WO2025190718A1

WO2025190718A1 - Method for selecting target foam pieces from a vehicle scrap material

Info

Publication number: WO2025190718A1
Application number: PCT/EP2025/055762
Authority: WO
Inventors: Nicolas Stefan Schork; Vikas Aggarwal; Matthias Hinrichs; Achim Stammer; Oliver Pikhard; Patrick SCHMATZ-ENGERT; Patrick Weiss; Martin Binder; Christopher Alec ANDERLOHR; Andreas Thomas HAEDLER
Original assignee: BASF SE
Current assignee: BASF SE
Priority date: 2024-03-13
Filing date: 2025-03-04
Publication date: 2025-09-18
Anticipated expiration: 2026-09-13

Abstract

Method for selecting target foam pieces that comprise target foam material that is suitable for a predetermined recycling process, the method (102) comprising the steps of: providing a scrap material obtained by dismantling and/or shredding a vehicle, the scrap material comprising one or more foam pieces, performing a first analysis step (102A) for determining first composition data of a sample foam piece, the first composition data being indicative of a composition of the sample foam piece, performing a second analysis step (102B) for determining second composition data of the sample foam piece, the second composition data being indicative of the composition of the sample foam piece; and selecting (102C) the sample foam piece as a target foam piece upon determining that the first composition data and the second composition data are indicative of the target foam material.

Description

Method for selecting target foam pieces from a vehicle scrap material

Technical field

The invention is directed to a method for selecting target foam pieces that comprise target foam material suitable for a predetermined recycling process from scrap material. The invention is further directed to a method for pre-processing scrap material, to a pre-processing arrangement and to a computer program.

Background Art

Disposal of solid waste material creates an enormous problem nowadays and in the future. As ongoing landfill is not a sustainable solution, alternatives such as solid waste material sorting and recycling systems are under development.

In the field of plastic foam recycling, one option is a mechanical recycling. In a mechanical recycling process, the foam flakes are typically mixed with a binding agent and the mixture is steamed and pressed, for instance in a cylindrical press, a process with is antibacterial and actives the binding agent. After the pressed cylinder has dried, it can be peeled to a desired thickness. The rolls are ultimately cut to size into a recycled foam product, for instance as fall absorbing plates or sound or heat isolating material.

Currently, innovative alternatives to mechanical recycling processes are being developed and deployed that are categorized as chemical recycling. These processes aim at depolymerizing the plastic foam to obtain components from which the polymer has been produced. As an example, a polystyrene foam (PS foam) may be depolymerized to obtain the monomer styrene. As a further example, a polyurethane foam (PU foam) may be depolymerized to obtain polyols and aromatic amines (e.g. TDA or MDA) for the production of the respective aromatic diisocyanates (e.g. TDI or MDI).

Polyurethane (PU) is one of the most important materials of the wide-ranging and diverse family of polymers and plastics. It can be solid or have an open cellular structure. In this case it is referred to as foam. Foams, in turn, can be flexible or rigid. Polyurethane is typically manufactured by reacting polyols and diisocyanates, both products derived from crude oil. A series of additives are then added to produce high-quality PU foam products. The nature of the additives depends on the application the foam will be used for, which include, among others, bedding, furniture, and automotive.

Products containing polyurethane materials are widely used in industry and in everyday applications. Because of the tremendous and still increasing prevalence of polyurethane materials, there is a large amount of waste of polyurethane materials, e.g., from old mattresses, seating furniture, insulation boards, construction material or interior parts of vehicles like car seats. This waste of polyurethane materials should be used appropriately and as ecologically friendly as possible. One way of such use of polyurethane materials is the recovery of raw materials from the polyurethane materials.

Apart from household waste, the disposal of scrap or junk vehicles is of particular concern since millions of passenger cars, trucks and busses continuously become old or non-usable. In order to recycle many of the components in such vehicles, shredders have been designed which mechanically tear the vehicles apart and separate them into two products, i.e. metallic scrap and automotive shredder residue (also named "automobile shredder residue” and abbreviated as "ASR”). The metallic scrap is shipped to metal reprocessing centers, and the ASR material is shipped to a dump or landfill. However, due to the fact that automobiles are being designed to reduce the amount of metal components and increase the number of non-metal components, it has become desirable to develop systems for sorting and recycling as many of the reusable components as possible from the ASR material.

The recycling of automotive shredder residue presents several challenges that hinder its efficient and effective recycling. ASR is usually a complex mixture of materials, including metals, plastics, rubber, glass, and various organic and inorganic compounds. The diverse composition makes it difficult to separate and recover individual components, leading to suboptimal recycling rates. Without proper separation, valuable resources remain trapped within the ASR, limiting their recycling. Addressing these problems is crucial to enhance the recycling of ASR and maximize its potential as a valuable resource. Developing effective methods and systems that can efficiently separate and recover the diverse components of ASR, while safely managing and disposing of hazardous substances, will play a vital role in promoting a sustainable and circular economy.

Several ASR sorting and recycling systems have been developed. For example, document EP 0692356 A2 suggests to recycle automotive shredder residue by preparing a composite material comprising ASR and a virgin polymer.

