% to 95%, 20% to 90%, 30% to 85%, 40% to 80%, or 50% to 75% by weight of polyolefin blend components, respectively, all weight percentages based on the total weight of the polymer blend. In some embodiments, the virgin polyolefin is visbroken. Visbreaking of such virgin polyolefins may be thermal visbreaking and / or peroxide visbreaking. In some embodiments, such visbreaking conditions for virgin polyolefins include thermal visbreaking in the absence or substantially absence of oxygen at a temperature above the melting point of the polyolefin and at or above 300° C., or in the range of 320° C. to 400° C.

[0099] In some embodiments, the blend of processed polyolefin reclaim and polyolefin blend components, in combination with or independently of the preceding blend ratios, comprises a bimodal polymer, where the processed polyolefin reclaim product has a weight average molecular weight ("M w3 "), and the polyolefin blend component has a weight average molecular weight ("M w4 "). And M w3 / M w4 is less than or equal to 0.9, 0.8, 0.7, 0.6, 0.5, or greater than or equal to 1.1, 1.25, 1.5, 1.75, 2.0. Bimodal Blend

[0100] Polyolefins with superior performance combinations are so-called bimodal or multimodal polyolefins. These polyolefins consist of two or more components with different composition. The components of multimodal polyolefins may differ with respect to molecular weight and / or comonomer composition. Multimodal polyolefin compositions are often prepared in combination of two or more polymerization zones operated at different polymerization conditions. The two or more polymerization zones are usually arranged in a series of two or more polymerization reactors.

[0101] Multimodal polyolefins are useful in a wide range of applications. However, different applications require different combinations of polymer properties. Thus, multimodal polyolefins designed for use in different applications typically contain different components with varying molecular weights and comonomer compositions, and typically contain different amounts of different components. Also, by employing components with narrow molecular weight distributions, the overlap of different components is reduced, allowing for more precise customization of the polyolefin composition. -Compression molding

[0102] Compression molding is a high speed plastic conversion process for caps and closures, resulting in efficient processing in terms of short cycle times and low energy consumption. This results in superior performance in terms of throughput and dimensional consistency of the final product. The low conversion temperatures mean that materials are less susceptible to degradation.

[0103] Polyolefins used in injection molding processes are also commonly used in compression molding processes, including but not limited to the manufacture of bottle caps and seals. In some embodiments, compression molding polyolefins have significant shear thinning and non-proportional low flow resistance. These properties contribute to maintaining superior properties, such as, but not limited to, ESCR, in the final product produced.

[0104] Die swell is a common phenomenon in polyolefin extrusion processes where a melt stream of polymer material passes through a die. Related processes include, but are not limited to, compression molding, injection molding, and blow molding. Die swell is a phenomenon directly related to the entropy and relaxation of the polymer in the stream. The polymer melt flow stream has a constant velocity before entering the die, and the polymer chains in the stream occupy a roughly spherical conformation where entropy is maximized. Upon extrusion through the die, the cross-sectional area of ​​the die may also decrease, increasing the polymer flow rate. The polymer chains in the polymer melt flowing through the die begin to lose their spherical shape due to the increased flow rate. The polymer chains become longer, and the physical entanglements between the polymer chains are reduced to an extent that depends on the length of time of the polymer in the die. As the polymer stream exits the die, the remaining physical entanglements cause the polymer chains in the die stream to regain some of their previous shape and spherical volume in order to return to a roughly spherical conformation that maximizes entropy.

[0105] Since polymer chain disentanglement is a dynamic process, longer dies and lower flow rates result in longer disentanglement times. Commercial incentives set both a lower limit on the polymer flow rate through the die and an upper limit on the time the polymer will remain in the die. Thus, there is a need for polymers with a high degree of chain disentanglement resistance.

[0106] One of the challenges when using polymer reclaims in compression molding caps and closures is excessive die swell. Die swell causes problems during the slicing step of the extrudate and during transfer to the die. The polymer swells and becomes "mushroom-like" and difficult to transfer. This swell can be caused by the polymer reclaim flow, especially with low I2 and / or I 21 are material properties inherent to the polymer reclaim stream.

[0107] Die swell is related to polymer elasticity since polymer systems can shrink and expand. When a system of random coils of entangled polymer chains enters a capillary die under molten conditions, it undergoes contraction and partial relaxation in the capillary before partially recovering at the exit when it is no longer restrained by the capillary. The expansion upon exit from the capillary can be very strong in polyolefins such as (but not limited to) polyethylene and / or polypropylene. The effect of swell is important in some polymer processes such as, but not limited to, compression molding. Excessive swell can lead to processing problems and defects in the molded part. ISO 11443 specifies the method for the measurement of die swell using a capillary rheometer accessory.

