Mechanical

Recycling
Solutions

Internal
 Color of plastic materials
makes recycling more
difficult

Main Smell present in

recycled materials

challenges Properties downgrade due to

of the thermic and mechanical
degradation
recycling Cross polymer contamination
– resins mixture
of plastics
Access to quality residues

Internal
Internal
General Plastic Recycling Process
& BASF Solutions

01 Sorting 02 Washing 03 Extrusion 04 Conversion

Product
Extrusion Pelletizing conversion
trinamiX® Gardoclean®
Mobile NIR Spectroscopy Gardobond® & Additive Blends Additives contributing to
Solutions Soluprat® for stability and durability ready-to-recycle end products

Internal
General Plastic Recycling Process
& BASF Solutions

03 Plastic
Extrusion Additives
Solutions

Extrusion Pelletizing

Internal
 03
Phenolic antioxidants Radical scavengers Extrusion
and hindered amines capture carbon-
react with free radicals to yield centered radicals
inactive products

Polymer
Light, shear, melt
processing, catalyst O2
residues

R•
RO• ROO•
HO•
ROOH

How stabilizers Polymer

can tackle the quality

challenge: auto-oxidation R•
Phosphites
and degradation chemistry react with hydroperoxides Phenolic antioxidants
to yield inactive products react with oxygen-centered radicals

6 07.07.2022 | Optionale Zusatzinformationen

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 03
Extrusion

stabilizers enable polymer recycling

Days to embrittlement
Example 1: 100% virgin HDPE/PP 95/5 HDPE/PP 95/5
HDPE stabilized not restabilized restabilized
Recycled HDPE bottles
embrittlement 131
116

18

Note: “HDPE”: high density Polyethylene; “PP”: Polypropylene l Source: BASF internal analysis at Plastic Additives Lab in Kaisten
Tests presented in the slide used IrgaCycle™ PS 032
Internal
 03
Extrusion
Why specific additive packages recyclates?
Competing reaction in mixed polymer compositions

Carbonyl index before and after aging Recyclates have higher carbonyl index
(all materials unstabilized) than virgin

• Recyclates are pre-damaged

• Additive package needs to counter act
Virgin pre-damage

Recyclates degrade significantly

faster than virgin
Recyclate
• Additive package needs to be stronger

1:1 blend oxidizes even faster than

1:1 Blend pure recyclates

0 0,5 1 1,5 2 • Recyclates can show unexpected behavior

• Additive package needs to mitigate such effects
Initial 57 days

Specific additive packages needed to make recycled Polyolefins fit for the next applications

Internal
 IrgaCycle™
General Plastic PS 030
Recycling Process 01
& BASF
Solutions
05 02
Protects
Degradation
Long Term
Thermal
Protection IrgaCycle™
B-Cycle IrgaCycle™
Ensure smooth
conservation Weatherability XT 034 PS 031
of Recycled PO
Minimize Gel Protects from
Formation Impurities

Processing Deactivates
Stability Carbon Black 04 03
Improves Repairs TPO
mechanical Contaminated
Properties with Paint
IrgaCycle™ IrgaCycle™
UV 033 PS 032

Internal
 IrgaCycle™
General Plastic PS 030
Recycling Process 01
& BASF
Solutions
05 02
Protects
Degradation
Long Term
Thermal
Protection
B-Cycle
Ensure smooth
conservation Weatherability
of Recycled PO
Minimize Gel Protects from
Formation Impurities

Processing Deactivates
Stability Carbon Black 04 03
Improves Repairs TPO
mechanical Contaminated
Properties with Paint

Internal
B-Cycle Portfolio 03

IrgaCycle™ PS 030 Extrusion

Polyolefins for restabilization

Protects
Degradation

Offer processing stability and long-

term thermal protection for HDPE,
Ensure smooth
polyolefin blends and mixed polymers conservation of
Recycled PO

• Maintains the mechanical

properties and outdoor stability
• Maintains melt flow
• Ensures smooth conversation HDPE /
of recycled PO
PO blends /
• Applied to source-materials
such as waste bins, drums, Mixed
non-pressure pipes, cable polymers
ducts, pallets, playground
materials, bottles, caps

Internal
BASF Research Press Conference 2020
B-Cycle Portfolio 03

IrgaCycle™ PS 030 Extrusion

Oven aging – break on bending [days]

No restabilization
Long-term stability
experimental
details
0,2% IrgaCycle
• rHDPE, PCR
PS 030 G
• Oven aging of
compression molded 0 50 100 150
plaques at 120°C
Days
• Days until breaking