Vijayan, S.K.; Kibria, M.A.; Uddin, M.H.; Bhattacharya, S. “Pretreatment of Automotive Shredder Residues, Their Chemical Characterisation, and Pyrolysis Kinetics." Sustainability 2021 , 13, 10549 suggests to recycle automotive shredder residue by pyrolysis.

Ezzat El Halabi, Mike Third, and Matthew Doolan “Machine-based dismantling of end of life vehicles: A life cycle perspective" Procedia, 29 (2015) 651-655 suggest to recycle automotive shredder residue by machine based dismantling.

Juliana Argente Gaetano, Valdir Schalch, Javier Mazariegos Pablos “Characterization and recycling of the fine fraction of automotive shredder residue (ASR) for concrete paving blocks production" Clean Technologies and Environmental Policy (2020) 22:835-847 suggest to recycle ASR by solidification with cement, gravel and sand for paving blocks production.

Won-Seok Yang et al. “Utilization of automobile shredder residue (ASR) as a reducing agent for the recovery of black copper¹’ Korean J. Chem. Eng., 33(4), 1267-1277 (2016) suggests to recycle ASR by using it instead of lump coal as a reducing agent in the copper production.

There remains a need, however, for an improved system wherein the waste material can be processed into usable products. Compared to treatment processes for other (non-foam) recycling materials, for foams special problems arise due to the low density of the material and the large dimensions of the material, making an efficient handling mandatory to be economically successful.

It is an object of the present invention to provide an optimized method for sorting target foam pieces that enables a general reduction of the recycling costs and, in particular in the case of chemical recycling, results in a higher yield and higher product quality.

These tasks are solved according to the invention by a method for selecting target foam pieces according to claim 1 , a method for pre-processing a scrap material according to claim 8, a pre-processing arrangement according to claim 9, and a computer program according to claim 15. Advantageous variants of the method are presented in the dependent claims.

Brief description

As used herein, the terms "have”, "comprise” or "include” or any arbitrary grammatical variations thereof are used in a non-exclusive way. Thus, these terms may both refer to a situation in which, besides the feature introduced by these terms, no further features are present in the entity described in this context and to a situation in which one or more further features are present. As an example, the expressions "A has B”, "A comprises B” and "A includes B” may both refer to a situation in which, besides B, no other element is present in A (i.e. a situation in which A solely and exclusively consists of B) and to a situation in which, besides B, one or more further elements are present in entity A, such as element C, elements C and D or further elements.

Further, it shall be noted that the terms "at least one”, "one or more” or similar expressions indicating that a feature or element may be present once or more than once typically are used only once when introducing the respective feature or element. In most cases, when referring to the respective feature or element, the expressions "at least one” or "one or more” are not repeated, notwithstanding the fact that the respective feature or element may be present once or more than once. Further, as used herein, the terms "preferably", "more preferably", "particularly", "more particularly", "specifically", "more specifically" or similar terms are used in conjunction with optional features, without restricting alternative possibilities. Thus, features introduced by these terms are optional features and are not intended to restrict the scope of the claims in any way. The invention may, as the skilled person will recognize, be performed by using alternative features. Similarly, features introduced by "in an embodiment of the invention" or similar expressions are intended to be optional features, without any restriction regarding alternative embodiments of the invention, without any restrictions regarding the scope of the invention and without any restriction regarding the possibility of combining the features introduced in such way with other optional or non-optional features of the invention.

In a first aspect of the invention, a method for selecting target foam pieces that comprise target foam material that is suitable for a predetermined recycling process is disclosed. The method comprises the steps of: providing a scrap material obtained by dismantling and/or shredding a vehicle, the scrap material comprising one or more foam pieces; in a first analysis step, determining first composition data of a sample foam piece by means of a first analysis setting, the first composition data being indicative of a composition of the sample foam piece; in a second analysis step, determining second composition data of the same sample foam piece by means of a second analysis setting, the second composition data being indicative of the composition of the sample foam piece; and

- selecting the sample foam piece as a target foam piece upon determining that the first composition data and the second composition data are indicative of the target foam material.

Typical sorting methods involve the use of sensors, e.g. optical sensors, to detect and identify the foam material before deciding if the foam material has an acceptable quality or not for the predetermined recycling process, i.e. if the foam material qualifies as a target foam material. However, due to the variety of different compositions, layered or packed material design, and dust and dirt contaminating the composition to be analysed, the detection and sorting process is sometimes falsified and some foam pieces can be regarded as having sufficient quality although it might comprise a layer or section of unacceptable foam material. If such a composite foam piece is fed to the recycling process it can cause severe trouble or spoil the product quality.

Thus, according to the invention, by combining at least two analysis steps, it is possible to better analyse the sample foam piece currently being sorted and improve the compositional homogeneity of the selected target foam pieces through a more accurate sorting. The combination of at least two analysis steps can increase the yield of the target foam material for the recycling process, since they enable a reduction of the contamination by the presence of foam materials not suitable for the recycling process. Due to the resulting lower impurities in the material stream, the product quality of the recycling process can be significantly increased. Foam, also referred to as foamed plastic, is a synthetic resin converted into a spongelike mass with a closedcell or open-cell structure, either of which may be flexible or rigid. Foam is used for a variety of products, including cushioning materials, air filters, furniture, toys, thermal insulation, sponges, plastic boats, panels for buildings, lightweight beams, and many automotive applications. Under appropriate conditions almost every thermosetting or thermoplastic resin can be converted into a foam. Plastics that are commonly foamed include vinyls, polystyrene, polyethylene, phenolics, silicones, cellulose acetate and urethanes, such as polyurethane (PU). PU foams is typically used in the fabrication of mattresses and upholstery. Different types of PU foam include, for instance, standard PU foam, high resilience PU foam, viscoelastic PU foam, etc. Depending on foam parameters such as the density, resilience or chemical compositions, PU foams are available as, for example, and non-restrictively, charcoal foam, dry fast foam, high density foam, lux foam (evlon foam), latexrubber foam, rebond foam, etc., which are all open-cell polyurethane foams.

