Comparing End-of-Life Vehicle (ELV) and Packaging-Based Recyclates as Components in Polypropylene-Based Compounds for Automotive Applications.

Increasing recycled plastic content in cars to 25% by 2030 is one of the key measures for decarbonizing the automotive industry defined by the European Commission. This should include the recovery of plastics from end-of-life vehicles (ELVs), but such materials are hardly used in compounds today. To close the knowledge gap, two ELV recyclate grades largely based on bumper recycling were analyzed in comparison to a packaging-based post-consumer recyclate (PCR). The composition data were used to design polypropylene (PP) compounds for automotive applications with virgin base material and mineral reinforcement, which were characterized in relation to a commercial virgin-based compound. A compound with a 40 wt.-% ELV-based bumper recyclate can exceed one with just a 25 wt.-% packaging-based recyclate in terms of stiffness/impact balance. While the virgin reference can nearly be matched regarding mechanics, the flowability is not reached by any of the PCR compounds, making further development work necessary.

Combining different analytical approaches to identify odor formation mechanisms in polyethylene and polypropylene.

In a previous study, we identified carbonyls as highly odor-active compounds in both unprocessed and processed polypropylene (PP) with higher intensities after processing, indicating a temperature-driven forming mechanism. In the presented work, we studied whether (a) these carbonyls are the major odor drivers to the overall odor of polyolefins, (b) their formation is taking place already at moderate temperatures well below the typical processing temperatures, (c) conventional antioxidants in polyolefins can prevent or reduce their formation, and (d) whether reducing the amount of oxygen present can decrease the overall odor. One polyethylene (PE) and one PP were selected, and both stabilized and unstabilized polymer powder samples were exposed to conditions differing in oxygen concentration and aging time. The changes in the volatile fraction as well as the formation of odor-active compounds were monitored using a multidisciplinary approach by combining analytical methods based on gas chromatography (GC), multivariate data analysis, and sensory methods (GC-olfactometry and a sensory panel). Both investigated materials (PE and PP) showed similar degradation products (aldehydes, ketones, carboxylic acids, alcohols, and lactones) which increased dramatically with increasing aging time and the lack of stabilization. Oxidation products, mainly carbonyl compounds, were responsible for the odor of the investigated materials. The main odor drivers were unsaturated ketones and aldehydes with a chain length between six and nine C-atoms. Interestingly, similar odor patterns were found for both stabilized and unstabilized samples, indicating that similar formation processes take place independent of the stabilization.