Processing behavior evolution of recycled polypropylene: An integrated experimental and Computer-Aided engineering simulation study

Estela-García, John E.; Hohoff, Paula; Osswald, Tim A.

doi:10.1063/5.0260486

Processing behavior evolution of recycled polypropylene: An integrated experimental and Computer-Aided engineering simulation study

Journal Article · Tue Mar 04 23:00:00 EST 2025 · Physics of Fluids

DOI:https://doi.org/10.1063/5.0260486· OSTI ID:2528016

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University of Wisconsin, Madison, WI (United States)

Polypropylene (PP) comprises 21% of global plastics production and 18% of plastics waste, yet less than 1% of solid-waste PP is recycled in the United States (U.S.), representing significant environmental and economic challenges. Mechanical recycling, the most prevalent recycling method, subject's materials to thermomechanical stresses, which typically degrade polymer properties, affecting the quality of polymer products. This study replicates the impact of mechanical recycling through multiple extrusion cycles to examine the effects on PP's processing behavior. Dynamic scanning calorimetry (DSC) measurements showed stable melting behavior across all processing conditions, while crystallization analysis exhibited consistent shifts in kinetic parameters. Rheological characterization demonstrated progressive viscosity reductions through successive cycles, particularly pronounced at elevated reprocessing temperatures. Here, the integration of this experimental data into injection molding simulations showed that recycled PP maintains viable processing characteristics. Our findings establish quantitative correlations between processing history and material behavior, enabling optimization of processing parameters directly rather than relying on trial-and-error approaches. While these results reflect idealized recycling conditions with minimal contamination, they provide a framework for understanding fundamental property evolution during mechanical recycling.

View Accepted Manuscript (DOE)

Research Organization:: University of Wisconsin, Madison, WI (United States)

Sponsoring Organization:: USDOE Office of Energy Efficiency and Renewable Energy (EERE), Office of Sustainable Transportation. Bioenergy Technologies Office (BETO)

Grant/Contract Number:: EE0009285

OSTI ID:: 2528016

Journal Information:: Physics of Fluids, Journal Name: Physics of Fluids Journal Issue: 3 Vol. 37; ISSN 1070-6631

Publisher:: American Institute of Physics (AIP)Copyright Statement

Country of Publication:: United States

Language:: English

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Processing behavior evolution of recycled polypropylene: An integrated experimental and Computer-Aided engineering simulation study

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