The composition data is data that is indicative of the composition of the foam piece under analysis, from which information regarding the type of foam material and/or contained additives can be inferred, based on which the suitability of the foam piece for the predetermined recycling process, i.e. whether the foam piece comprises or not the target foam material, can be decided.

The composition data is determined by means of an analysis setting, which refer to any analysis method or analysis device suitable for obtaining the composition data.

In the following, embodiments of the method of the first aspect of the invention will be disclosed.

In an embodiment, the first analysis setting and the second analysis setting are different analysis settings. In an alternative embodiment, the first analysis setting and the second analysis setting are the same analysis setting.

In an embodiment, the method further comprises performing at least a third analysis step for determining at least a third composition data indicative of a composition of the sample foam piece and selecting the sample foam piece as a target foam piece upon determining that all determined composition data is indicative of the target foam material. In an alternative embodiment, the sample foam piece is selected as a target foam piece upon determining that at least predetermined percentage of the determined composition data is indicative of the target foam material. For instance, in an exemplary and non-restricting embodiment, four different analysis steps are performed and the sample foam piece is selected as a target foam piece upon determining that at least 75%, i.e., three out of the four determined composition data, is indicative of the target foam material. In another embodiment, the first analysis step for determining the first composition data and the second analysis step for determining the second composition data are performed using different analytical methods. This enables a better qualification or even quantification of the composition of the foam piece under analysis, i.e. the current sample foam piece, which is typically not possible when applying only one analytical method.

In yet another embodiment, the first composition data is indicative of a type of foam, in particular of a type of polyurethane foam of the sample foam piece and the second composition data is indicative of a type of additive and/or impurity of the sample foam piece. Preferably, in a further embodiment, the second composition data is indicative of one or more additives selected from a group consisting of water, inorganic fillers, such as, but not limited to CaCO3, organic fillers, flame retardants, styrenes (in particular styrene acrylonitrile, "SAN”), silicon stabilizers, crosslinker, chain extenders, monools, such as phenoxyethanol, antioxidants, defoamers, catalysts and dyes.

Alternatively, or additionally, the second composition data can be indicative of dust, dirt, humidity, microbial contamination or fungal contamination. In another embodiment, the first composition data is indicative of a type of additive and/or impurity and the second composition data is indicative of a type of foam.

The above-mentioned SAN content generally may embrace content of "graft polyols” often also termed polymer polyols. Polymer polyols mean dispersions of polymers, mostly acrylonitrile-sty rene copolymers, in particular stabilized by the co-polymerization of macromers in a polyether polyol matrix. The graft polyols used for the preparation of polyurethane foams usually have a hydroxy value in the range from 15 to 120 mg KOH/g. They may be present in the polyurethane foams in an amount of up to 25 wt.%.

Water represents in many cases the additive with a highest content, sometimes forming up to 70% of the total amount of additives. Typically it reacts to CO2 during the foaming process.

In particular for flexible polyurethane foams, the fillers promote an increase in density and resistance to compression. However, they reduce the resilience and contribute to the increase in permanent deformation. In addition, properties such as tear strength are significantly affected by the introduction of fillers. Accordingly, it is necessary to determine the correct concentration of the filler in the polymer matrix, so as to obtain a product of reliable quality. Some notable fillers include inorganic materials such as calcium carbonate, dolomite, aluminum silica, titanium dioxide, chalk and talc while some of the organic materials used as filler are SAN carbon black and natural fibers.

Silicone stabilizer or surfactants for PU foams are typically grafted copolymers which consist of a polydimethylsiloxane backbone and polyethylene oxide-co-propylene oxide pendant groups. Some silicone stabilizers include siloxanes with polyetherol sidechains. Stabilizers are typically used as surfactants to stabilize the foam cells in the flexible polyurethane foaming process. It increases the compatibility of raw materials, decrease surface tension in polyurethane foam systems, improve emulsification and nucleation, prevent coalescence and stabilize cell membranes.

The chemical nature of the PU, the high air permeability, and the high inner surface area of the foam structure cause this material to be highly flammable. Consequently, the application of flame retardants to flexible PU foams is an important issue. The use of halogenated flame retardants is not considered optimal, in part due to the high emission level and the possible phase-out by the European Risk Assessment Body. Consequently, melamine as a non-halogenated flame retardant is applied more and more frequently. Other flame retardants include, but are not limited to formaldehyde-based retardants and phosphorus-based retardants. Also, expandable graphite may be used as flame retardant.

Typically, the addition of crosslinking additives, or crosslinkers, to PU foams serves to reduce or eliminate deterioration under humid aging conditions of these foams, in particular those made using non-fugitive tertiary amine urethane catalysts. Examples of crosslinkers, in particular for high resilient (HR) PU foams include glycerine, diethanolamine, and sorbitol.