Addition of Melt Flow Index vs Extrusion passes

IrgaCycle™ PS 030
improves 8 0% IrgaCycle PS 030 G
processing and 7 0,1% IrgaCycle PS 030 G
output due 6 0,2% IrgaCycle PS 030 G

to melt flow 5 0,4% IrgaCycle PS 030 G

retention 4
3
2
1
0
Ext 0 Ext 1 Ext 2 Ext 3 Ext 4
IrgaCycle™ PS 030 restabilizes the polymer for a new life cycle
Internal
General Plastic
Recycling Process 01
& BASF
Solutions
05 02
Protects
Degradation
Long Term
Thermal
Protection
B-Cycle IrgaCycle™
Ensure smooth PS 031
conservation Weatherability
of Recycled PO
Minimize Gel Protects from
Formation Impurities

Processing Deactivates
Stability Carbon Black 04 03
Improves Repairs TPO
mechanical Contaminated
Properties with Paint

Internal
B-Cycle Portfolio 03

IrgaCycle™ PS 031 Extrusion

Polyolefins restabilization
Minimize Gel
Formation

Improves processing and

durability, highly recommended Processing
Stability
for films

• Provides stability during Improves

processing and long-term mechanical
Properties
thermal stability
• Low gel formation
• Improves mechanical
properties LDPE /
• Applications such as bags
LLDPE
and sacks

Internal
B-Cycle Portfolio 03

IrgaCycle™ PS 031 Elongation at break Tensile Strength

Extrusion

350 20
Mechanical properties
300
Experimental details
250 15
•

[N/mm2]
200 rLDPE (mixed LD/LLD)
% 10
150 • Post-consumer
100
5 • Blown films, 30 um
50
0 0 • Tensile strength and
elongation at break
No restabilization 0,2% IrgaCycle PS 031 G
improved with use
of stabilizer

Change of elongation at break

Long-term stability
120
Experimental details
100 • rLDPE vs. vLDPE
80 • Post-consumer
% 60 LD-/LLD- mix
40 • 50 um cast film
20
• Oven aging at 100 °C
0
No restabilization IrgaCycle PS 031 G Virgin • Tensile properties
0 days 39 days

Internal
 03
Main challenge of Extrusion

gel formation in films

with recycled content
addressed with
IrgaCycle™ PS 031

Without restabilization

No restabilization 0,2% IrgaCycle PS 031 G

Differences observed in Differences observed in

rLDPE, film grade Germany rLDPE, film grade Brazil With IrgaCycle
PS 031 G
Internal
BASF Research Press Conference 2020

General Plastic
Recycling Process 01
& BASF
Solutions
05 02
Protects
Degradation
Long Term
Thermal
Protection
B-Cycle
Ensure smooth
conservation Weatherability
of Recycled PO
Minimize Gel Protects from
Formation Impurities

Processing Deactivates
Stability Carbon Black 04 03
Improves Repairs TPO
mechanical Contaminated
Properties with Paint
IrgaCycle™
PS 032

Internal
BASF Research Press Conference 2020
B-Cycle Portfolio 03

IrgaCycle™ PS 032 Extrusion

Restabilization of polyolefins w/ acid waste

Long Term
Thermal
Protection
A solution for highly
degraded materials
Processing
• Provides processing stability Stability
and long-term thermal
protection
• Reduction of degradation
during processing and the
prolonged service time
• Improves long-term thermal PP /
stability of PP block Polyolefin
copolymers with high loading blends
of acidic residues
• Minimizes negative effects of
acidic residues

Internal
 03
B-Cycle Portfolio Extrusion

IrgaCycle™ PS 032 for PP Battery Cases

Oven aging – break on bending
• rHDPE
No restabilization • Post-consumer
• Oven aging of
compression molded
0.2% IrgaCycle PS 032 G
plaques at 120 °C

0 50 100 150
• Days until breaking

Days

Retained tensile impact strength Addition of

IrgaCycle™ PS 032
140 • rPP from battery cases
Improves the long-term
120 • Post-consumer
thermal stability of PP
100
80
• Oven aging of 2 mm recyclates from battery cases
% injection molded plaques
60
at 140 °C Minimizes negative effects
40
20 • Comparison of tensile of acidic residues
0 impact strength over time
No restabilization 0.5% IrgaCycle PS 032 G 1.0% IrgaCycle PS 032 G

Initial 6 weeks 12 weeks

PP from battery cases can be used in high-end applications

Internal
General Plastic
Recycling Process 01
& BASF
Solutions
05 02
Protects
Degradation
Long Term
Thermal
Protection
B-Cycle
Ensure smooth
conservation Weatherability
of Recycled PO
Minimize Gel Protects from
Formation Impurities

Processing Deactivates
Stability Carbon Black 04 03
Improves Repairs TPO
mechanical Contaminated
Properties with Paint IrgaCycle™
UV 033

