Environmentally friendly additives for plastic and process for producing the same

Abstract: An environmentally friendly additive for plastics, comprising 1 to 40% by weight of ash, 20 to 80% by weight of a carrier, 1 to 60% by weight of a first hydroxide, and 1 to 50% by weight of a second hydroxide. The environmentally friendly additive for plastics can be added to all of polyolefin plastics such as general-purpose plastics. The environmentally friendly additive can decrease the amount of hydrochloric acid gas produced when the plastics containing the additive is burned in an incinerator. A process for producing the environmentally friendly additive for plastics is also provided.

Description: The present invention relates to environmentally friendly additives for plastics and a process for producing the same. The ability of organic or inorganic chlorine-containing substances to dissociate and release chlorine ions in incinerators, the amount of hydrogen provided by water existing in wastes, and the concentration of alkaline metals contained in the wastes are the main factors to influence the formation of hydrochloric acid and heavy metal chlorides during the incineration of wastes. The chlorine ions released from different chlorine-containing substances in incinerators easily react with a large amount of hydrogen provided by humid wastes and to form hydrochloric acid. "Dioxin" is an organic chloride compound, which comprises 75 chloride compounds. Among monochloro dioxin and polychloro dioxin, the most hazardous and poisonous dioxin is 2,3,7,8-tetrachloro dioxin because of the different arrangement of the chlorine atoms. The chemical formula of dioxin is as follows; Accordingly, it is highly necessary to obtain an environmentally friendly additive to be incorporated into plastic products to reduce the amount of hydrochloric acid released when the plastic products are incinerated. Attempts to reduce released hydrochloric acid in plastic materials are known is the art (see US-A-5 744 690, JP-A-10182909, and EP-A-0103175). Figure 1 is a flow chart for producing the environmentally friendly additive for plastics. Figure 2 shows a few high-density polyethylene bags, in which Figure 2a shows a shopping bag, Figure 2b shows a merchandise bag, Figure 2c shows a roll bag, and Figure 2d shows a waste bag. Figure 3 is a flow chart for producing the high-density polyethylene shopping bags, in which raw materials and additives for plastics are subject to the steps, for example, metering, blending, film blowing and printing, to make products. Figure 4 shows a few plastic products, in which Figure 4a shows a sheet product (by extrusion molding), Figure 4b shows a film product by blow molding), Figure 4c shows plate products (by extrusion molding), Figure 4d shows tubular products (by extrusion molding), Figure 4e shows a package product (by extrusion molding), and Figure 4f shows bottle and tube products (by injection molding). By way of illustration and to provide a more complete appreciation of the present invention with many of the attendant advantages thereof, the following detailed description is given concerning environmentally friendly additives for plastics and a process for producing the same. The invention is directed to the use of ash and hydroxides. The plastic products in which ash and hydroxides are added can provide environmental protection effect. Ash and hydroxides can be incorporated into polyolefins, such as general purpose plastics, to render the plastics environmentally advantageous for reducing the amount of hydrochloric acid gas released and for preventing formation of dioxins. The additive is environmentally friendly since it preferably absorbs more than 0.2 g of hydrochloric acid gas per gram of additive, for instance, 0.2 to 1, preferably 0.3 to 0.9, more preferably 0.45 to 0.8 g per gram of additive. The invention is related to an environmentally friendly additive for plastics, comprising 1 to 40% by weight of ash, 20 to 80% by weight of a polyolefin carrier, 1 to 60% by weight of a first hydroxide which is calcium hydroxide, and 1 to 50% by weight of a second hydroxide selected from the group consisting of aluminium hydroxide, ferric hydroxide, magnesium hydroxide and mixtures thereof. The invention is also related to a process for producing an environmentally friendly additive for plastics, comprising the steps of mixing, kneading, melting, extruding, degassing, and pelleting a combination of 1 to 40% by weight of ash, 20 to 80% by weight of the polyolefin carrier, 1 to 60% by weight of the first hydroxide, and 1 to 50% by weight of the second hydroxide to produce the additive. The ash is preferably ash which has been incinerated in thermo-power plants. The most preferable ash is bottom ash produced from thermo-power plants. The alkaline metals contained in the ash such as Mg, K, and Ca react with hydrochloric acid in incinerators to form chlorides. The chlorides are incinerated to form precipitated residues which are easily treated and will not spread out and pollute the environment. The particle size of the ash is 0.1 to 240 µ m, preferably 0.1 to 120 µ m, and most preferably 0.1 to 4 µ m. The ash is preferably in an amount of 5 to 20% by weight and more preferably in an amount of 5 to 10% by weight. The polyolefin carrier should be such that it can be blended homogeneously with and cover the ash and hydroxides. The carrier is preferably a low molecular weight polyolefin. The preferable molecular weight is in a range from 15,000 to 200,000, more preferably 15,000 to 150,000, and most preferably 15,000 to 50,000. Examples of the polyolefin include polyethylene (PE), polypropylene (PP), acrylonitrile-butadiene-styrene (ABS), polystyrene (PS), polyvinyl chloride (PVC) and ethylene vinyl acetate (EVA). The preferable carrier is polyethylene. The carrier is preferably in an amount of 20 to 50% by weight and more preferably in an amount of 35 to 50% by weight. The first hydroxide is calcium hydroxide. The first hydroxide is preferably in an amount of 10 to 60% by weight and more preferably in an amount of 10 to 50% by weight. The second