Chain extenders are typically low molecular weight diols or diamines that react with diisocyanates to build polyurethane molecular weight and increase the block length of the hard segment. Much like the diisocyanates, chain extenders can be either aliphatic or aromatic. Examples of chain extenders, in particular for VE foams, include butandiol and methylpropanediol.

Generally, for ensuring a safe production of PU foams, a foam stabilizer possesses weak uniformizing power and a defoaming agent is required for the purpose of controlling the formation of open cells. Commonly used defoaming agents include insoluble oils, polydimethylsiloxanes and other silicones, certain alcohols, stearates and glycols.

There are mainly two types of catalysts used in polyurethane technology, i.e. amine catalysts and organometallics. Amine catalysts generally catalyze the isocyanate-water reaction better than the isocyanatepolyol reaction, while organometallics are considered as gel catalysts although they additionally influence blowing reactions. The amine catalysts, especially tertiary amines, are the most common organic base catalysts in the synthesis of polyurethanes. One of the most commonly used tertiary amine catalyst is 1 ,4- diazobicyclo[2,2,2]octane (DABCO). It catalyzes both isocyanate-polyol and isocyanate-water reactions. One of the drawbacks of using tertiary amines is their offensive fishlike odor and high volatility. Increasing environmental concerns toward decreasing of emissions of volatile organic compounds (VOC) have contributed to the development of nonfugitive catalysts. In another. Tertiary amines are typically present in small concentrations, e.g., under 0.5% of the total foam and they are typically volatile and no longer detectable in the final foam. In addition, metal-catalysts are also used in PU foam manufacturing. For instance tin-organic compounds (mostly DBTL dibutyltin dilaurate) are now only permitted in very small quantities by the testing institutes (including their degradation products). However, alternative tin compounds are currently being used.

Further, the optical sorting methods can be advantageously used to sort out material which is covered with or contains unacceptable dirt, dust, or microbial or fungal layers, irrespectively of the material having the right foam composition for the recycling process. In this cases the composition data is indicative of the presence of said unacceptable dirt, dust, or microbial or fungal material.

In yet another embodiment the first analysis step for determining the first composition data and/or the second analysis step for determining the second composition data is performed by one or more analytical methods selected from the group consisting of a near-infrared spectroscopy based method, a medium-infrared spectroscopy based method, a Raman spectroscopy based method, a THz spectroscopy based method, a UV- VIS spectroscopy based method, an optical-cameras based method, a laser induced breakdown spectroscopy method and an X-ray fluorescence based method.

Infrared spectroscopy (IR spectroscopy or vibrational spectroscopy) is the measurement of the interaction of infrared radiation with matter by absorption, emission, or reflection. It is used to study and identify chemical substances or functional groups in solid, liquid, or gaseous forms. It can be used to characterize new materials or identify and verify known and unknown samples.

The infrared portion of the electromagnetic spectrum is usually divided into three regions; the near-, mid- and far- infrared, named for their relation to the visible spectrum. The higher-energy near-IR, approximately 14,000-4,000 cm^-1 (0.7-2.5 pm wavelength) can excite overtone or combination modes of molecular vibrations. The mid-infrared, approximately 4,000-400 cm^-1 (2.5-25 pm) is generally used to study the fundamental vibrations and associated rotational-vibrational structure. For instance, near infrared spectroscopy (NIRS) is a spectroscopic method that uses the near-infrared region of the electromagnetic spectrum (approximately from 700 nm to 2500 nm). Typical applications include medical and physiological diagnostics, and control quality. Near-infrared spectroscopy is not a particularly sensitive technique, but it can be very useful in probing bulk material with little or no sample preparation. Instrumentation for NIRS includes a source, a detector, and a dispersive element (such as a prism, or, more commonly, a diffraction grating) to allow the intensity at different wavelengths to be recorded. The instrumentation is very similar to that used for the UV-visible and mid-IR ranges.

UV-VIS spectroscopy refers to absorption spectroscopy or reflectance spectroscopy in part of the ultraviolet and the full, adjacent visible regions of the electromagnetic spectrum. Being relatively inexpensive and easily implemented, this methodology is widely used in diverse applied and fundamental applications. The only requirement is that the sample absorb in the UV-VIS region, i.e. be a chromophore. Absorption spectroscopy is complementary to fluorescence spectroscopy. Parameters of interest, besides the wavelength of measurement, are absorbance (A) or transmittance (%T) or reflectance (%R), and its change with time. UV- VIS spectroscopy is routinely used in analytical chemistry for the quantitative determination of diverse analytes or sample, such as transition metal ions, highly conjugated organic compounds, and biological macromolecules.

Raman spectroscopy is a spectroscopic technique typically used to determine vibrational modes of molecules, although rotational and other low-frequency modes of systems may also be observed. Raman spectroscopy is commonly used in chemistry to provide a structural fingerprint by which molecules can be identified. Typically, a sample is illuminated with a laser beam. Electromagnetic radiation from the illuminated spot is collected with a lens and sent through a monochromator. Elastic scattered radiation at the wavelength corresponding to the laser line (Rayleigh scattering) is filtered out by either a notch filter, edge pass filter, or a band pass filter, while the rest of the collected light is dispersed onto a detector.