Internal
B-Cycle Portfolio 03

IrgaCycle™ UV 033 Extrusion

Outdoor applications
Long Term
Thermal
Protection
Restabilization and Light Protection
for outdoor applications
Weatherability

• Provides weatherability, and

gives processing and long-
term outdoor stability
• Maintains PCR properties
during outdoor exposure
• Allows long-term PCR
application even under heat HDPE /
stress LDPE / PP
• Maintains melt flow and
constant production process
• Crates, bins, pallets / street
furniture / outdoor
applications

Internal
 03
B-Cycle Portfolio Extrusion

IrgaCycle™ UV 033 for Outdoor Applications

Retained Tensile Impact strength in %

110

100

90

80 Addition of
IrgaCycle™ UV 033:
70

60 Retains mechanical
properties of polyolefins
50 in outdoor applications
40
0 2000 4000 6000 8000 Perfect fit for bins, crates,
pallets, street furniture…
without restabilization Artificial Weathering [hours], Xenon-Arc, RH 60% , water spray
0.2% IrgaCycle™ UV 033 Extrusion: twin screw, max 240ºC, 100 rpm

IrgaCycle™ UV 033 provides weatherability and long service time

Internal
General Plastic
Recycling Process 01
& BASF
Solutions
05 02
Protects
Degradation
Long Term
Thermal
Protection IrgaCycle™ B-Cycle
Ensure smooth
conservation Weatherability
XT 034
of Recycled PO
Minimize Gel Protects from
Formation Impurities

Processing Deactivates
Stability Carbon Black 04 03
Improves Repairs TPO
mechanical Contaminated
Properties with Paint

Internal
B-Cycle Portfolio 03

IrgaCycle™ XT 034 Extrusion

Repair system for polyolefins

Protects from
Impurities

Processing and long-term stability

Deactivates
for highly contaminated materials Carbon Black

• Enhances processing, long-

Repairs TPO
term heat stability (durability) Contaminated
and mechanical properties with Paint

• Paint and other solid TPO /

contaminations
Polymers
• Reduction of the negative w/ Fillers,
influence of impurities
Carbon Black,
• Compatibilizer Impurities
• Deactivates carbon black
• Repairs TPO contaminated
with paint residues

Internal
BASF Research Press Conference 2020
03
B-Cycle Portfolio Extrusion

IrgaCycle™ XT 034 Repair System for Polyolefins

Tensile Impact strength kJ/mm2 0.5% paint residues

600

400

Addition of
IrgaCycle™ XT 034 200

Neutralizes negative effects

of solid impurities and retains 0
mechanical properties 0 500 1000 1500 2000 2500

Typical applications: without restabilization

bumpers, rotomolding, 0,70% IrgaCycle™ XT 034 Oven Aging at 135ºC [hours]
filled PP systems 1,2% IrgaCycle™ XT 034

IrgaCycle™ XT 034 improves mechanical properties of contaminated polyolefins

Internal
BASF Research Press Conference 2020
03
Extrusion

IrgaCycle XT 034 DD Retained tensile impact strength

significantly enhances 140

mechanical properties over time 120

100
and outperforms a conventional
80
sole process stabilizer package %
60
40
Initial
20
0
No restabilization 0.7% IrgaCycle XT 034 DD 0.2% conventional solution 3 weeks

IrgaCycle™ XT 034 DD
6 weeks
enhances mechanical
properties of contaminated Retained tensile impact strength
140 9 weeks
rPP/EPDM
120
100 12 weeks
80
Long-term stability Experimental details %
60 15 weeks
• rPP/EPDM (car bumper with paint residues)
40
• Post-consumer 20
• 2 mm injection molded plaques 0

• Oven aging at 135 °C

No restabilization 0.7% IrgaCycle XT 034 DD 1.2% IrgaCycle XT 034 DD

• Comparison of tensile impact strength over time

Internal
General Plastic Recycling Process
& BASF Solutions

04 Additives contributing
Conversion to ready-to-recycle
end products

Product
conversion

Internal
 04
IrgaCycle™ enables Conversion

ready-to-recycle products

High performance
process
Application: Protection of
polyolefins in high production lines

Results Advantages

• Reduction of build-up • Substitution of process

in ~50% aid masterbatches with
• Productivity increase lower cost
through less • Reduction of operative
maintenance and production costs
cleaning stops of • Expressive decrease
~50% of gel formation
• Reduction of scrap in • Constant Melt Flow Index
~50%
• Ready-to-use products in
granules physical form

28
Internal
BASF Research Press Conference 2020

Access
shop@BASF
B-Cycle

www.b-cycle.basf.com

Internal
Internal