[0108] Since polymer chain disentanglement is a dynamic process, longer dies and lower flow rates result in longer disentanglement times. Commercial incentives set both a lower limit on the polymer flow rate through the die and an upper limit on the time the polymer will remain in the die. Thus, there is a need for polymers with a high degree of chain disentanglement resistance.

[0109] In general, die swell can also be reduced by using polymers that are less susceptible to such chain entanglement, e.g., polymers with shorter average chain lengths, thereby resulting in higher I2 and / or I 21 The polymer regenerator itself contains a large amount of long chain polymers, and therefore the I2 and / or I 21High I2 and / or I 21 Virgin polymer is dry blended and / or compounded with polymer reclaim, and the low flow polyethylene is mixed with the total I2 and / or I 21 However, this approach is limited in improving overall die swell due to the continued presence of long molecular weight chains in the polymer reclaim component of the blend.

[0110] The visbroken polymer reclaim has I2 and / or I3 high enough to reduce die swell during compression molding to an acceptable level. 21 Such processed polymer reclaim can be used in a compression molding operation, either alone or in combination with one or more virgin polymers and / or one or more other processed polymer reclaims.

[0111] Visbreaking can be achieved by thermal visbreaking, peroxide visbreaking, or a combination. Using polyethylene as is or as part of a blend with virgin polyethylene is a potential solution. Controlled visbreaking targets long molecular weight chains, reduces die swell, and improves processability in compression molding of caps and closures.

[0112] In some embodiments, the processed polyolefin reclaim for compression molding has a die swell of 150% or less, 140% or less, 130% or less, 120% or less, 110% or less, or 100% or less (as measured by ASTM D3835 or ISO 11443).

[0113] In some embodiments, the processed polyolefin reclaim for compression molding has a die swell (measured by ASTM D3835 or ISO 11443) of 200% or less, 190% or less, or 180% or less. Specific Embodiments

[0114] In some embodiments, a method of processing high density polyethylene ("HDPE") reclaim and / or medium density polyethylene ("MDPE") reclaim includes providing a polyolefin reclaim feedstock, adding the polyolefin reclaim to a first extruder to produce a first polyolefin reclaim melt, and subjecting the first polyolefin reclaim melt to visbreaking conditions to produce a second polyolefin reclaim melt. The polyolefin reclaim feedstock has a first density of 0.900 g / cm. 3 ~0.970g / cm 3 The first melt index (2.16 kg, 190° C.) is 5.0 g / 10 min or less, and the first molecular weight distribution (M w / M n ) is greater than 6.0, greater than 8.0, or greater than 10, and / or less than 25, less than 20, or less than 15; w1 ") is greater than or equal to 85,000 daltons, greater than or equal to 100,000 daltons, greater than or equal to 150,000 daltons, greater than or equal to 200,000 daltons, greater than or equal to 250,000 daltons, and / or less than or equal to 600,000 daltons, less than or equal to 500,000 daltons, less than or equal to 400,000 daltons, less than or equal to 300,000 daltons, and has a first melt elasticity ("ER") of 0.5 or greater.

[0115] In the second polyolefin recycled melt, the second density has a ratio to the first density of 1 or more, the second melt index has a ratio to the first melt index of 5.0 or more, the second molecular weight distribution has a ratio to the first molecular weight distribution of 0.99 or less, 0.95 or less, or 0.80 or less, and the second weight average molecular weight ("M w2 ") is M w2 / M w1 is 0.99 or less, 0.95 or less, 0.80 or less, or 0 or less, and the second molten elastomer has a ratio to the first molten elastomer of 0.90 or less, 0.70 or less, or 0.50 or less.