Laser induced breakdown spectroscopy is a type of atomic emission spectroscopy which uses a highly energetic laser pulse as the excitation source. The laser is focused to form a plasma, which atomizes and excites samples. The formation of the plasma only begins when the focused laser achieves a certain threshold for optical breakdown, which generally depends on the environment and the target material.

X-ray fluorescence (XRF) refers to the emission of characteristic "secondary" (or fluorescent) X-rays from a material that has been excited by being bombarded with high-energy X-rays or gamma rays. The phenomenon is widely used for elemental analysis and chemical analysis.

Terahertz spectroscopy detects and controls properties of matter with electromagnetic fields that are in the frequency range between a few hundred gigahertz and several terahertz (abbreviated as THz). In many-body systems, several of the relevant states have an energy difference that matches with the energy of a THz photon. Therefore, THz spectroscopy provides a particularly powerful method in resolving and controlling individual transitions between different many-body states.

In an embodiment, the first analysis step for determining the first composition data is performed using a hand held near infrared spectroscopy device. In a further embodiment, the second analysis step for determining the second composition data is performed using a hand held near infrared spectroscopy device.

In a further embodiment, the first analysis step, the second analysis step, the third analysis step or any combination of analysis steps comprises: - determining a composition of a sample foam piece or a sample foam element at a first location, thereby obtaining first composition data indicative of the composition of the sample foam piece or sample foam element at said first location;

- determining a composition of the sample foam piece or the sample foam element at a non-overlapping second location different than the first location, thereby obtaining second composition data indicative of the composition of the sample foam piece or of the sample foam element at the second location; and

- selecting the sample foam piece as a target foam piece or the sample foam element as a target foam element upon determining that the composition data obtained at the first location and the second location is indicative of the target foam material.

This is particularly advantageous in the case of foam with a mixed composition that includes sections made of the target foam material and other sections of non-target foam material.

In an embodiment, the method further comprises determining respective composition data indicative of the composition of the sample foam piece at three or more different non overlapping locations and selecting the sample foam piece as a target foam piece upon determining that at least predetermined percentage of the determined composition data is indicative of the target foam material. For instance, in an exemplary and nonrestricting development, the sample foam piece is analysed at four different non-overlapping locations and the sample foam piece is selected as a target foam piece upon determining that at least 75%, i.e., three out of the four determined composition data, are indicative of the target foam material. In a more preferred development, a sample foam piece is selected as a target foam piece upon determining that at least 80%, at least 85%, at least 90% or are least 95% of the determined composition data, are indicative of the target foam material. In a most preferred development, the sample foam piece is selected as a target foam piece upon determining that all determined composition data are indicative of target foam material.

The scrap material comprising one or more foam pieces is obtained by dismantling a vehicle, shredding a vehicle or dismantling and shredding a vehicle.

In an embodiment, the scrap material is obtained from dismantling a vehicle. The dismantling of vehicles may comprise selective removal of parts, such as engines, gearboxes, tires, glass, and plastics, for being reused as spare parts for the second-hand market. The dismantling may also comprise the removal of larger plastic components. In view of the inventive method for selecting target foam pieces, plastic components made of a flexible or rigid foam are of particular interest. In an embodiment, the scrap material comprises a vehicle seat, a headliner, a dashboard, an interior panel or any other foam containing component of a vehicle that can be easily dismantled before shredding the vehicle. In a further embodiment, the scrap material is obtained from a material resulting from shredding a vehicle, either with or without prior dismantling of the vehicle. Preferably, the scrap material comprises an automotive shredder residue, a shredder light fraction (SLF) separated from automotive shredder residue, a shredder heavy fraction (SHF) separated from automotive shredder residue, or any combination thereof.

The term "automotive shredder residue” (also called "ASR”) as used herein is a broad term and is to be given its ordinary and customary meaning to a person of ordinary skill in the art and is not to be limited to a special or customized meaning.

The automotive shredder residue may be obtainable, preferably is obtained, by shredding vehicles. Preferably, the automotive shredder residue is obtainable by depollution of the vehicles, dismantling the vehicles, shredding the vehicles, and separating metal particles from the shredded vehicles.

The vehicles are typically end-of-life vehicles (also called “ELV”), which are typically at least 15 years old. The vehicles can be passenger cars, light-duty or heavy-duty trucks, motorbikes, a utility vehicle, an agricultural vehicle, or recreational vehicles. The vehicle can be an electric vehicle, such as a fully electric vehicle or a hybrid electric vehicle.

In depollution of vehicles hazardous liquids such as fuel, lubricating oil, coolants, brake fluids and batteries can be removed from the vehicles prior to shredding.

The dismantling of vehicles may comprise selective removal of parts, such as engines, gearboxes, tires, glass, and plastics, for being reused as spare parts for the second-hand market. The dismantling may also comprise the removal of larger plastic components, such as bumpers, dashboard, fluid containers for recycling the plastics separately.

The ASR may comprise further waste from other sources. For examples, garbage from the last owners may remain in the trunk or interior of the vehicles. The advantage of the present process is that it can handle broadly varying compositions of the ASR.

