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Materials and Energy Recovery from E-Waste Plastics Sriraam Ramanathan Chandrasekaran, Sumant M Avasarala, Dheeptha Murali, Nandakishore Rajagopalan, and Brajendra K. Sharma ACS Sustainable Chem. Eng., Just Accepted Manuscript • DOI: 10.1021/ acssuschemeng.7b03282 • Publication Date (Web): 22 Feb 2018 Downloaded from http://pubs.acs.org on February 22, 2018

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ACS Sustainable Chemistry & Engineering

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Materials and Energy Recovery from E-Waste Plastics

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Sriraam R Chandrasekaran1*, Sumant Avasarala2, Dheeptha Murali1, Nandakishore Rajagopalan1, Brajendra K. Sharma1,*

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Prairie Research Institute-Illinois Sustainable Technology Center, University of Illinois Urbana Champaign, 1 East Hazelwood Drive, Champaign, IL 61820-7465 2

Department of Civil and Environmental Engineering, 1 University of New Mexico, Albuquerque, NM 87131

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* Corresponding email address: [email protected], [email protected]

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Telephone: (001) (217) 300-1477, (001) (217) 265-6810

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Fax: (001) (217) 333-8944

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1 ACS Paragon Plus Environment

ACS Sustainable Chemistry & Engineering 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60

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Abstract

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The objective of the current study was to investigate environmentally sustainable and energy

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efficient processes to recover value added material and energy from e-waste as a means to divert

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these non-degradable materials from landfills. We studied two different types of plastics (1)

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simple mixtures like polyamide/polycarbonate (PC/PA)) found in cell phone plastics for solvent

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extraction and (2) complex mixtures like PC/PA/ Acrylonitrile butadiene styrene (ABS)/ Poly-

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methyl methacrylate (PMMA) found in many other e-waste streams for pyrolysis. Solvent

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extraction using N- Methyl 2- pyrrolidone (NMP) was performed as an alternate to

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dichloromethane (DCM) for selective dissolution and recovery of PC from simple mixtures of

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cell phone plastic (CPP) to avoid the use of chlorinated compounds. Using distillation a recovery

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of 89% and 87% pure PC was observed for NMP and DCM, respectively. Relatively close to the

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first run, the recycled NMP also recovered 87% of pure PC. However, in order to reduce energy

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consumption in the NMP solvent recovery step a non-solvent approach using methanol

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precipitation was demonstrated as an alternate route. Energy consumption through methanol

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distillation (343.3 kJ kg-1) was significantly lower than that of NMP (413.2 kJ kg-1). For other e-

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waste plastic mixtures like PC/PA/ABS/PMMA, pyrolysis approach was demonstrated for waste

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reduction to 57% potentially decomposable solid residue, while generating pyrolysis oil.

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The results obtained in this work contribute to the development of a commercial and sustainable

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process to recycle e-waste plastics effectively. The development of these effective recycling practices

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helps to reduce the prevailing e-waste plastics related environmental pollution.

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Keywords: Polycarbonate, polyamide, solvent dissolution, phase diagram, pyrolysis


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Introduction

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About 280 million tons of polymers are produced globally of which 20 to 50 million tons

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become e-waste, comprising more than 5% of all municipal solid waste.1, 2 In the United States,

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about 39.3 million tons of plastic waste were produced from which 3.4 million tons were e-waste

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in 2012.2, 3 E-waste includes hard disk drives (HDD), liquid crystal displays (LCD), light

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emitting diodes (LED), printed circuit boards (PCB), photovoltaics (PV) and about a third of the

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weight of polymeric materials are from items such as refrigerators, televisions, computers,

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monitors, mobile phones, and video game consoles.4-6 Only one million tons (29.2 %) of the e-

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waste was recycled and mostly included glass, valuable metals (steel, gold, copper, etc.), and

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highly toxic metals, such as cadmium,7-9 while the remaining materials were sent to landfills or

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incinerated.2 Waste plastics are an untapped source for recovering valuable polymers, such as

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PCs among many others with demand being approximately 3.4 million metric tons in 2010 and

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are expected to grow at a six percent rate annually.10 It is estimated that up to 2.5 million tons of

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PCs can potentially be recovered from e-waste each year.9 PCs are thermoplastic polymers

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containing carbonate groups that have high resistance to chemicals, high temperatures, and

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mechanical impact. They are widely used in electronic devices, construction materials, data

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storage devices, automobiles, airplanes, medical devices, and many other applications. They are

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more expensive than other polymers commonly found in waste and their bulk cost ranges from

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$2.50 to $5.00 per kilogram.9

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Previous studies to recover the polymer material or energy from e-waste include alcoholysis,

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hydrolysis, and solvent dissolution.9-12 Liu et al. demonstrated recovery of monomers such as

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Bisphenol A (BPA) through methanolysis of PC in presence of ionic liquids. Oku et al.

