Delamination and Evaluation of Multilayer PE/Al/PET Packaging Waste Separated Using a Hydrophobic Deep Eutectic Solvent.

This research concerns the development and implementation of ground-breaking strategies for improving the sorting, separation, and recycling of common flexible laminate packaging materials. Such packaging laminates incorporate different functional materials in order to achieve the desired mechanical performance and barrier properties. Common components include poly(ethylene) (PE), poly(propylene) (PP), and poly(ethylene terephthalate) (PET), as well as valuable barrier materials such as poly(vinyl alcohol) (PVOH) and aluminium (Al) foils. Although widely used for the protection and preservation of food produce, such packaging materials present significant challenges for established recycling infrastructure and, therefore, to our future ambitions for a circular economy. Experience from the field of ionic liquids (ILs) and deep eutectic solvents (DESs) has been leveraged to develop novel green solvent systems that delaminate multilayer packaging materials to facilitate the separation and recovery of high-purity commodity plastics and aluminium. This research focuses on the development of a hydrophobic DES and the application of a Design of Experiments (DoE) methodology to investigate the effects of process parameters on the delamination of PE/Al/PET laminate packaging films. Key variables including temperature, time, loading, flake size, and perforations were assessed at laboratory scale using a 1 L filter reactor vessel. The results demonstrate that efficient separation of PE, Al, and PET can be achieved with high yields for material and solvent recovery. Recovered plastic films were subsequently characterised via Fourier-transform infra-red (FTIR) spectroscopy, Differential Scanning Calorimetry (DSC) and Thermogravimetric Analysis (TGA) to qualify the quality of plastics for reuse.

Formulation and Characterization of Deep Eutectic Solvents and Potential Application in Recycling Packaging Laminates.

Deep Eutectic Solvents (DESs) show promising abilities for the delamination of multilayer packaging films that are used in food packaging and in pharmaceutical blister packs. Due to the complexity of their structure, the recycling of such materials is a challenging task, leading to the easiest or cheapest disposal option of either landfill or incineration. Towards the development of 'green' solvents for efficient waste management and recycling, this research focuses on the preparation of a range of hydrophobic and hydrophilic DESs based on carboxylic acids in combination with various naturally derived aliphatic and aromatic organic compounds as well as amino acids. Chemical and physical characterization of the solvents was undertaken using differential scanning calorimetry, rheometry, and density measurements for the determination of their properties. Subsequently, batches of solvent were tested against different types of consumer packaging to evaluate the ability of the DES to delaminate these structures into their component materials. The laminate packaging waste products tested were Al/PE, PE/Al/PET, Al/PE/paper, and PVC/PE/Al. Separated films were collected and studied to further examine the effect of solvent delamination on the materials. Depending on the DES formulation, the results showed either partial or full delamination of one or more of the packaging materials, albeit there were challenges for certain solvent systems in the context of delivering a broad delamination efficiency. Variables including temperature, agitation rate, mixing time, and solvent ratios were investigated via a Design of Experiments process to assess the effects of these parameters on the delamination outcome. The results showed that the DESs presented in this research can offer an efficient, low-energy, affordable, and green option for the delamination of laminate packaging materials.

Progress in Solvent-Based Recycling of Polymers from Multilayer Packaging.

Conversion of chemical feedstocks derived from fossil fuels to virgin polymer, manufacturing of plastics in coal-dependent economies, and increasing consumption of virgin polymers for plastics packaging contribute significantly to environmental issues and the challenges we face. Nowadays, promoting sustainable development has become the consensus of more and more countries. Among them, the recycling of multilayer packaging is a huge challenge. Due to the complexity of its structure and materials, as well as the limitations of existing recycling frameworks, currently, multilayer packaging cannot be commercially recycled thus resulting in a series of circular economy challenges. It is undeniable that multilayer packaging offers many positive effects on products and consumers, so banning the use of such packaging would be unwise and unrealistic. Developing the appropriate processes to recycle multilayer packaging is the most feasible strategy. In recent years, there have been some studies devoted to the recycling process of multilayer packaging. Many of the processes being developed involve the use of solvents. Based on the recycled products, we categorised these recycling processes as solvent-based recycling, including physical dissolution and chemical depolymerisation. In physical dissolution, there are mainly two approaches named delamination and selective dissolution-precipitation. Focusing on these processes, this paper reviews the solvents developed and used in the last 20 years for the recycling of polymers from multilayer packaging waste and gives a summary of their advantages and disadvantages in terms of cost, product quality, ease of processing, and environmental impact. Based on existing research, one could conclude that solvent-based recycling methods have the potential to be commercialised and become part of a standard recycling process for polymer-based multilayer packaging. The combined use of multiple solvent-based recycling processes could be a breakthrough in achieving unified recycling of multilayer packaging with different components.