The shredding can be made with a vehicle shredder machine. Vehicle shredder machines are manufactured in different sizes. Typically, a vehicle shredder machine comprises a heavy fast-turning rotor, which may revolve in a vertical or a horizontal plane and is often equipped with swinging hammers. The vehicle shredder machine tears and shreds the car hulk until its parts are reduced to fragments with a desired fragment size, such as up to 30 cm, preferably 1 mm to 15 cm. Then the fragments may pass through grids and leave the rotor housing. After shredding, the metal fragments such as ferrous and non-ferrous metal fragments can be separated from the shredded vehicles. The ferrous metal fragments can be removed by magnetic separators. The non-ferrous metal fragments can be separated from the shredded vehicles by eddy current separators, by heavy media sink/float units which separate on the basis of density, or by manual sorting. Typically, 60 - 90 wt% of the vehicle weight is metal, which can be separated from the shredded vehicle.

The automotive shredder residue may represent about 10 - 40 wt%, preferably from 15 - 35, and in particular from 20 - 30 wt% of the original vehicle weight.

The automotive shredder residue may comprise fragments of various polymeric vehicle parts, such as fragments of bumpers, interior panels, dashboard, cable insulation, fuel tank, electrical insulation, flexible foam seating, foam insulation panels, automotive suspension bushings, electrical potting compounds, car body parts, pillar coverings, spoilers polymer parts coated with automotive paint, wheel covers, gears, bushes, cams, bearings, weatherproof coatings, interior and exterior trims, fuel systems, gear housings, headlamp retainer, engine cover, connector housings, door handles, carburetor components, exterior mirror components, windscreen wiper components, windscreen wiper protective housings, decorative grilles, cover strips, roof rails, window frames, sliding roof frames, antenna cladding covers, front and rear lights, radiator grill and body exterior parts, engine covers, cylinder head covers, intake pipes, cylinder head covers, engine covers, housings for charge air coolers, charge air cooler valves.

The automotive shredder residue may comprise fragments of various polymeric vehicle parts, such as fragments of bumpers, interior panels, dashboard, cable insulation, where these fragments are often made of polypropylene;

- fuel tank, electrical insulation, where these fragments are often made of polyethylene;

- flexible foam seating, foam insulation panels, automotive suspension bushings, electrical potting compounds, hard plastic parts, transmission mounts, motor mounts, seals, impact foam parts, where these fragments are often made of polyurethane; body parts, dashboards, wheel covers, where these fragments are often made of aery lonitri le-butadiene- styrene;

- gears, bushes, cams, bearings, charge air coolers, cylinder head covers, oil pans, engine cooling systems, thermostat and heater housings, exhaust systems including mufflers and housings for catalytic converters, air intake manifolds, timing chain belt front covers, where these fragments are often made of nylon 6 or nylon 6.6.; interior and exterior trims, fuel systems, small gears, where these fragments are often made of polyoxymethylene; - wiper arm and gear housings, headlamp retainer, connector housings, where these fragments are often made of polyethylene terephthalate; and

- door handles, bumpers, carburetor components, where these fragments are often made of polybutylene terephthalate.

The automotive shredder residue may comprise at least 30 wt%, preferably at least 40 wt%, and in particular at least 50 wt% of the fragments of the polymeric vehicle parts.

The automotive shredder residue may comprise at least 20 wt%, preferably at least 30 wt%, and in particular at least 40 wt% of the fragments of the polymeric vehicle parts, which are black polymeric vehicle parts. The black polymeric vehicle parts usually comprise carbon black pigments.

The automotive shredder residue may comprise up to 15 wt%, preferably up to 10 wt%, and in particular up to 5 wt% of metal fragments, such as ferrous and non-ferrous metal particles.

The automotive shredder residue may comprise up to 15 wt%, preferably up to 10 wt%, and in particular up to 5 wt% of wood and cardboard.

The automotive shredder residue may comprise up to 15 wt%, preferably up to 10 wt%, and in particular up to 5 wt% of glass fragments, e.g. broken window glass fragments.

The automotive shredder residue can be separated into a shredder light fraction (also called "SLF”) and a shredder heavy fraction (also called "SHF”). The separation of the SLF and the SHF can be achieved by air classification. Another air classification can be made by the rotary movement of the vehicle shredder machine may create a fanning action that can blow out the shredder light fraction, and the shredder heavy fraction may leave the vehicle shredder machine through a grid.

The SLF can be present in an amount of 55 - 90 wt%, preferably 65 - 85 wt%, and in particular at 70 - 80 wt% of the automotive shredder residue. The SHF may represent the remaining amount to 100 wt%.

The SHF can be present in an amount of 10 - 45 wt%, preferably 15 - 35 wt%, and in particular at 20 - 30 wt% of the automotive shredder residue. The SLF may represent the remaining amount to 100 wt%.

The SLF usually contains a lower weight percentage of rubber particles than the SHF. The SLF usually contains a lower weight percentage of glass particles than the SHF. The SLF usually contains a lower weight percentage of metal particles than the SHF. The SLF usually contains a higher weight percentage of polyurethane foam particles than the SHF. The SLF usually contains a lower weight percentage of solid and sand than the SHF.