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demonstrated the recovery of monomers through alkali catalyzed methanolysis. Through



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laboratory experiments, Achilias et al. and Weeden et al. demonstrated about 99% recovery of

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PC from e-waste using dichloromethane (DCM). Weeden et al.9 also demonstrated sequential

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extraction for polymer recovery using multiple solvents for a mixture of plastics. Recycling of

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plastic waste for substitution of virgin plastic is the preferred option in the context of reducing

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greenhouse gases (GHG). However for complex plastic mixtures (contamination), energy

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recovery may be a better option than polymer recovery. A commonly used process for energy

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recovery from waste plastic is pyrolysis, which is a thermochemical conversion process and an

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alternative route to divert wastes from landfills. Hall et al. studied the pyrolysis process for

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producing oil from e-waste plastics with relatively low halogen content and better fuel

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properties.13 Chiu et al. studied the thermal degradation of PC using metal chlorides.14 Yoshioka

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et al. studied chemical recycling of polycarbonate to raw materials by thermal decomposition

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with calcium hydroxide/steam.15 Furthermore, the energy requirement for pyrolysis is about

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1kWh kg-1 of plastic. Thus, pyrolysis was utilized as an alternative to solvent extraction for

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mixed e-waste plastics to recover energy.

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Earlier solvent dissolution methods involved DCM use which is a highly toxic volatile solvent at

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room temperature and are known carcinogens.16 The current study focused on recovery of PC

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from simple mixtures such as PC/PA found in the cell phone plastic through solvent dissolution

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approach using a commonly used industrial solvent N-Methyl-2-Pyrrolidone (NMP) as a

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substitute for DCM. NMP is a suggested alternative chemical to chlorinated solvent DCM in

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Fisher Science Educational material.17 Literature comparison between DCM and NMP suggests

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that NMP is a viable substitute to DCM because it is cheap, efficient, and less toxic.17-20 NMP

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has a high boiling point around 202 - 204oC and due to its low vapor pressure, it is less

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susceptible to volatilization.21, 22 The volatilized inhalable concentrations of NMP is significantly


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low at low temperature22, 23 (

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350°C) followed by diesel#1 like fraction (185-290°C) and motor gasoline like fraction (35°C-

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185°C) were dominant in the oil from E-Waste. In pyrolysis oil from PC/PA, the dominant

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fraction was in the range motor gasoline followed by vacuum gas oil and diesel#1 (Table 5).

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Environmental Implications

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More than 280 million tons of polymers are produced globally each year, with 10% of them

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being recycled. Most monomers used in polymer synthesis are petroleum-based, therefore

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recycling them would curb excessive production of polymers and our dependence on petroleum

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sources. The key to efficient recycling is through effective separation of plastics by their

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properties. For instance, in this study we identified solvent dissolution using NMP for simple

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PC/PA mixtures as an effective technique to recycle PC from waste electronics (cell phone

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cases). N-methyl pyridine (NMP) was found to be a viable substitute for chlorinated solvents like



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DCM because it is cheap, efficient, and less toxic under the required experimental conditions.

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The information gathered in the study will be beneficial to e-waste recycling centers and as well

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to materials recycling facility (MRF) that handles various types of plastic and mixtures.

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Recyclers are not interested in treating small products (cell phones and its related gadgets,

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keyboards and other small devices) due to lack of volumes and specific processes are not yet

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available at industrial level. The study also identified pyrolysis as another economical approach

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to recover energy and convert complex PC/PA/ABS/PMMA mixtures (that commonly appear in

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e-waste plastics) into 40% reduced waste for sending to landfill. Impact analysis of carbon-

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dioxide from home electrical appliances suggest that material recycling of plastics is a best

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option for recycling in terms of reducing greenhouse gas (GHG) emission. However, further

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research is needed to see if NMP or any other green solvents can be used for other simple

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polymer matrices.

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Acknowledgements

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The authors thank HOBI International, Inc. for their financial support and for providing cell

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phone plastic materials and Hazardous Waste Research Funds of ISTC for financial support. The

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authors thank the Materials Research Laboratory facilities for access to the TGA instrument. The

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authors also thank John Scott for conducting GC analysis on solvents and Hyunjin Lee and Joe

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Yin for their assistance in conducting experiments.

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Supplemental Information

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Additional information include impurities found in NMP solvent, estimation of energy

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requirement for pyrolysis process; FTIR spectra of the analyzed cell phone plastic; pyrograms 18 ACS Paragon Plus Environment

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comparing pure polycarbonate and recovered polycarbonate; chromatograms of impurities; GPC

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chromatograms of recovered polycarbonate; FTIR spectra and pyrograms of separated

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dye/impurities.