hydroxide is different from the first hydroxide. The second hydroxide is at least one of aluminum hydroxide, ferric hydroxide, and magnesium hydroxide. The most preferable second hydroxide is aluminum hydroxide. The second hydroxide is preferably in an amount of 1 to 40% by weight and more preferably in an amount of 1 to 30% by weight. Persons skilled in the art can choose an appropriate amount for each second hydroxide if more than one are used so that the total of all second hydroxides is 1 to 50% by weight of the additive. The environmentally friendly additive for plastics can further comprise 0.03 to 5% by weight, preferably 0.03 to 2% by weight, of an internal lubricant. Examples of the internal lubricant are wax such as polyethylene wax, calcium stearate, zinc stearate, lead stearate, stearamide, and ethylene-bisstearamide. The operation conditions for the mixing, kneading, melting, extruding, degassing, and pelleting are known to persons skilled in the art and can be appropriately chosen by skilled persons to practice the process. An amount of 1 to 50% by weight of the additive can be incorporated into polyolefin plastic materials such as general purpose plastic materials with the proviso that the incorporation will not negatively influence the original properties of the plastic materials. The incorporation of the additive may affect the original properties of the plastic materials, but that any negative influence is sufficiently minor that it can be tolerated in practice. After the incorporation, the mixture of the additive and plastic materials are subjected to well known steps such as blending and film blowing to produce plastic products. The plastic products thus obtained can chemically bond with the chlorine ion released from organic or inorganic chlorines, which have been burned in incinerators, so as to prevent the formation of hydrochloric acid gas during incineration. Examples of the polyolefin plastic materials are high-density polyethylene (HDPE), low-density polyethylene (LDPE), polypropylene (PP), acrylonitrile-butadiene-styrene (ABS), polystyrene (PS), polyvinyl chloride (PVC) and ethylene vinyl acetate (EVA). The mechanism of the reduction of the formation of hydrochloric acid gas by hydroxides is as follows: A(OH)m+B(OH)n+(m+n)HCl→AClm+BCln+(m+n)H2O The environmentally friendly additive for plastics can be applied in the production of plastic bags. High-density polyethylene (HDPE) is widely used to mass-produce shopping bags and waste bags because it is without toxicity and is easily produced by blowing molding. The ordinary family even uses bags produced from high-density polyethylene as waste bags and hence a relatively large amount of wastes in incinerators are high-density polyethylene bags. The incorporation of the environmentally friendly additive for plastics of the invention into the plastic bags, such as high-density polyethylene plastic bags, provides the additive for bonding with the chlorine ions released from incinerators so as to reduce the formation of hydrochloric acid gas and the emission of dioxin. Hence, because of the use of the additive of the subject invention, plastic bags are environmentally protective. Example 1 Preparation of environmentally friendly additive for plastics 45g polyethylene (PE), 43g calcium hydroxide, 5g aluminum hydroxide, 5g ash, and 2g wax are mixed with a high speed in a blender for 5 minutes. When the temperature of the mixture reaches 95°C, the above mixture is applied to an extruder and the mixture is thoroughly dispersed to produce a melt. The extruder must be controlled at a temperature below 190°C. After leaving a gate of the extruder, the melt is cut into pellet-like additive for plastics with a rolling knife for further blending with plastics. Example 2 Effect of additive for plastics in absorbing hydrochloric acid gas 2g additive for plastics produced from Example 1 is powdered and blended homogeneously with 2g polyvinyl chloride (PVC) in an Erlenmeyer flask (Flask A) equipped with a nitrogen inlet. The flask is further connected to an Erlenmeyer flask (Flask B) containing 90 ml sodium hydroxide aqueous solution (0.5N) through a U-shaped glass tube. The Flask A is heated on a plate at a temperature from 300 to 310°C for about ten minutes. When no further bubbles evolve from the sodium hydroxide aqueous solution, nitrogen gas is applied to the Flask A. The rate of nitrogen gas is maintained so that the nitrogen gas can flow out from the sodium hydroxide aqueous solution. The Flask A is further heated from 40 to 50 minutes. Finally, the chlorine content of the 90 ml absorbent sodium hydroxide (0.5N) is analyzed and the amount of hydrochloric acid gas converted is calculated. The data obtained are listed in the Table below: Amount of environmentally friendly additive for plastics (g) Amount of PVC for producing hydrochloric acid gas (g) Amount of hydrochloric acid gas which is absorbed by environmentally friendly additive for plastics (g) Amount of hydrochloric acid gas which is absorbed by sodium hydroxide solution (g) Total amount of hydrochloric acid gas produced (g) Amount of hydrochloric acid gas absorbed by per gram of environmentally friendly additive for plastics (g) 2 2 1.04 0.06 1.10 0.52 2 2 1.06 <0.01 1.06 0.53 Example 3 Effect of absorbing hydrochloric acid gas of PE bags comprising environmentally friendly additive for plastics 0.4g high-density polyethylene (HDPE) film comprising the additive for plastics produced from Example 1 is applied to a test plate provided in a high temperature test tube which is set at 800°C and has an air input of 0.5 ml per minute. The test tube is maintained at that temperature for 10 minutes. After thorough burning, a gas sample is collected for testing. The result of the testing indicates that each gram of the environmentally friendly additive for plastics absorbs 400 mg of hydrochloric acid gas. Since the amount of "hydrochloric acid gas," the source for producing dioxin, can be great decreased, it is believed that the environmentally friendly additive for plastics of the invention can effectively inhibit the formation of dioxins.

