Lesson 1Dewatering and drying methods: centrifuges, thermal dryers, vacuum, target moisture levels prior to extrusionFocuses on dewatering an drying of washed flakes before extrusion. Compares centrifuges, mechanical dewatering, thermal an vacuum dryers, an defines target moisture levels fi different polymers fi prevent hydrolysis, voids, an processing instability.
Mechanical dewatering: screw presses and centrifugesThermal dryers: hot air, infrared, and contact typesVacuum drying for hygroscopic polymers like PETTarget moisture levels for PET, PA, and othersEnergy optimization and dryer performance controlLesson 2Solid-state cleaning and post-extrusion steps: melt filtration, solid-state polycondensation (SSP) for IV recovery in PETCovers post-extrusion steps fi high-performance recyclates, including melt filtration polishing, pellet cooling, an solid-state polycondensation fi PET IV recovery. Explains process conditions, quality control, an regulatory considerations fi food-contact use.
Melt filtration polishing and fine contaminant removalStrand and underwater pelletizing system choicesSolid-state polycondensation principles for PETIV monitoring, residence time, and temperatureFood-contact compliance and decontamination testsLesson 3Separation and density-based processes: float-sink tanks, hydrocyclones, specific gravity windows for PET/PE separationExplains density-based separation use in recycling, including float-sink tanks an hydrocyclones. Describes specific gravity windows fi common polymers, process water conditioning, an how operating parameters affect separation sharpness an yield.
Principles of density separation in water mediaFloat-sink tank design and operating parametersHydrocyclone configuration and cut-point controlSpecific gravity windows for PET, PE, and PPWater chemistry, surfactants, and contaminationLesson 4Reception and pre-sorting: manual sorting, trommels, ballistic separators, size and throughput considerationsIntroduces reception an pre-sorting of incoming plastic waste. Covers feed inspection, manual picking, trommels, an ballistic separators, wid emphasis on removing non-conformities, managing throughput, an preparing a stable feed fi automated sorting.
Incoming load inspection and quality checksManual sorting stations and ergonomicsTrommel screens for size classificationBallistic separators for 2D and 3D separationBalancing throughput, staffing, and safetyLesson 5Reject handling and residue processing: contaminants, fines, wastewater solids, and safe disposal or valorization optionsCovers handling of rejects an residues from sorting, washing, an extrusion. Addresses typical contaminants, fines, an wastewater solids, wid options fi safe disposal, energy recovery, or material valorization while meeting environmental an regulatory requirements.
Typical contaminants and off-spec plastic streamsCollection and treatment of fines and dustWastewater solids thickening and dewateringSafe landfill, co-processing, and incineration routesValorization options: RDF, co-processing, and reuseLesson 6Sizing and shredder options: coarse shredding, granulators, knife mills, particle size targets and energy useDetails size reduction strategies from coarse shredding to fine granulation. Explains equipment types, rotor an knife configurations, an how particle size targets, throughput, an energy consumption influence downstream washing, drying, an extrusion performance.
Coarse shredders for bulky plastic feedstocksGranulator design, rotor types, and screen selectionKnife mill applications and wear managementParticle size targets for film, rigid, and fiberEnergy use, throughput, and maintenance trade-offsLesson 7Automated sorting technologies: NIR, VIS cameras, float-sink, eddy current, X-ray and typical sorting efficienciesDescribes automated sorting technologies use in plastic recycling, including NIR an VIS systems, float-sink, eddy current, an X-ray. Reviews typical sorting efficiencies, limitations, an how system design affects purity, yield, an operating costs.
NIR sorting for polymer type identificationVIS cameras for color and label detectionEddy current separators for non-ferrous metalsX-ray systems for PVC and metal contaminationSorting efficiency, purity, and yield metricsLesson 8Washing and cleaning stages: hot-wash, counter-current washers, caustic washes, surfactant use, temperatures and residence timesDetails washing an cleaning stages fi plastic flakes, including pre-wash, hot-wash, caustic an surfactant systems. Discusses temperature, residence time, mechanical action, an how process design removes labels, adhesives, an organic residues.
Pre-wash and friction washer configurationsHot-wash conditions for label and glue removalCaustic washing chemistry and controlSurfactant selection and foaming managementResidence time, agitation, and soil loadingLesson 9Compounding and additive dosing: stabilizers, odor absorbers, impact modifiers, dosing system considerationsExamines compounding of recycled plastics, focusing on stabilizers, odor control, impact modifiers, an colorants. Discusses dosing technologies, feeding accuracy, dispersion quality, an how additive packages are tailored to target applications an regulatory limits.
Thermal and UV stabilizers for recycled resinsOdor absorbers and deodorization approachesImpact modifiers and toughness enhancementColor masterbatches and pigment selectionGravimetric and volumetric dosing system designLesson 10Extrusion, filtration and degassing: single-screw vs twin-screw, melt filtration (screen changers, pore sizes), melt temperature rangesExplores extrusion in mechanical recycling, comparing single-screw an twin-screw designs, melt temperature control, an degassing. Covers melt filtration hardware, pore size selection, an how dese factors influence contaminant removal an pellet quality.
Single-screw extruder design and operating windowsTwin-screw extruders for compounding and devolatilizationMelt temperature control and residence time effectsMelt filtration hardware, screen changers, pore sizesVacuum degassing, vent design, and volatile removal
