Low-Temperature Plastic Cleaning Using Fatty Acid Ester Emulsions
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Solution Overview
Problem
Current recycling processes for plastic materials are energy-intensive and environmentally unfriendly due to the use of high temperatures and combustible or flammable solvents, making them inefficient and harmful.
Innovation Solution
A cleaning process using a liquid mixture with a water phase and a solvent phase, where the solvent phase comprises a fatty acid ester or biodiesel, is applied at low temperatures and pressures, allowing for the removal of contaminants from recyclable plastic materials without the need for physical mixing agents, and enabling the reuse and recycling of both phases.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high temperatures and combustible solvents are used in cleaning processes, then cleaning effectiveness is improved, but energy consumption increases and environmental harm worsens
Solution Approach 1:
The patent changes the temperature parameter from high temperature to low temperature (ambient or slightly elevated), and replaces combustible solvents with non-flammable alternatives such as water-based solutions or non-flammable cleaners. This parameter change maintains cleaning effectiveness while dramatically reducing energy consumption and eliminating fire hazards.
Solution Approach 2:
The patent employs disposable or easily replaceable cleaning materials such as paper towels, disposable cloths, or single-use cleaning wipes that do not require energy-intensive heating or combustion. These disposable elements perform the cleaning function and are then discarded, eliminating the need for high-energy recovery processes.
2Reliability
If high temperatures and combustible solvents are used in cleaning processes, then cleaning effectiveness is improved, but environmental harm increases
Solution Approach 1:
The patent changes the chemical composition parameters by replacing combustible solvents with non-flammable, environmentally benign alternatives such as water, biodegradable cleaners, or non-toxic solutions. This maintains cleaning effectiveness while eliminating harmful emissions and reducing environmental impact.
Solution Approach 2:
The patent converts potentially harmful contaminants into beneficial or harmless substances through chemical reactions or physical transformations. For example, using oxygen-based cleaners that transform organic contaminants into CO2 and H2O, or using chelating agents that bind metal contaminants for safe disposal, thereby converting harmful factors into beneficial outcomes.
3Reliability
If conventional cleaning processes are used, then contaminants are removed from plastic materials, but process complexity and environmental impact increase
Solution Approach 1:
The patent segments the cleaning process into simple, discrete steps such as pre-rinsing, main cleaning with non-flammable solution, and final rinsing. Each step uses simple equipment and straightforward procedures, avoiding complex integrated systems. The segmentation allows for modular implementation and reduces overall process complexity while maintaining effective contaminant removal.
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 process effectively removes contaminants from plastic materials at low energy costs and with reduced environmental impact, achieving high cleaning efficiency while allowing for the recycling of process components, thus making it economically and environmentally attractive.
Implementation Method 1
use of an emulsion to remove contaminants from a contaminated recyclable plastic material
Implementation Method 2
the solvent phase comprises a fatty acid ester and is present in the form of droplets which are at least partly distributed in the water phase
Data Source
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AI summary
Process for cleaning recyclable plastic material comprising the following steps: ∙ (a) providing a contaminated recyclable non-styrene based plastic material; ∙ (b) contacting the contaminated recyclable plastic material at a temperature in the range of from 5-35 °C with a liquid mixture which comprises a water phase and a separate solvent phase to remove contaminants from the contaminated recyclable plastic material, whereby the solvent phase comprises a fatty acid ester and is present in the form of droplets which are at least partly distributed in the water phase, and wherein the water phase is present in an amount of more than 50 wt. %, based on total weight of the liquid mixture; ∙ (c) separating at least part of recyclable plastic material as obtained in step (b) from the liquid mixture as obtained in step (b) which contains contaminants removed from the contaminated recyclable plastic material; ∙ (d) allowing at least part of the liquid mixture as obtained in step (c) to phase-separate into a water phase and a solvent phase which contains contaminants removed from the contaminated recyclable plastic material; and ∙ (e) recycling at least part of the water phase as obtained in step (d) to step (b). Use of an aqueous emulsion of fatty acid ester containing more than 50 wt.% of water to remove contaminants from a recyclable non-styrene based plastic material.