Claims: An environmentally friendly additive for a plastic, comprising 1 to 40% by weight of ash, 20 to 80% by weight of a polyolefin carrier, 1 to 60% by weight of a first hydroxide which is calcium hydroxide, and 1 to 50% by weight of a second hydroxide, wherein said second hydroxide is selected from the group consisting of aluminum hydroxide, ferric hydroxide and magnesium hydroxide and mixtures thereof. An environmentally friendly additive according to claim 1, wherein said ash is obtainable from an incineration product of a thermo-power plant. An environmentally friendly additive according to claim 1 or 2, wherein said second hydroxide is aluminum hydroxide. An environmentally friendly additive according to any one of the preceding claims, wherein said carrier is a lower molecular weight polyolefin. An environmentally friendly additive according to claim 4, wherein said polyolefin is polyethylene (PE), polypropylene (PP), acrylonitrile-butadiene-styrene (ABS), polystyrene (PS), polyvinyl chloride (PVC) or ethylene vinyl acetate (EVA). An environmentally friendly additive according to claim 5, wherein said polyolefin is polyethylene. An environmentally friendly additive for plastics according to any one of the preceding claims, further comprising 0.03 to 5% by weight of an internal lubricant. An environmentally friendly additive for plastics according to claim 7, wherein said lubricant is selected from the group consisting of wax, calcium stearate, zinc stearate, lead stearate, stearamide or ethylene-bisstearamide. An environmentally friendly additive for plastics according to claim 8, wherein said wax is polyethylene wax. A product which comprises a polyolefin plastic material which releases hydrochloric acid gas when it is incinerated and an environmentally friendly additive as claimed in any one of the preceding claims, said additive being present in an amount of 1 to 50% by weight based on the total weight of the plastic material and additive. A product according to claim 10, wherein said plastic material is high-density polyethylene (HDPE), low-density polyethylene (LDPE), polypropylene (PP), acrylonitrile-butadiene-styrene (ABS), polystyrene (PS), polyvinyl chloride (PVC) and ethylene vinyl acetate (EVA). A process for producing an environmentally friendly additive for plastics, comprising the steps of mixing, kneading, melting, extruding, degassing, and pelleting a combination of 1 to 40% by weight of ash, 20 to 80% by weight of a polyolefin carrier, 1 to 60% by weight of a first hydroxide which is calcium hydroxide, and I to 50% by weight of a second hydroxide which is aluminum hydroxide, ferric hydroxide or magnesium hydroxide to produce the additive. A process according to claim 12, wherein said ash is obtainable from a incineration product of a thermo-power plant. A process according to claim 12 or 13, wherein said second hydroxide is aluminum hydroxide. A process according to any one of claims 12 to 14, wherein said carrier is a lower molecular weight polyolefin. A process according to claim 15, wherein said polyolefin is selected from the group consisting of polyethylene (PE), polypropylene (PP), acrylonitrile-butadiene-styrene (ABS), polystyrene (PS), polyvinyl chloride (PVC) or ethylene vinyl acetate (EVA). A process according to claim 16, wherein said polyolefin is polyethylene. A process according to any one of claims 12 to 17, wherein said additive further comprises 0.03 to 5% by weight of an internal lubricant. A process according to claim 18, wherein said lubricant is selected from the group consisting of wax, calcium stearate, zinc stearate, lead stearate, stearamide or ethylene-bisstearamide. A process according to claim 19, wherein said wax is polyethylene wax.

Inventors: CHANG CHIN-TONG, CHANG, CHIN-TONG, CHANG, Chin-Tong, Citizen of Taiwan R.O.C.
Applicants: FORMOSA TAFFETA CO LTD, FORMOSA TAFFETA CO. LTD.
Application year: 2000
Main classification: C08K3
IPC codes: C08K5, C08L27, C08L101, C08K3, C08L23