[0116] In further embodiments, the method is further characterized by one or more of the following: a) Polyolefin recycled material feedstock includes post-consumer recycled waste, post-industrial recycled waste, or a combination thereof. b) Visbreaking conditions include thermal visbreaking, optionally carried out at a temperature above 300°C, or in the temperature range of 320°C to 400°C. c) the first HDPE polyolefin recycled melt is further subjected to volatilization conditions to produce a second polyolefin recycled melt, wherein the polyolefin recycled feedstock has a first volatile organic compound content, and the first HDPE polyolefin recycled melt has a second volatile organic compound content, and the ratio of the second volatile organic compound content to the first volatile organic compound content is 0.9 or less, and optionally the volatilization conditions further include: i) injection and extraction of a scavenging gas; and optionally, the scavenging gas comprises nitrogen, carbon dioxide, water or a combination thereof; ii) aeration conditions, vacuum conditions or a combination thereof; d) passing the melt of the second polyolefin reclaim material through a melt filter; e) adding an antioxidant to the first extruder; and f) the polyolefin recycled raw material has a first high-load melt index (21.6 kg, 190°C), the second polyolefin recycled melt has a second high-load melt index, and the ratio of the second high-load melt index to the first high-load melt index is 2.0 or more, 3.0 or more, 4.0 or more, or 5.0 or more; g) The polyolefin recycled material has a first melt index ratio (I 21 / I2), and the second polyolefin recycled melt has a second melt index ratio, the ratio of the second melt index ratio to the first melt index ratio being 0.90 or less, 0.85 or less, 0.80 or less, or 0.75 or less; h) a total polydispersity measurement ("PDR"), wherein the second polyolefin recycle melt has a second PDR, the ratio of the second PDR to the first PDR being 0.90 or less, 0.80 or less, 0.70 or less, or 0.50 or less; i) The polyolefin recycled material is the first complex viscosity ratio (η * 0.1 / η * 100 the second polyolefin recycled melt has a complex viscosity ratio, the ratio of the second complex viscosity ratio to the first complex viscosity ratio being 0.70 or less, 0.60 or less, 0.50 or less, or 0.40 or less; and j) The polyolefin recycled raw material has a first intrinsic viscosity [η], and the second polyolefin recycled melt has an intrinsic viscosity, and the ratio of the second intrinsic viscosity to the first intrinsic viscosity is 0.70 or less, 0.60 or less, 0.50 or less, or 0.40 or less.

[0117] In some embodiments, the method further comprises removing the second polyolefin recycled melt from the first extruder for further processing or granulation of the second polyolefin recycled melt to form a polyolefin recycled product.

[0118] In further embodiments of the above method, polyolefin reclaim and the first polyolefin blend component are added to a second extruder and mixing conditions are affected in the second extruder to form a polyolefin product consisting of a melt blended mixture of the processed polyolefin reclaim and the first polyolefin blend component. In some embodiments, such mixing conditions include a temperature of 300° C. or less. In some embodiments, the first polyolefin blend component includes virgin polyolefin, polyolefin reclaim feedstock, processed polyolefin reclaim, or combinations thereof. In further embodiments, the virgin polyolefin includes virgin LDPE, virgin LLDPE, virgin polyolefin, virgin MDPE, virgin polypropylene, or combinations thereof, and the polyolefin reclaim feedstock includes LDPE reclaim feedstock, LLDPE reclaim feedstock, polyolefin reclaim feedstock, MDPE reclaim feedstock, polypropylene reclaim feedstock, or combinations thereof. The processed polyolefin reclaim includes processed LDPE reclaim, processed LLDPE reclaim, second processed HDPE reclaim, processed MDPE reclaim, processed polypropylene reclaim, or combinations thereof. In some embodiments, the first polyolefin blend component comprises virgin polyolefin, recycled polyolefin feedstock, processed recycled polyolefin, or a combination thereof.

[0119] In further embodiments of the above method, the polyolefin recycled product is added in an amount ranging from 5 wt. % to 90 wt. %, or 20 wt. % to 60 wt. %, based on the combined weight of the polyolefin recycled product and the first polyolefin blend component, and / or the polyolefin recycled product has a third weight average molecular weight ("M w3 "), and the first polyolefin blend component has a fourth weight average molecular weight ("M w4 ") M w3 / M w3 is less than 0.8 and more than 1.25.

[0120] In further embodiments of the above process, the first polyolefin blend component is a first virgin polyolefin comprising a polymer product prepared in a first polymerization equipment, where the polymer product, in some cases, is subjected to a visbreaking process after polymerization, and in some embodiments, the visbreaking process comprises thermal visbreaking, peroxide visbreaking, or a combination thereof.

[0121] In a further embodiment of the method, the first polyolefin blend component comprises a polyolefin powder prepared in a first polymerization apparatus.

[0122] In a further embodiment of the above process, an antioxidant is added to the second extruder.

[0123] In a further embodiment of the aforementioned method, the method further comprises the steps of adding a second polyolefin blend component to a third extruder, achieving melting conditions in the third extruder to produce a second polyolefin blend component melt, and withdrawing the second polyolefin blend component melt as the first polyolefin blend component.

[0124] In a further embodiment of the above method, the second polyolefin blend component comprises virgin polyolefin, recycled polyolefin feedstock, processed recycled polyolefin, or a combination thereof.

[0125] In a further embodiment of the above process, the second polyolefin blend component undergoes a visbreaking process after polymerization, and optionally the visbreaking process comprises thermal visbreaking.

[0126] In a further embodiment of the above process, the second polyolefin blend component comprises polyethylene powder and / or polyethylene particles prepared in a second polymerization equipment.

