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The challenge of repairing polymers in recycling
What questions do you have about this RFP?
Get them answered by the team at BASF.
Background

Mechanical recycling is the dominant “circular plastics” technology today for polyolefins (LDPE, HDPE, PP) and polyester (PET). However, when the polymers endure several rounds of use by consumers and processing through recycling streams, it creates molecular damage that causes undesired effects. For polyolefins, this degradation is due to heat, shear and oxygen. For polyester, this degradation is due to hydrolysis. 

 

The quality of recycled material is directly dependent on the quality and purity of input materials. Several approaches have been tried to improve the quality of recycled polyolefins and polyesters.  

 

For polyesters, there has been success in using reactive chain extenders as an additive to regenerate higher molecular weight. Another solution has been introducing an additional solid state polymerization step to mitigate molecular weight loss. 

 

For polyolefins, there has been success in preventing chain cleavage in reprocessing by adding fresh antioxidants as restabilization additives. However, any damage to the polymer’s main chain is irreversible and there is currently no solution available to achieve full end-to-end connectivity and restore the molecular weight of the polymer’s backbone. 

 

BASF is seeking a solution that enables an increase in the molecular weight of cleaved polyolefins during recycling, with a focus on two potential approaches: 

  1. End-to-End Connectivity: Our preferred solution involves extending the main chain of polyolefins through end-to-end connectivity. This approach results in a mostly linear, long-chain structure, which enhances the polymer's ability to form entanglements. These entanglements serve as tie-chains between crystallites, ultimately improving the mechanical properties of the polymer. This is the most desirable outcome for us. 

  2. Statistical Crosslinking: We are also open to solutions involving statistical crosslinking. In this approach, radicals are induced during extrusion, leading to an increase in molecular weight through the addition of various branched structures. While this method does impact the polymer's architecture and reduces its entanglement capability and is less preferred, it remains of interest to us if it involves novel approaches that go beyond the state-of-the-art peroxides.

What we're looking for

BASF is seeking a solution for polyolefins that will extend the chain of cleaved polyolefins in recycling.

Solutions of interest include:
  • Novel additives/agents that can promote reactive chain extension of cleaved polyolefins (through end-to-end connectivity or statistical crosslinking)
Our must-have requirements are:
  • Safe chemistry that does not introduce hazardous substances into recycled material
Our nice-to-have's are:
  • Green chemistry approaches
  • Non-leaching residues after repair
  • Safe compounds and reactants after “repair”
What's out of scope:
  • “Traditional” cross-linking strategies, e.g. with peroxides, that are not selective at a preferred end-to-end reattachment
  • Purely stabilization strategies that aim at preventing chain cleavage
Acceptable technology readiness levels (TRL):
Levels 1-9
What we can offer you
Eligible partnership models:
Sponsored research
Material transfer
Benefits:
Sponsored Research
We will screen the potential ideas and depending on the maturity level, set up a sponsored research collaboration (Proof of concepts typically ranges from $150-300k for 1-2 years).
Tools and Technologies
Trials with experimental materials, support with materials characterization
Reviewers
LJ
Lauren Junker
Technology Scout
TH
Tom Holcombe
Collaboration & Scouting NA
RG
Rohini Gupta
Innovation Manager, Academic Research Alliance
KB
Kavita Bitra
Technology scout
SS
Sophia Steffens
Innovation & Scouting
RS
Ricarda Schulte
Senior Associate Venture Portfolio Management
Q&A with BASF

The Q&A is now closed.

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Most upvoted
Q.
Dear BASF: One clarifying question: could the idea be implemented during the mechanical processing stage or should it only be applied to plastics that have presumably been mechanically processed already? Thank you!
1
A.
Dear Andrew, the potential solution would be applied during melt (or similar, extrusion based) processing. Hope this helps! Best - Rohini Gupta
RG
Rohini Gupta, Innovation Manager, Academic Research Alliance, BASF
November 6, 2023
Is this response helpful?
1
0
Q.
We published a paper recently (Nature '23) on using vitri,er type ideas to upcycle saturated polymers (including polyolefin) and their blends. We are interested in expanding these to more green chemistries. Is this of interest?
1
A.
Dear Sanat, we would not rule this out. Although we are less interested in heavily dynamically crosslinked materials after recycling, it might be interesting to see if this helps to bring polyolefin performance back to high levels, while maintaining their processing ability. The compatibilization aspect is another interesting feature, while the chemistry looks expensive. Hope this helps - Rohini Gupta
RG
Rohini Gupta, Innovation Manager, Academic Research Alliance, BASF
December 9, 2023
Is this response helpful?
1
0
Q.
Dear BASF: What are the polymer endgroups, i.e. the chemical structure of the endgroups of the polymer(s) to be elongated?
1
A.
Dear David, this is not entirely clear. Oxidized species are mentioned in literature, but in a radical cleavage mechanism, a large variety of terminating reactions leading to different endgroups could be in play. Ideally, a solution would build on literature findings / hypotheses, or include smart ways to elucidate this issue. Hope this helps - Rohini Gupta
RG
Rohini Gupta, Innovation Manager, Academic Research Alliance, BASF
December 9, 2023
Is this response helpful?
1
0
Q.
Upon discussion of this call with Emir Islamovic (BASF-CARA), we suspect that upgrading of waste polymers to make fungal biocontrol agents might be responsive. Would you entertain such a proposal?
1
A.
Thank you for your interest and your question! Unfortunately, this is beyond the scope of the current challenge. Best - Rohini Gupta
RG
Rohini Gupta, Innovation Manager, Academic Research Alliance, BASF
November 22, 2023
Is this response helpful?
1
0
Q.
Dear BASF: Have you looked into melt blending as an idea to recover the backbone ?
1
A.
Dear Daniel, Could you kindly elaborate what will be used to blend the melt to recover broken chains? Best - Rohini Gupta
RG
Rohini Gupta, Innovation Manager, Academic Research Alliance, BASF
January 15, 2024
Is this response helpful?
0
0
Q.
Is BASF is looking for a technology connecting the ends of the mechanochemically cleaved polyolefin molecular chains during the mechanical recycling or an end connecting for a given "damaged" polyolefin sample.
1
A.
Dear Jinwen, these aren't mutually exclusive. We are looking for a technology to reconnect the ends of cleaved polymer chains due to processing (or some event during use phase). Best - Rohini Gupta
RG
Rohini Gupta, Innovation Manager, Academic Research Alliance, BASF
January 15, 2024
Is this response helpful?
1
0
Q.
Dear BASF, what is the starting material for this: eg. 1. virgin polyethylene; 2. from main manufacturer; 3. Formulated/processed; 4. Post-consumer use material; 5. Landfill materials
1
A.
Dear David, Starting material could be PP, HDPE or LDPE - likely artificially aged in a controlled way by a finite number of re-extrusions, potentially with some weathering/ oven-oxidation in between. Samples could be prepared on site with a collaborator, to allow for fast iterations and adjustments, or also be provided. Starting material grades could be selected based on availability. Best - Rohini Gupta
RG
Rohini Gupta, Innovation Manager, Academic Research Alliance, BASF
January 15, 2024
Is this response helpful?
0
0
Q.
Dear BASF, Will you supply the polyethylene sample for us to do research on?
1
A.
Please see above.
RG
Rohini Gupta, Innovation Manager, Academic Research Alliance, BASF
January 15, 2024
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