DMS cyclone separation processes for optimization of plastic wastes recycling and their implications

It is demonstrated that substantial reductions in plastics presently disposed of in landfills can be achieved by cyclone density media separation (DMS). In comparison with the size fraction of plastics presently processed by industrial density separations (generally 6.4 to 9.5 mm), cyclone DMS methods are demonstrated to effectively process a substantially greater range of particle sizes (from 0.5 up to 120 mm). The purities of plastic products and recoveries obtained with a single stage separation using a cylindrical cyclone are shown to attain virtually 100% purity and recoveries >99% for high-density fractions and >98% purity and recoveries were obtained for low-density products. Four alternative schemas of multi-stage separations are presented and analyzed as proposed methods to obtain total low- and high-density plastics fraction recoveries while maintaining near 100% purities. The results of preliminary tests of two of these show that the potential for processing product purities and recoveries >99.98% of both density fractions are indicated. A preliminary economic comparison of capital costs of DMS systems suggests cyclone DMS methods to be comparable with other DMS processes even if the high volume capacity for recycling operations of these is not optimized.