[0127] In a further embodiment of the above process, the first and / or second polymerization apparatus respectively comprise two or more polymerization reactors and / or two or more polymerization zones within a polymerization reactor.

[0128] In further embodiments of the above process, the first and / or second polymerization apparatus each comprise two or more gas-phase fluidized bed reactors connected in series, two or more slurry-phase reactors connected in series, or a gas-phase fluidized bed reactor connected in series with a multi-zone circulating reactor.

[0129] In a further embodiment of the above process, an antioxidant is added to the third extruder.

[0130] In some embodiments, the composition comprises a polymer blend of a first polymer and a second polymer. The first polymer is a first processed polyolefin reclaim and is present in an amount ranging from 5% to 90% by weight. The second polymer is a virgin polyolefin, a polyolefin reclaim feedstock, a processed polyolefin reclaim, or a combination thereof and is present in an amount ranging from 10% to 95% by weight. All weight percentages are based on the combined weight of the first and second polymers.

[0131] In further embodiments of the composition, the virgin polyolefin comprises virgin LDPE, virgin LLDPE, virgin HDPE, virgin MDPE, virgin polypropylene, or combinations thereof, the polyolefin reclaim feedstock includes LDPE reclaim feedstock, LLDPE reclaim feedstock, HDPE reclaim feedstock, MDPE reclaim feedstock, polypropylene reclaim feedstock, or combinations thereof, and the processed polyolefin reclaim comprises processed LDPE reclaim, processed LLDPE reclaim, a second processed HDPE reclaim, a second processed MDPE reclaim, processed polypropylene reclaim, or combinations thereof.

[0132] In further embodiments of the above compositions, they are subjected to a processing step of heat visbreaking, or heat visbreaking and devolatilization. In some embodiments, the blend comprises a visbroken polyolefin comprising virgin polyolefin having a first I2 and a second I2, polyolefin reclaim feedstock, processed polyolefin reclaim, or a combination thereof;

number

[0133] The following embodiments illustrate the present invention, however, those skilled in the art will recognize many variations within the spirit of the present invention and the scope of the claims. In order to facilitate a better understanding of the present invention, the following are examples of preferred embodiments. The following embodiments should not be construed as limiting or defining the scope of the present invention. Working Example

[0134] The following examples are included to illustrate preferred embodiments of the present invention. Those skilled in the art will appreciate that the techniques disclosed in the following embodiments represent techniques that the inventors have discovered to work well in embodiments of the present invention and can be considered to constitute preferred forms of embodiments of the present invention. However, those skilled in the art will appreciate, based on this disclosure, that many changes can be made in the specific embodiments disclosed and still obtain the same or similar results without departing from the spirit and scope of the present invention.

[0135] In the following embodiments, a commercially available HDPE composition having a low melt index is used as a replacement for HDPE regrind feedstock. After processing as described herein, the visbroken low melt index HDPE is compared to higher melt index virgin HDPE, either alone or blended with other components.

[0136] How we tested

[0137] Density is measured according to ASTM D-4703 and ASTM D-1505 / ISO-1183.

[0138] Die swell is measured herein by an in-house developed test using a Goetfert Rheograph 25 capillary rheometer. The polymer melt was subjected to a temperature of 190 °C and a shear rate of 525 s -1 The extrudate is extruded through a die at 78 mm below the bottom of the die. The die swell is measured by a laser positioned 78 mm below the bottom of the die. The die orifice diameter is 1 mm, L / D is 0.25, and the entrance angle is 90°. The extrudate strand is cut 120 mm below the bottom of the die before measurement.

[0139] High Load Melt Index (I 21 '') is measured by ASTM D-1238-F (190°C / 21.6 kg).

[0140] Shear rheology measurements were performed according to ASTM 4440-95a to measure the dynamic viscoelastic properties (storage modulus G', loss modulus G", and complex viscosity (η) as a function of the oscillation frequency ω. * ) are characterized. A rotational rheometer (TA Instruments) is used for the rheological measurements. A 25 mm parallel plate fixture is used. The samples are compression molded into disks (diameter approximately 29 mm, thickness approximately 1.3 mm) using a hot press at 190 °C. Oscillatory frequency sweep experiments (from 398.1 rad / sec to 0.0251 rad / sec) are performed at 190 °C. The magnitude of the applied strain is approximately 10% and the processing clearance is set to 1 mm. Nitrogen gas flow is applied in the sample chamber to minimize thermal oxidation during the measurements.

