Latest Innovations in Recycling Techniques

🌍♻️ Transforming Aluminum Waste into Steel: A Sustainable Breakthrough from Germany Metallurgists in Germany have made a significant breakthrough in recycling aluminum production waste. Their novel method, documented in 'Nature', efficiently extracts iron from red mud, a hazardous byproduct of aluminum manufacturing. This innovative process presents a promising solution to the environmental challenges posed by aluminum production. Aluminum production, essential for numerous products, results in the generation of red mud. This sludge, amounting to about 180 million metric tons annually, is both alkaline and rich in heavy metals, posing environmental risks. While some red mud is used in construction, it constitutes only a minor fraction of the total waste. The German team's method involves exposing red mud to hydrogen plasma in a specialized chamber for about 15 minutes, converting it into a viscous melt. This process ultimately separates liquid iron and steam, with iron globules being collected for further use. Economically viable and potentially scalable, this technique could significantly reduce red mud waste. Additionally, the extracted iron offers a resource for steel production. However, the process requires further refinement to manage the resulting fumes. This innovative method of extracting iron from aluminum production waste could revolutionize waste management in the metal industry. By converting hazardous red mud into a valuable resource for steel manufacturing, the research paves the way for more sustainable practices in metal production. This approach not only addresses a major environmental concern but also creates economic opportunities, illustrating the potential of scientific innovation in solving industrial challenges. Stay informed, stay curious! 🌐📚 Science never ceases to amaze! 🌟✨ #SustainableMetalProduction #RecyclingRedMud #InnovativeResearch #NatureJournal #EnvironmentalSolutions Max-Planck-Institut für Eisenforschung GmbH RWTH Aachen University Bundesanstalt für Materialforschung und -prüfung Matic Jovičević-Klug, Isnaldi Souza Filho, Hauke Springer, Christian Adam & Dierk Raabe https://lnkd.in/g_FawD_9

🌱♻️ Excited to share our latest publication in #Nature, where we introduce a holistic aqueous-based recycling strategy for perovskite photovoltaics, reducing environmental impact while preserving high efficiency. This green-solvent-based recycling approach that restores nearly all essential materials—including perovskite layers, charge-transport layers, metal electrodes, and glass substrates—achieving an impressive 99% recycling efficiency. Our findings show a 96.6% reduction in resource depletion and a 68.8% reduction in human toxicity (cancer effects) compared to landfill disposal. ⚡ Beyond sustainability, this strategy lowers the levelized cost of electricity (LCOE) for residential and utility-scale perovskite PV systems, helping to build a circular solar economy. This work highlights the power of international collaboration in tackling sustainability challenges at the intersection of materials science, energy, and AI. Huge thanks to Xueyu Tian and 王秉政 in our interdisciplinary team for making this possible! Read the full paper here: https://lnkd.in/gWCX-8SQ #Sustainability #SolarEnergy #PerovskitePV #Recycling #CircularEconomy #AIforSustainability

♻️ New Preprint Alert! ♻️ As global plastic waste levels continue to rise, the need for innovative chemical recycling strategies grows more urgent. In our latest study, we explore how catalytic pyrolysis can convert mixed plastic waste into valuable products, supporting the shift toward a circular economy. 🔬 We focus on a realistic feedstock—a mixture of polypropylene (PP) and polyethylene terephthalate (PET)—commonly found in multilayer packaging, a notoriously difficult-to-recycle waste stream. 📌 Key contributions: Investigated catalyst:feedstock ratio, polymer composition, and heating rate effects using TGA. Developed a kinetic modeling framework to predict degradation behavior under varying conditions. Evaluated catalyst deactivation through shifts in thermal profiles and quantified acidity loss using pyridine and collidine adsorption. To our best knowledge, we provided the first kinetic and deactivation study on co-pyrolysis of PP and PET—a major step forward in understanding mixed plastic waste behavior during catalytic recycling. 📉 Our findings show that PET’s high coking tendency significantly accelerates catalyst deactivation, underscoring the need for tailored strategies in mixed waste pyrolysis. 🔗 Read the full preprint here: https://lnkd.in/eBcU_6Az We hope this work sparks discussion and collaboration in the field of sustainable plastic recycling and catalytic process engineering. #Catalysis #PlasticsRecycling #CircularEconomy #ChemicalEngineering #Kinetics #HZSM5 #Pyrolysis #Sustainability #PlasticWaste