Electrochemical Characterization of Electrodeposited Copper in Amine CO2 Capture Media.

This study explores the stability of electrodeposited copper catalysts utilized in electrochemical CO2 reduction (ECR) across various amine media. The focus is on understanding the influence of different amine types, corrosion ramifications, and the efficacy of pulse ECR methodologies. Employing a suite of electrochemical techniques including potentiodynamic polarization, linear resistance polarization, cyclic voltammetry, and chronopotentiometry, the investigation reveals useful insights. The findings show that among the tested amines, CO2-rich monoethanolamine (MEA) exhibits the highest corrosion rate. However, in most cases, the rates remain within tolerable limits for ECR operations. Primary amines, notably monoethanolamine (MEA), show enhanced compatibility with ECR processes, attributable to their resistance against carbonate salt precipitation and sustained stability over extended durations. Conversely, tertiary amines such as methyldiethanolamine (MDEA) present challenges due to the formation of carbonate salts during ECR, impeding their effective utilization. This study highlights the effectiveness of pulse ECR strategies in stabilizing ECR. A noticeable shift in cathodic potential and reduced deposit formation on the catalyst surface through periodic oxidation underscores the efficacy of such strategies. These findings offer insights for optimizing ECR in amine media, thereby providing promising pathways for advancements in CO2 emission reduction technologies.

Influence of Electrolyte Choice on Zinc Electrodeposition.

Zinc electrodeposition serves as a crucial electrochemical process widely employed in various industries, particularly in automotive manufacturing, owing to its cost effectiveness compared to traditional methods. However, traditional zinc electrodeposition using aqueous solutions faces challenges related to toxicity and hydrogen gas generation. Non-aqueous electrolytes such as ionic liquids (ILs) and deep eutectic solvents (DESs) have gained attention, with choline-chloride-based DESs showing promise despite raising environmental concerns. In this study, zinc electrodeposition on mild steel was investigated using three distinct electrolytes: (i) halide-free aqueous solutions, (ii) chloride-based DES, and (iii) halide-free acetate-based organic solutions. The study examined the influence of deposition time on the growth of Zn on mild steel substrates from these electrolytes using physical characterization techniques, including scanning electron microscopy (SEM) and X-ray diffraction (XRD). The results indicate that glycol + acetate-based non-aqueous organic solutions provide an eco-friendly alternative, exhibiting comparable efficiency, enhanced crystalline growth, and promising corrosion resistance. This research contributes valuable insights into the impact of electrolyte choice on zinc electrodeposition, offering a pathway towards more sustainable and efficient processes. Through a comprehensive comparison and analysis of these methods, it advances our understanding of the practical applications of zinc electrodeposition technology.

Progress in Novel Electrodeposited Bond Coats for Thermal Barrier Coating Systems.

The increased demand for high performance gas turbine engines has resulted in a continuous search for new base materials and coatings. With the significant developments in nickel-based superalloys, the quest for developments related to thermal barrier coating (TBC) systems is increasing rapidly and is considered a key area of research. Of key importance are the processing routes that can provide the required coating properties when applied on engine components with complex shapes, such as turbine vanes, blades, etc. Despite significant research and development in the coating systems, the scope of electrodeposition as a potential alternative to the conventional methods of producing bond coats has only been realised to a limited extent. Additionally, their effectiveness in prolonging the alloys' lifetime is not well understood. This review summarises the work on electrodeposition as a coating development method for application in high temperature alloys for gas turbine engines and discusses the progress in the coatings that combine electrodeposition and other processes to achieve desired bond coats. The overall aim of this review is to emphasise the role of electrodeposition as a potential cost-effective alternative to produce bond coats. Besides, the developments in the electrodeposition of aluminium from ionic liquids for potential applications in gas turbines and the nuclear sector, as well as cost considerations and future challenges, are reviewed with the crucial raw materials' current and future savings scenarios in mind.