[0141] Melt Elasticity ("ER") is determined by, as discussed by R. Shroff and H. Mavridis in Appliance Polymer Science 57 (1995) 1605. U.S. Patents 7,238,754, 6,171,993 and 5,534,472 (column 10, lines 20-30) are incorporated herein by reference. Thus, the storage modulus (G') and loss modulus (G'') are measured. Nine lowest frequency points (five per decade of frequency) are used, and a linear equation is fitted to logG' versus logG'' by least squares regression. ER is then calculated based on the following formula:

number

[0142] PDR or "total polydispersity measurement" is defined as G* by R. Shroff and H. Mavridis in Equation 27 of Applied Polymer Science 57 (1995) pp. 1605-1619. ref,1 =1.95*10 4 dyn / cm 2 and log 10 (G* ref,3 / G* ref,1 )=2. Similar procedures and equations are used to perform PDR calculations for linear and long-chain branched polyolefins.

[0143] The ratio of complex viscosities at a frequency of 0.1 rad / s (η * 0.1 / η * 100 η * 0.1 ) and the ratio of complex viscosity at a frequency of 100 rad / s η * 100 is used as an additional measure of the shear sensitivity and the rheological breadth or polydispersity of the polymer melt.

[0144] Melt index ("I2") is measured by ASTM D-1238-E (190°C / 2.16 kg).

[0145] Melt flow rate ("MFR") is measured by ASTM D-1238-L (230°C / 2.16 kg).

[0146] High temperature polymeric charcoal gel permeation chromatography ("GPC"), also known as size exclusion chromatography ("SEC"), was used to measure molecular weight distribution ("MWD") and molecular weight average (number average molecular weight M) with a filter-based infrared detector IR5, a 4-capillary differential bridge viscometer, and a Wyatt 18 angle light scattering detector. n , weight average molecular weight M w and z-average molecular weight M z ) is measured. M n , M w , M zThe , MWD, and short-chain branching (SCB) curves are reported using an infrared detector, and the long-chain branching parameter g' is determined using a combination of a viscometer and an infrared detector at 145 (°C) based on the hydrodynamic dimensions in 1,2,4-trichlorobenzene (TCB). Polymer fractionation was carried out at 145 (°C) using three Anchillen PLgel Olexis GPC columns with 300 ppm of the antioxidant butylated hydroxytoluene (BHT) as the mobile phase. 16 mg of polymer was weighed into a 10 mL vial and sealed for the GPC measurement. The dissolution step was carried out at 160 (°C) (8 mL The samples were automatically obtained in TCB) for 1 h and continuously shaken in an Ajilon autosampler. In the dissolution step, 20 L of heptane was injected into the vial as a flow rate indicator. After the dissolution step, 200 L of the solution was injected into the GPC column. The GPC column is calibrated based on 12 monodisperse polystyrene (PS) standards (provided by PSS) ranging from 578 g / mole to 3,510,000 g / mole. The comonomer composition (or SCB distribution) was reported based on different calibration distributions obtained using a relatively narrow series of polyethylenes (Polymer Carbon provides polyethylene with 1-hexene and 1-octene comonomers and internally synthesizes polyethylene with 1-butene comonomer) with known values ​​of CH3 / 1000 total carbon measured using established solution NMR techniques. The data are analyzed using GPC one software. The long chain branching parameter g' is determined by the following equation:

number

number

number

[0147] Volatile organic compounds ("VOCs") are measured by pyrolysis gas chromatography / mass spectrometry ("P-GC / MS") in parts per billion (ppb), parts per million (ppm), or micrograms per cubic meter (g / m 3 ) is measured.

[0148] The zero shear viscosity η was determined using the Sabia equation fitting of dynamic complex viscosity to radian frequency as described in "Long Chain Branching Index of Substantially Linear Polyethylenes" by Shroff & Mavridis (1999) Macromolecules, 32, 8454-8464 (particularly Appendix B), the disclosure of which is incorporated herein by reference in its entirety.

[0149] The LCBI is determined using Equation 13.

number

[0150] Long-chain branching frequency, characterized by the ratio of long-chain branches per million carbon atoms, or LCB / 106 C is determined by the method of Janzen & Colby (J. Janzen and RH Colby, "Diagnosing Long Chain Branching in Polyethylenes," Journal of Molecular Structure, Vol. 485-486, August 10, 1999, pp. 569-583) using the constants in Table 2 of the above reference. Specifically, as described elsewhere, the zero shear viscosity at 190°C, η, is determined by extrapolating complex viscosity data using the Sabia equation. * The weight average molecular weight Mw is measured by GPC. Using these two parameters and the Janzen & Colby method, the long chain branching frequency LCB / 10 6 C can be determined numerically, and three parameters (η0, M w , LCB / 10 6 C) All satisfy equation (2-3). The Janzen & Colby method calculates the zero shear viscosity η0 / η 0,線形 and a completely linear polymer with the same average molecular weight (LCB / 10 6 C = 0) is the ratio of zero shear viscosity to LCB / 10 6 It is predicted that the maximum value of C will be reached at some value of η0 / η 0,線形 For each value of LCB / 10 6 We have shown that there are two levels or values ​​of C, making this ratio possible. For this calculation, LCB / 10 6 The minimum value of C is always η0 / η 0,線形 are selected in a predetermined ratio.