Biocycling: Using 3D imaging to transform plastic waste recycling. University of Waterloo researchers have used 3D imaging to understand the fine details of microplastics, paving the way for more effective methods of plastic waste recycling. Canada. September 05, 2024 Excerpt: In collaboration with National Research Council (NRC), researchers leveraged 3D imaging technology in addition to traditional 2D microscopy, to observe degradation of micro and nanoplastics with unprecedented detail. "Most microscope images provide a two-dimensional view, similar to a medical X-ray, which provides some information but lacks depth," said William Anderson, a professor in Waterloo’s Department of Chemical Engineering. "3D imaging is like a CT scan, offering far more detailed insights into the structure and degradation of microplastics. This level of detail has been challenging to achieve, but it's crucial for understanding what is happening at the surface of micro and nanoplastics and how degradation processes work." The research group used a novel combination of physical and biological approaches to obtain new visual data. They utilized a photocatalytic process, which treated micro and nanoplastics with UV light and a titanium oxide catalyst. The team was able to observe and analyze degradation at a microscopic level. "Using this methodology reveals not just that degradation is happening, but exactly how and where it's occurring on the surface of micro and nanoplastics, said chemical engineering professor Boxin Zhao, a University of Waterloo Endowed Chair in Nanotechnology. “This knowledge is crucial for developing more effective methods of breaking down plastics on the micro and nanoscales.” Note: Anderson and Zhao, in collaboration with researchers from the Department of Chemical Engineering and the Department of Biology at Waterloo, are developing biocycling methods where microplastics could be used as a carbon source for bacteria. The bacteria would ingest microplastics and then excrete an environmentally friendly biopolymer that could be used to create new materials like plastic bags or packaging films. This study has broader implications for Waterloo’s research team, which is now forming a multidisciplinary plastics biocycling research initiative. The collaboration underscores the importance of bringing together different fields of expertise to tackle complex environmental challenges. This research offers valuable insights that could pave the way for more effective methods of plastic waste recycling and contribute to a circular economy. Publication: IOP Science | Nanotechnology 12 July 2024 3D imaging photocatalytically degraded micro-and nanoplastics https://lnkd.in/e6P42e2a https://lnkd.in/e95Cexbr

There is a cash cow of an opportunity for the companies that can figure out how to make new products out of repurposing wind turbine blades.  Challenges with repurposing the fiberglass blades have led to fields of retired blade graveyards and/or disposal in landfills.  According to NREL, an average of 5500 blades will be retired each year for the next 5 years in the US alone; that figure would increase between 10,000 and 20,000 until 2040. Can you say "Houston, we have a problem"?   Here are 3 US based companies that are figuring out solutions to reduce and repurpose this difficult material:   Carbon Rivers, Inc. This Tennessee-based company has developed a process to recover clean, mechanically intact glass fiber from decommissioned wind turbine blades. The recycled fiberglass is then upcycled into new composite materials, contributing to a circular wind turbine economy. Veolia North America: In partnership with GE Renewable Energy, Veolia processes decommissioned blades by shredding them and incorporating the fiberglass and resin into cement production. This method not only recycles the blade materials but also reduces CO₂ emissions in cement manufacturing by approximately 27%. REGEN Fiber Located in Fairfax, Iowa, Regen Fiber has established a facility capable of processing up to 30,000 tons of wind turbine blades annually. Their proprietary process recycles 100% of the blade materials into fibers and additives that enhance the durability and environmental resistance of concrete and asphalt.   In a country where the DOT loves to temporarily fill or resurface roadways with composites that can't withstand the wear/tear, I love the idea of resins being created that strengthen our building materials with repurposed materials from otherwise wasted products.    What other ways have you heard of these materials being re-purposed?

The U.S. throws away over $11.4 billion worth of recyclable containers each year. What's a simple way to reverse this trend outside the home? ♻️ Reverse vending machines (RVMs) are making a comeback, and not just in bottle bill states! Waste Dive had a great piece last week illuminating the trend: 🟢 Closed Loop Partners provided a catalytic loan to Olyns, a provider of AI-powered RVMs, to expand its manufacturing and deployment. Olyns' AI-powered Cubes can collect and sort up to 90% of recyclable materials, according to the company. 🟢 Recycle Track Systems (RTS) acquired RVM company Cycle and successfully implemented their technology at the Super Bowl, offering instant prizes and incentives to fans who recycled. In a pilot program, Cycle's RVMs increased beverage container recycling rates by up to 50% at sports stadiums. 🟢 Ball Corporation partnered with RTS to install an RVM at Copper Mountain Resort in Colorado to collect aluminum cups. Ball Corporation estimates that RVMs can capture up to 97% of beverage containers for recycling. 🟢 The University of Alabama installed four RVMs on campus in partnership with The Coca-Cola Company's World Without Waste program and recorded a 20% increase in recycling rates after installing the RVMs. These examples demonstrate the growing momentum and potential of RVMs in promoting recycling and sustainability. By providing convenient and engaging recycling solutions, RVMs are empowering individuals to actively participate in creating a more circular economy. As we look ahead, the future of RVMs looks bright. With the potential for collecting reusable packaging and further integration with EPR initiatives, RVMs are poised to play an even greater role in reducing waste and promoting sustainability "on the go". Read more here: https://lnkd.in/gBvv8AQS 🌱 #sustainability #circulareconomy #reversevendingmachines