Ionic Liquids and Deep Eutectic Solvents for CO2 Conversion Technologies-A Review.

Ionic liquids (ILs) have a wide range of potential uses in renewable energy, including CO2 capture and electrochemical conversion. With the goal of providing a critical overview of the progression, new challenges, and prospects of ILs for evolving green renewable energy processes, this review emphasizes the significance of ILs as electrolytes and reaction media in two primary areas of interest: CO2 electroreduction and organic molecule electrosynthesis via CO2 transformation. Herein, we briefly summarize the most recent advances in the field, as well as approaches based on the electrochemical conversion of CO2 to industrially important compounds employing ILs as an electrolyte and/or reaction media. In addition, the review also discusses the advances made possible by deep eutectic solvents (DESs) in CO2 electroreduction to CO. Finally, the critical techno-commercial issues connected with employing ILs and DESs as an electrolyte or ILs as reaction media are reviewed, along with a future perspective on the path to rapid industrialization.

Erosion and Corrosion Resistance Performance of Laser Metal Deposited High-Entropy Alloy Coatings at Hellisheidi Geothermal Site.

Geothermal process equipment and accessories are usually manufactured from low-alloy steels which offer affordability but increase the susceptibility of the materials to corrosion. Applying erosion-corrosion-resistant coatings to these components could represent an economical solution to the problem. In this work, testing of two newly developed laser metal deposited high-entropy alloy (LMD-HEA) coatings-CoCrFeNiMo0.85 and Al0.5CoCrFeNi, applied to carbon and stainless steels-was carried out at the Hellisheidi geothermal power plant. Tests in three different geothermal environments were performed at the Hellisheidi site: wellhead test at 194 °C and 14 bar, erosion test at 198 °C and 15 bar, and aerated test at 90 °C and 1 bar. Post-test microstructural characterization was performed via Scanning Eletron Microscope (SEM), Back-Scattered Electrons analysis (BSE), Energy Dispersive X-ray Spectroscopy (EDS), optical microscopy, and optical profilometry while erosion assessment was carried out using an image and chemical analysis. Both the CoCrFeNiMo0.85 and Al0.5CoCrFeNi coatings showed manufacturing defects (cracks) and were prone to corrosion damage. Results show that damage in the CoCrFeNiMo0.85-coated carbon steel can be induced by manufacturing defects in the coating. This was further confirmed by the excellent corrosion resistance performance of the CoCrFeNiMo0.85 coating deposited onto stainless steel, where no manufacturing cracks were observed.

Microstructure and Thermal Analysis of Metastable Intermetallic Phases in High-Entropy Alloy CoCrFeMo0.85Ni.

CoCrFeMoNi high entropy alloys (HEAs) exhibit several promising characteristics for potential applications of high temperature coating. In this study, metastable intermetallic phases and their thermal stability of high-entropy alloy CoCrFeMo0.85Ni were investigated via thermal and microstructural analyses. Solidus and liquidus temperatures of CoCrFeMo0.85Ni were determined by differential thermal analysis as 1323 °C and 1331 °C, respectively. Phase transitions also occur at 800 °C and 1212 °C during heating. Microstructure of alloy exhibits a single-phase face-centred cubic (FCC) matrix embedded with the mixture of (Co, Cr, Fe)-rich tetragonal phase and Mo-rich rhombohedron-like phase. The morphologies of two intermetallics show matrix-based tetragonal phases bordered by Mo-rich rhombohedral precipitates around their perimeter. The experimental results presented in our paper provide key information on the microstructure and thermal stability of our alloy, which will assist in the development of similar thermal spray HEA coatings.