[0151] raw materials

[0152] The raw materials used here are as shown in Table 1. [Table 1] *Available from LyondellBasell Industries NV ** 190℃ / 2.16kg *** 230℃ / 2.16kg Examples 1 to 9

[0153] Examples 1-9 in Table 2 show the visbreaking crushing results of LLDPE, LDPE and their blends. P1 is believed to be representative of LLDPE reclaim feedstock. P2 is believed to represent low density polyethylene reclaim feedstock. Examples 2-8 are prepared through the visbreaking section of P1, P2 and their blends. Visbreaking was carried out by feeding P1, P2 and their blends into a Werner & Pfleiderer ZSK40 twin screw extruder at a feed rate of 50 lbs / hr, screw speed of 600 rpm and a target temperature profile of 200 / 250 / 325 / 325 / 325 / 325 / 325 / 325 / 325°C (feed through die). Examples 3-7 show the I2, density, HLMI, HLMI / MI, ER, PDR, η0, η produced from visbroken blends of P1 and P1. * 0.1 , η * 100 , η * 0.1 / η * 100 , M w , M z , M w / M n , M z / M w , IV, g', and LCBI changes are shown. [Table 2] [Table 3] Table 2 (continued) [Table 4] [Table 5]

[0154] The vibration data generated based on the analysis of Examples 1-9 is shown in Table 3. The data in Table 3 show that for Examples 1-9, the complex viscosity decreases with increasing frequency. Table 3 further shows that the visbroken blends of LLDPE and LDPE in Examples 2-8 exhibited low complex viscosities, η, for all test frequency values. * This shows that. Table 3 [Table 6] [Table 7] [Table 8] Table 3 (continued) [Table 9] [Table 10] [Table 11] [Table 12] Examples 10 to 17

[0155] Examples 10-17 in Table 4 show the results of visbreaking HDPE, PP, and their blends. P3 is considered to be a superior HDPE reclaim feedstock. P4 is considered to be equivalent to polypropylene reclaim feedstock. Examples 11-15 are prepared through the visbreaking section of P3, P4, and their blends. Visbreaking was carried out by feeding P3, P4, and their blends into a Werner & Pfleiderer ZSK40 twin screw extruder at a feed rate of 50 lbs / hr, screw speed of 600 rpm, and a target temperature profile of 200 / 250 / 325 / 325 / 325 / 325 / 325 / 325 / 325°C (feed inlet to die). Examples 12-14 show the I2, MFR, ER, PDR, η0@200°C, η0@190°C ... * 0.1, η * 100, η * 0.1 / η * 100, changes in Mw, Mz, Mw / Mn, Mz / Mw, IV, g', and LCBI are shown. Table 4 [Table 13] [Table 14] Table 4 (continued) [Table 15] [Table 16]

[0156] Dynamic vibration data generated based on the analysis of Examples 11-16 is shown below in Table 5. The data in Table 5 show that the complex viscosity decreases as frequency increases for Examples 11-16. Table 3 further shows that the visbroken blends of HDPE and PP in Examples 12-14 had lower complex viscosities (η * ) is shown. Table 5 [Table 17] [Table 18] Table 5 (continued) [Table 19] [Table 20]

[0157] Figure 7 is a comparison of the molecular weight curves generated for Examples 4 and 5. The overlaid graphs show both the molecular weight reduction and narrowing of the molecular weight distribution achieved by visbreaking. Examples 18 to 25

[0158] Examples 18-25 in Table 6 show the results of visbreaking HDPE, PP, and their blends. P3 is considered to be a good HDPE reclaim feedstock. P5 is considered a reasonable representative of PP reclaim feedstock. Examples 19-23 are prepared through the visbreaking section of P3, P5, and their blends. Visbreaking was carried out by feeding P3, P5, and their blends into a Werner & Pfleiderer ZSK40 twin screw extruder at a feed rate of 50 lbs / hr, screw speed of 600 rpm, and a target temperature profile of 200 / 250 / 325 / 325 / 325 / 325 / 325 / 325 / 325°C (feed inlet to die). Examples 20-22 show the I2, MFR, ER, PDR, η0@200°C, η0@190°C, η * 0.1 , η * 100 , η * 0.1 / η * 100 , M w , M z , M w / M n , Mz / M w , IV, g' and LCBI changes are shown. Table 6 [Table 21] [Table 22] Table 6 (continued) [Table 23] [Table 24]