The method of the first aspect of the invention thus enables a high-quality sorting process. Any process that requires to sort out unsuitable foam pieces will benefit from this method. For instance, processes for recycling plastic material from scrap material obtained from dismantling and or shredding a vehicle, in particular a chemical recycling process, will benefit from a more stable feed supply, leading to a more stable chemical recycling process with a higher yield. Further, the recycled raw materials, such as polyol and TDI, will have a higher purity and a more stable composition, which will enable to replace virgin material with the recycled raw materials during the production of new plastic components. Additionally, shutdowns, cleaning efforts or repair works in the chemical recycling process can be reduced by providing a higher quality material to the reactor.

In a second aspect of the invention, a method for pre-processing a scrap material for feeding a reactor of a recycling process is disclosed. The method comprises the steps of: performing steps of the method for selecting target foam pieces from the scrap material according to the first aspect of the invention;

- transporting the selected target foam pieces to a shredding unit;

- shredding, at the shredding unit, the selected target foam pieces to form shredded foam elements; and

- optionally feeding the shredded foam elements to the reactor for recovering raw materials.

Alternatively, or additionally a method for pre-processing a scrap material also in accordance with the invention comprises the steps of:

- transporting the scrap material comprising one or more foam pieces to a shredding unit;

- shredding, at the shredding unit, the foam pieces to form shredded foam elements; performing steps of the method for selecting, among the shredded foam element, shredded target foam elements comprising the target foam element according to the first aspect of the invention; and

- optionally feeding the selected shredded target foam elements to the reactor for recovering raw materials.

Alternatively, or additionally a method for pre-processing a scrap material also in accordance with the invention comprises the steps of: performing steps of the method for selecting target foam pieces from the scrap material according to the first aspect of the invention;

- transporting the selected target foam pieces to a shredding unit; - shredding, at the shredding unit, the selected target foam pieces to form shredded foam elements; performing steps of the method for selecting, among the shredded foam element, shredded target foam elements comprising the target foam element according to the first aspect of the invention; and

In this particular embodiment, the foam containing objects to be sorted are the shredded foam elements, and the result of the sorting step are selected target foam elements.

In an embodiment of the method of the second aspect, the method for selecting target foam pieces and/or target foam elements, i.e. , generally speaking, foam objects comprising target foam material, is performed twice, once using foam pieces as input before shredding the selected target foam pieces, and a second time using foam elements as input before feeding the selected target foam elements to the reactor.

The method for pre-processing a scrap material of the second aspect thus shares the advantages of the method for selecting target foam pieces (or target form elements) of the first aspect of the invention.

In the context of the present invention the shredded foam elements, respectively target foam elements, in particular mean shredded PU foam elements. Shredded PU foam elements embrace generally a "comminuted polyurethane or polyisocyanurate foam or the like foam material”. Preferably this means the material is obtained from a foam, and the comminuted polyurethane or polyisocyanurate is for example used in shredded form, i.e. in the form of granules, flakes, as an agglomerate, or as a powder.

The polyurethane or polyisocyanurate foams can be comminuted by conventional methods, for example by shredding, e.g. in a rotation mill or rotary mill at room temperature, to a particle size of ordinarily less than 500 mm, for example to a particle size in the range of from 10 to 500 mm, preferably to a particle size of less than 20 mm, or ground, e.g. by known cold grinding processes.

Preferably, for a milled foam a particle size of less than 5 mm is selected, for example a particle size in the range of 0.01 mm to 5 mm, and preferably in the range of 0.01 mm to 1 mm.

The properties of the polyurethane or polyisocyanurate foams might vary in broad ranges. Preferably, polyurethane foams are used in the process of the present invention. According to a further embodiment, the present invention is also directed to the process as disclosed above, wherein the polyurethane foams are selected from the group consisting of polyisocyanate derived polyurethane foams. The polyurethane or polyisocyanurate foams used in the present invention are preferably obtained from items produced from polyurethane foams at a time after use for the purpose for which they were manufactured or polyurethane foam waste from production processes.

Before subjecting to the process of the present invention, the items may be subjected to sorting steps and/or to mechanical comminution. That is, further sorting and bringing the items into appropriate sizes, e.g. by shredding, sieving or separation by rates of density, i.e. by air, a liquid or magnetically.

Optionally, these fragments may then undergo processes to eliminate impurities, e.g. paper labels. Furthermore, steps to remove blowing agents may be included in the process. Suitable methods are in principle known to the person skilled in the art.

Herein, the term "polyurethane foam waste” includes end-of-life polyurethane foams and production rejects of PU foams or waste generated through further processing of PU foams. In this context, the term "spent polyurethane foam” denotes an item produced from a polyurethane foam at a time when it has already been used for the purpose for which it was manufactured. "Production rejects of polyurethane foams" denotes polyurethane foam waste occurring in production processes of PU foams.

Generally, polyurethane foams are produced by a reaction between a polyisocyanate component and a polyol component. Typically, further materials, in particular additives, such as flame retardants (e.g. phosphorous- based), polymerization catalysts (e.g. tertiary amines), fillers and surfactants as siloxanes can be added in the production process of the polymers.

The properties of a polyurethane foam are influenced by the chemistry of polyisocyanate and polyol components used and the recipe applied in polymerization. For example, the starting materials may influence the crosslinking density of the polymers in a three-dimensional network. Rigid polyurethane are typically obtained from monomers with a comparably low molecular weight and high functionality creating a highly crosslinked, dense network.