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Table 1. TGA results on PC/PA and e-waste mixtures Temp Temp Peak 1% 5% Char Char Temp Sample mass mass weight% weight% dTGA loss loss 600°C 700°C (°C) (°C) (°C) E-Waste mixture 156 372 390 56.3 56.1 Cell Phone Plastic (PC/PA) 341 417 475 35.1 34 E-Waste mixture residue 655 NA NA 99.3 98.9 Cell Phone Plastic Residue (PC/PA) 608 NA 663 99.1 97 The values presented here are average from duplicate runs NA- Not applicable


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Table 2. Polymer and solvent recovery from solvent dissolution

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Solvents

DCM

NMP

Quantity (g) 1 50 100* 1 50 100*

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Recovery (%) Polycarbonate 97±1.3 88±6.6 87 96±1.9 93±2.3

Polyamide 99±0.5 99±0.2 99 99±0.1 100

89 98 * represents average of 2 runs

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Solvent 94±2.1 91±7.2 90 92±3.4 95±3.1 89


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Table 3. Polymer and solvent purity

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Polycarbonate Polymer type Tg (Deg C) PC (Literature) 145 Pure PC 139 Fresh Solvent 146 Reuse (First run)* 134 Reuse (Second run)* 149 Fresh Solvent 149 Reuse (First run)* 140 Reuse (Second run)* 147 na- not analyzed

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* make up solvent was added

Solvents

DCM

NMP

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Solvent %Purity na na na 89 80 79

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Table 4. Energy requirements for solvent recovery Properties Mass (m) Boiling point (Tb) Room temperature (Tr) Molecular Weight Specific Heat (Cp) Reflux (assumed 20%) Latent Heat of Vaporization (∆Hv) Heat to Boiling point (mCp∆T) Heat to evaporate reflux (m∆Hv) Total Energy Required

Units kg o C o C g mol-1 J g-1 oC-1 % kJ mol-1 kJ kg-1 kJ kg-1 kJ kg-1

DCM 1 39.6 20 84.9 1 20 28.8 19.6 67.9 87.5

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NMP 1 204.3 20 99.1 1.7 20 49.5 313.3 99.9 413.2

Methanol 1 65 20 32.6 2.53 20 37.4 113.9 229.4 343.3


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Table 5. Yield and chemical composition of pyrolysis oil from pyrolysis of PC/PA and e-waste mixtures

Yield (%)

Elemental Analysis (%) GPC analysis Simulated Distillation (%)

Pyrolysis Oil Solid Residue Gases Carbon Hydrogen Nitrogen Oxygen Mw Motor Gasoline range fraction #1 Diesel range fraction #2 Diesel range fraction Vacuum Gas Oil range fraction

Cell Phone Plastic (PC/PA) 40.1 46.7 13.3 69.3 6.6 1.6 22.5 245 39 23 8 30

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E-Waste (PC/PA/ABS/PMMA mixture) 33.3 56.5 10.2 76 9 6.8 8.2 295 23 28 13 33

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Table 6. Chemical composition of pyrolysis oil from pyrolysis of PC/PA using GC-MS Component Phenol 4-Methyl Phenol 2-Methylphenol 4-Methylphenol 4-Ethylphenol 2-(1-methylethyl)-phenol, Methyl carbamate 1-(2,3-Dimethyl-phenyl)-3-methyl-butylamine 4-(1-methyl-1-phenylethyl)-phenol 3,5-Diethyl-2-phenylpyridine 4-(1-methyl-1-phenylethyl)-phenol

Area % 6.97 24.01 1.34 11.00 8.46 15.81 11.25 1.55 2.07 1.96

Total Area

84.41

Minor Peaks with Area less than 1% Percentage

15.59

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Table 7. Chemical composition of pyrolysis oil from pyrolysis of PC/PA/ABS/PMMA mixtures using GC-MS Component p or o-Xylene 1-Ethyl-4-methylbenzene .alpha.-Methylstyrene Cyclopropylbenzene 1-Phenyl-1-butene 1-Methyl-3-propylbenzene 1-Isocyano-2-methylbenzene (2-Methyl-1-propenyl)-benzene 1,2,3,4-Tetrahydro-5-methylnaphthalene Z-10-Pentadecen-1-ol 2,4,6-Trimethylphenol 3-Methylbenzyl Cyanide 2,6-Diphenyl-3-methylheptane 2,4-Difluorophenylhydrazine 1,2-Dihydro-6-methylnaphthalene 3-Methyl-2-(O-methyl benzyl)butanenitrile 4-Chloro-3-n-hexyltetrahydropyran 6,7-Dimethyl-1-naphthol 1,1'-(1-methyl-1,2-ethanediyl)bisbenzene 1,1'-Methylenebis[4-methyl]-benzene 1,1'-(1,3-propanediyl)bisbenzene 1-(4-methylphenyl)-pyrazol-3-amine .beta.-Phenylpropiophenone 1,1'-(1,2-dimethyl-1,2-ethenediyl)bis-(E)benzene

Area % 11.87 1.54 1.43 0.64 0.35 0.40 2.89 0.65 0.53 0.60 0.32 0.66 0.46 1.04 0.58 0.40 0.39 0.39 0.30 0.55 0.78 0.69 2.53

Total Area Minor Peaks Percentage=

30.77 69.23

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0.76

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Figure 1. Schematics of Flow Process

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Figure 2. FTIR spectra of PPC and CPPC recovered using DCM and NMP dissolution

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Figure 3. Solubility curves of CPPC and PPC in (a) DCM and (b) NMP

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Figure 4. Phase diagram representing solvent, non-solvent and polymer phases in wt%

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TOC Art

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Synopsis: The schematics represents the two pathways to recover material and or energy from waste plastic mixtures.


Materials and Energy Recovery from E-Waste ... - ACS Publications

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