Multilayer Packaging Recycling Separation Fluid
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Solution Overview
Problem
Current methods for recycling laminates in food packaging, such as those containing aluminum and plastic, face challenges including high energy consumption, safety risks, and environmental hazards due to the use of aggressive chemicals like acetic acid, which also result in aluminum loss and volatility issues.
Innovation Solution
A separation fluid comprising a mixture of water, short-chain carboxylic acids, phosphoric acid, and alkali metal hydroxides is used to separate metal and polymer layers in multilayer materials, minimizing environmental harm and safety risks by reducing volatility and avoiding high temperatures, with the fluid being recycled and reused.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high concentration acetic acid (80%) is used for separation at high temperature (80°C), then the separation effectiveness is improved, but energy consumption increases and safety risks arise due to volatility
Solution Approach 1:
The patent changes the chemical composition parameters of the separation fluid by adding phosphoric acid and alkali metal hydroxides to the carboxylic acid system. This chemical parameter modification allows the fluid to maintain effective separation performance while operating at lower temperatures, thereby reducing energy consumption and volatility-related safety risks
2Reliability
If high concentration acetic acid (80%) is used for separation, then the separation effectiveness is improved, but aluminum loss increases due to aggressive attack on aluminum components
Solution Approach 1:
The patent introduces phosphoric acid and alkali metal hydroxides as intermediary substances that modify the chemical environment. The phosphoric acid forms protective phosphate layers on aluminum surfaces, acting as a mediator that prevents direct aggressive attack by carboxylic acid while maintaining separation effectiveness
Solution Approach 2:
By modifying the chemical composition parameters - adding phosphoric acid and alkali metal hydroxides - the patent creates a balanced chemical environment that maintains separation effectiveness while reducing the aggressive nature of the fluid toward aluminum components
3Productivity
If the separation fluid is highly volatile to enable fast processing, then processing speed is improved, but environmental harm and safety risks increase
Solution Approach 1:
The patent modifies the volatility parameter of the separation fluid by selecting carboxylic acids with appropriate boiling points and adding phosphoric acid with high boiling point. This parameter change allows the fluid to maintain adequate processing speed while significantly reducing volatility-related environmental harm and safety risks
Solution Approach 2:
The patent creates a composite separation fluid system combining carboxylic acid, phosphoric acid, and alkali metal hydroxides. This composite formulation balances volatility for processing speed with environmental safety by leveraging the complementary properties of each component
4Reliability
If aggressive chemicals are used for separation, then the separation effectiveness is improved, but environmental friendliness deteriorates
Solution Approach 1:
The patent changes the chemical aggressiveness parameters by modifying the composition ratio and adding phosphoric acid with lower environmental toxicity. This allows maintaining separation effectiveness while reducing environmental harm through less aggressive but equally effective chemical action
Solution Approach 2:
The patent employs a separation fluid system that can be easily neutralized and disposed of with reduced environmental impact. The use of phosphoric acid and alkali metal hydroxides enables controlled neutralization, making the process more environmentally friendly compared to persistent aggressive chemicals
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method effectively recovers metal and polymer components with minimal aluminum loss and safety risks, enabling efficient recycling of packaging materials while being more environmentally friendly and energy-efficient compared to existing techniques.
Implementation Method 1
The separation fluid comprises a mixture of water, short-chain carboxylic acid, phosphoric acid and alkali metal hydroxide. The short-chain carboxylic acid and the phosphoric acid react partially with the alkali metal hydroxide to produce alkali metal phosphates and alkali metal carboxylates.
Data Source
AI summary
A method for recycling of packaging material is disclosed. The packaging material comprises a multilayer material (10) comprising a metal layer (30) and at least one polymer layer (20, 40). The method comprises placing the packaging material in a vat (310) comprising a separation fluid (330) to produce a mixture of metal shreds from the metal layer (30), plastic shreds from the polymer layer (20, 40) and residual components. The separation fluid comprises a mixture comprising a mixture of water, a short-chained carboxylic acid, phosphoric acid and an alkali metal hydroxide solution.