[0159] Dynamic vibration data generated based on the analysis of Examples 19-24 is shown below in Table 7. The data in Table 7 show that for Examples 11-16, the complex viscosity decreases as the frequency increases. Table 3 further shows that the visbroken blends of HDPE and PP for Examples 20-22 had lower complex viscosities (η * ) is shown. Table 7 [Table 25] [Table 26] Table 7 (continued) [Table 27] [Table 28]

[0160] For the sake of brevity, only certain ranges are expressly disclosed herein. However, in addition to the ranges described, any lower limit can be combined with any upper limit to describe a range not expressly described, and a range from any lower limit can be combined with any other lower limit to describe a range not expressly described. Similarly, any upper limit range can be combined with any other upper limit to describe a range not expressly described. Also, the range includes each point or individual value between the endpoints, even if not expressly recited. Thus, every point or individual value may function as its own lower or upper limit in combination with any other point or individual value or other lower or upper limit to describe a range not expressly described.

[0161] Although the present invention and its advantages have been described in detail, it should be understood that various changes, substitutions, and alterations can be made herein without departing from the spirit and scope of the present invention as defined by the appended claims. Moreover, the scope of the present specification is not intended to be limited to the specific embodiments of the processes, machines, film structures, layer compositions, apparatus, methods, and / or steps described herein. As one skilled in the art can readily appreciate from the present disclosure, any currently existing or hereafter developed processes, machines, film structures, layer compositions, means, methods, and / or steps that function substantially the same as the corresponding embodiments described herein or achieve substantially the same results can be utilized in accordance with the present invention. Thus, the claims are intended to include these processes, machines, film structures, layer compositions, apparatus, methods, and / or steps.

Claims

1. A method for processing polyolefin recycled material, comprising the steps of: a. providing a polyolefin feedstock, said polyolefin feedstock comprising: i) 0.900g / cm ３ ~0.970g / cm ３ The first density in the range ii) a first melt index (I) of 5.0 g / 10 min or less; ２ ), iii) a first molecular weight distribution (M ｗ / M ｎ ), iv) a first weight average molecular weight ("M") of 85,000 daltons or more; ｗ１ " ), and v) having a first melt elasticity ("ER") of 0.5 or greater; b. adding the polyolefin recycle to a first extruder to produce a first polyolefin recycle melt; c. subjecting the first polyolefin recycle melt to visbreaking conditions to produce a second polyolefin melt, the second polyolefin melt comprising: i) a second density having a ratio to the first density of 1.0 or greater; ii) a second melt index (I) having a ratio to the first melt index of 5.0 or greater; ２ ), iii) a second molecular weight distribution having a ratio to the first molecular weight distribution of 0.99 or less; iv) M ｗ２ / M ｗ１ A second weight average molecular weight ("M ｗ２ " ), and v) having a second melt elasticity having a ratio to said first melt elasticity of 0.90 or less.

2. 10. The method of claim 1, wherein the polyolefin feedstock comprises post-consumer recycled waste, post-industrial recycled waste, or a combination thereof.

3. The method of claim 1 , wherein the visbreaking conditions include thermal visbreaking.

4. 4. The method of claim 3, wherein the thermal visbreaking is carried out at a temperature of 300° C. or greater.

5. The method further comprises the step of subjecting the first polyolefin melt to devolatilization conditions to produce a second polyolefin recycled melt; The polyolefin regenerator feedstock has a first volatile organic compound content, the first polyolefin recycle melt has a second volatile organic compound content; 2. The method of claim 1, wherein the ratio of the content of the second volatile organic compound to the content of the first volatile organic compound is 0.9 or less.