After five years of work, I’m excited to finally share our new paper on a new method for upcycling titanium-based scrap material into a new useable alloy through a method we call compositional steering. This work showcases a wonderful ongoing relationship between the Office and Naval Research (ONR) and NASA JPL on technology that has dual-use for both the Navy and NASA. As we try to establish a sustainable presence in space, NASA will need technologies that can take feedstock in various forms (mostly Ti and Al, but possibly contaminated with regolith), and convert them into new alloys with useable properties. Similarly, the Navy needs to start preparing for a world where pure metals, like titanium, are scarce and new methods are needed to create unmanned submersibles from waste streams, or to perform in-theatre repairs. In this work, me and my co-authors develop a method for compositional steering and then apply it to a specific use-case of bulk metallic glass. We start with a scrap Ti alloy that was contaminated with oxygen and carbon during manufacturing and was off-composition and deemed scrap. By studying phase diagrams and the literature, we experimentally demonstrate that we can add only 25% mass of new elements strategically and convert the scrap material into a new bulk glass former that can be produced into parts up to 3 mm thick. The method we demonstrate has broad applications when coupled with machine learning and computational materials science, where unknown compositions of scrap materials can be steered towards the closest “useable” alloy with the least amount of additives. We further demonstrated our technique by taking scrap turnings of titanium, steel and aluminum from the JPL machine shop garbage cans and remelting into alloys with unique properties, such as a beta titanium alloy and a bulk metallic glass. We are looking forward to partnering with industry and the computational materials science community to start developing new methods for sustainable metallurgy by taking advantage of waste streams, like turnings or used additive manufacturing powder. My collaborators here are the incredible Punnathat Bordeenithikasem, Miguel de Brito Costa, Melanie Buziak, Thomas Freeman, and Anthony Botros, all working in the JPL metallurgy lab funded by ONR. With so much turmoil happening right now with government funding, I wanted to highlight what I consider to be a critical relationship between a national lab and a military funding organization on issues of importance to national security. These are great relationships that should be fostered. Our work was highlighted as an Editor’s Choice and will appear later in a special issue of sustainable metallurgy. We are grateful to ONR for ongoing funding in this area. https://lnkd.in/gmxeFiXT

Myth: "Nuclear waste is an unsolvable problem" This persistent myth continues to undermine nuclear energy's role in our clean energy future. It stems partly from outdated assumptions about how used fuel must be managed. Conventional wisdom suggests nuclear waste requires massive centralized facilities and complex transportation networks, feeding public concern and stalling practical solutions for decades. Argonne National Laboratory's recent work tells a different story. Their rotating packed bed (RPB) contactor technology represents a fundamental rethinking of used fuel management: • It harnesses centrifugal forces to dramatically enhance mass transfer between phases, significantly intensifying chemical separation processes • It enables processing at a fraction of the traditional size, potentially allowing for on-site recycling, reducing the need for long-distance transportation • It recovers valuable uranium and transuranic elements from materials previously destined for disposal • It extends beyond nuclear to other critical applications like rare earth element recovery from mining waste, coal fly ash, and even electronic waste The implications are significant. Instead of viewing used fuel as a liability requiring elaborate solutions, this approach treats it as a resource with recoverable value. This RPB technology shows promise of turning what was once considered “waste management” into “resource recovery.” As Anna Servis, the Argonne radiochemist leading this work, aptly notes: "Our research is not just about refining technologies, it's about redefining possibilities." Read more about Argonne's work here: https://lnkd.in/e__94eDB? #NuclearEnergy #CleanEnergy #Innovation

Latest efforts to develop effective methods to #recycle polyurethanes published in American Chemical Society journal Macromolecules: we find that a Zr catalyst increases its activity when heated with polyurethane thermosets or their precursors. The catalyst enables polyurethanes that would otherwise be discarded to be reshaped into new plastics. This effect can also be used to make #polyurethane foam when the catalyst activated with the polyol monomer. Great work to carefully understand the chemistry behind these processes by Subeen Kim, Jeremy Swartz, Molly Sun, and Alexander Oanta from our group at Northwestern, as well as our collaborators at BASF: Alaaeddin Alsbaiee, PhD, Oliver Sala, Jacob Brutman. Great ecosystem for this work at Northwestern University: via the Paula M. Trienens Institute for Sustainability and Energy and Northwestern University Department of Chemistry. https://lnkd.in/gvWefwn9

Direct Recycling and Remanufacturing of Lithium-ion Battery Electrode Scraps with Yaocai Bai from Oak Ridge National Laboratory. Manufacturing scraps from lithium-ion battery production are a primary source of recyclable materials. This presentation explores advances in directly recycling electrode scraps using solvent-based separation processes at low temperatures, developed at Oak Ridge National Laboratory, while preserving the integrity of electrode-active materials. The recovered materials can be remanufactured into new electrodes, achieving performance comparable to pristine materials, and thereby supporting a sustainable and circular battery economy. https://lnkd.in/exCe_cmg #AABC