6. The method of claim 5 , wherein the devolatilization conditions include injection and extraction of a sweep gas.

7. i) The polyolefin recycled material has a first high load melt index (i ２１ the second polyolefin recycled melt has a second high load melt index, and the ratio of the second high load melt index to the first high load melt index is 2.0 or greater; ii) The polyolefin recycled material has a first melt index ratio (I ２１ / I ２ the second polyolefin reclaim melt has a second melt index ratio, the ratio of the second melt index ratio to the first melt index ratio being within a range of 0.30 to 0.60; (iii) the polyolefin recycled feedstock has a first long chain branching parameter (g') and the second polyolefin recycled melt has a second g', the ratio of the second g' to the first g' being less than 1.0, and / or the first g' being within the range of 0.70 to 0.99; iv) the polyolefin recycled feedstock has a first long chain branching index ("LCBI") greater than or equal to 0.60, and the second polyolefin recycled melt has a second LCBI, the ratio of the second LCBI to the first LCBI being less than or equal to 0.40; v) the polyolefin recycled feedstock has a first total polydispersity measurement ("PDR") and the second polyolefin recycled melt has a second PDR, the ratio of the second PDR to the first PDR being less than or equal to 0.50; vi) the polyolefin recycled feedstock has a first complex viscosity ratio and the second polyolefin recycled melt has a second complex viscosity ratio, the ratio of the second complex viscosity ratio to the first complex viscosity ratio being 0.50 or less and / or 10 or less; vii) the polyolefin recycle feedstock has a first intrinsic viscosity and the second polyolefin recycle melt has a second intrinsic viscosity, the ratio of the second intrinsic viscosity to the first intrinsic viscosity being less than or equal to 0.

90.

8. 10. The method of claim 1, wherein the second polyolefin recycled melt is removed from the first extruder and the second polyolefin recycled melt is further processed or granulated to form a polyolefin recycled product.

9. adding the polyolefin recycle product and the first polyolefin blend component to a second extruder; 10. The method of claim 8, further comprising: achieving compounding conditions in the second extruder to form a polyolefin product comprising a melt blended mixture of the processed polyolefin reclaim product and the first polyolefin blend component.

10. 10. The method of claim 9, wherein the first polyolefin blend component comprises virgin polyolefin, recycled polyolefin feedstock, processed recycled polyolefin, or a combination thereof.

11. a. the virgin polyolefin comprises virgin LDPE, virgin LLDPE, virgin HDPE, virgin MDPE, virgin polypropylene, or combinations thereof; b. the polyolefin recycle feedstock comprises LDPE recycle feedstock, LLDPE recycle feedstock, HDPE recycle feedstock, MDPE recycle feedstock, polypropylene recycle feedstock, or a combination thereof; c) The composition of claim 10, wherein the processed polyolefin reclaim comprises a second processed LDPE reclaim, a second processed LLDPE reclaim, a second processed HDPE reclaim, a second processed MDPE reclaim, a second processed polypropylene reclaim, or a combination thereof.

12. 12. The method of claim 11, wherein the first polyolefin blend component comprises virgin polyolefin, recycled polyolefin feedstock, processed recycled polyolefin, or a combination thereof.

13. 10. The method of claim 9, wherein the polyolefin recycle product is added in an amount ranging from 5% to 90% by weight based on the combined weight of the polyolefin recycle and the first polyolefin blend component.

14. 10. The method of claim 9, wherein the compounding conditions include a temperature of less than or equal to 300°C.

15. adding the second polyolefin blend component to a third extruder; achieving melt conditions in said third extruder to produce said second polyolefin blend component melt; 10. The method of claim 9, further comprising the step of: withdrawing said second polyolefin blend component melt as said first polyolefin blend component.

16. 16. The method of claim 15, wherein the second blend component comprises virgin polyolefin, recycled polyolefin feedstock, processed recycled polyolefin, or a combination thereof.

17. 1. A composition comprising a polymer blend, the polymer blend comprising: a. a first polymer and b. a second polymer; The first polymer is i) a first processed polyolefin regrind; ii) is present in an amount ranging from 5% to 90% by weight; Also, The second polymer is i) virgin polyolefin, raw polyolefin reclaim, processed polyolefin reclaim, or a combination thereof; ii) is present in an amount ranging from 10% to 95% by weight; All weight percentages are based on the combined weight of said first and second polymers.

18. a. the virgin polyolefin comprises virgin LDPE, virgin LLDPE, virgin HDPE, virgin MDPE, virgin polypropylene, or a combination thereof; b. the polyolefin recycle feedstock comprises LDPE recycle feedstock, LLDPE recycle feedstock, HDPE recycle feedstock, MDPE recycle feedstock, polypropylene recycle feedstock, or a combination thereof; c) The composition of claim 17, wherein the processed polyolefin reclaim comprises processed LDPE reclaim, processed LLDPE reclaim, processed HDPE reclaim, processed MDPE reclaim, processed polypropylene reclaim, or combinations thereof.

19. 20. The composition of claim 17, wherein said processed means that it has been subjected to thermal visbreaking and optionally devolatilization.

20. No. 1 I ２ and a bisbroken polyolefin having the formula: Part II ２ and a virgin polyolefin, a polyolefin regrind feedstock, a processed polyolefin regrind, or a combination thereof, comprising: [0010] Where: (I ２ ) ブレンド is the target melt index of the final blend. n is the number of components in the mixture. Blend i is the i-th component of an n-component blend.

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