Industrially and consequently in large quantities, especially methylenedi(phenylisocyanate) (MDI) or its polymeric forms or tolylene 2,4- and 2,6-diisocyanate (TDI) are used as polyisocyanate components for the production of PU rigid foams and PU flexible foams. For a representative composition of these PU foams, see for example US 9,023,907 B2, WO 2015/121057 A1 and WO 2013/139781 A1.

Organic polyisocyanates that can be used in the preparation of polyurethanes are any of the known organic di- and polyisocyanates, preferably aromatic polyfunctional isocyanates. Suitable polyisocyanate components used for the production of the polyurethanes or polyisocyanurates comprise any of the polyisocyanates known for the production of polyurethanes or polyisocyanurates. These comprise the aliphatic, cycloaliphatic, and aromatic difunctional or poly-functional isocyanates known from the prior art, and also any desired mixtures thereof. Examples are diphenylmethane 2,2'-, 2,4'-, and 4,4'- diisocyanate, the mixtures of monomeric diphenylmethane diisocyanates with diphenylmethane diisocyanate homologs having a larger number of rings (polymer MDI), isophorone diisocyanate (IPDI) and its oligomers, tolylene 2,4- and 2,6-diisocy anate (TDI), and mixtures of these, tetramethylene diisocyanate and its oligomers, hexa-methylene diisocyanate (HD I ) and its oligomers, naphthylene diisocyanate (NDI), and mixtures thereof.

Preferably, tolylene 2,4- and/or 2, 6-di isocynate (TDI) or a mixture thereof, monomeric diphenyl-methane diisocyanates, and/or diphenylmethane diisocyanate homologs having a larger number of rings (polymer MDI), and mixtures of these. Other possible isocyanates are mentioned by way of example in "Kunststoffhandbuch [Plastics handbook], volume 7, Polyurethane [Polyure-thanes]", Carl Hanser Verlag, 3rd edition 1993, chapter 3.2 and 3.3.2.

The organic di- and polyisocyanates may be used individually or in the form of mixtures.

Common polyols used in huge quantities are, e.g., selected from the group consisting of polyether polyols, polyester polyols, polyetherester polyols and mixtures thereof.

Polyetherols are by way of example produced from epoxides, for example propylene oxide and/or ethylene oxide, or from tetrahydrofuran with starter compounds exhibiting hydrogen-activity, for example aliphatic alcohols, phenols, amines, carboxylic acids, water, or compounds based on natural substances, for example sucrose, sorbitol or mannitol, with use of a catalyst. Mention may be made here of basic catalysts and doublemetal cyanide catalysts, as described by way of ex-ample in WO 2006/034800 A1 , EP 0090444 A1, or WO 2005/090440 A1.

Polyesterols are by way of example produced from aliphatic or aromatic dicarboxylic acids and polyhydric alcohols, polythioether polyols, polyesteramides, hydroxylated polyacetals, and/or hydroxylated aliphatic polycarbonates, preferably in the presence of an esterification catalyst. Other possible polyols are mentioned by way of example in "Kunststoffhandbuch [Plastics handbook], volume 7, Polyurethane [Polyurethanes]", Carl Hanser Verlag, 3rd edition 1993, chapter 3.1.

In a preferred embodiment, the step of shredding the selected target foam pieces results in shredded foam elements with a maximum dimension in the range of 100 mm to 500 mm. In a further embodiment, the step of milling the selected target foam elements results in milled target foam flakes with a maximum dimension smaller than 120 mm preferably smaller than 90 mm even more preferable smaller than 70 mm. The method of the second aspect of the invention can be advantageously used for pre-processing a plastic mix, additionally or alternatively comprising other types of non-foam plastic and other non-plastic material.

In an embodiment, a method, preferably a method according to the first aspect of the invention or the second aspect of the invention, comprises the step of converting the target foam pieces obtainable by or obtained by the method according to the first aspect of the invention, and/or the shredded target foam elements and/or the raw materials obtainable by or obtained by the method according to the second aspect of the invention to obtain a product PRF1.

In an embodiment, the product PRF1 is selected from:

I) building block or monomer; or ii) polymer, preferably polymer A, polymer composition, preferably polymer composition A, or polymer product, preferably polymer product A; or ill) industrial use polymer, industrial use surfactant, descaling compound, industrial use biocide, industrial use solvent, industrial use dispersant, composition thereof or formulation thereof; or iv) agrochemical composition, agrochemical formulation auxiliary or agrochemically active ingredient; or v) active pharmaceutical ingredient or intermediate thereof, pharmaceutical excipient, animal feed additive, human food additive, dietary supplements, aroma chemical or aroma composition; or vi) aqueous polymer dispersion, preferably polyurethane or polyurethane - poly(meth)acrylate hybrid polymer dispersion, emulsion, binder for paper and fiber coatings, UV-curable acrylic polymer for hot melts and coatings polyisocyanates, hyperbranched polyester polyol, polymeric dispersant for inorganic binder compositions, unsaturated polyester polyol or 100% curable composition; or vii) cosmetic surfactant, emollient, wax, cosmetic polymer, UV filter, further cosmetic ingredient or composition or formulation thereof; or viii) polymer B, polymer composition B, coating composition, other functional composition, foil, molded body, coating or coated substrate.

The content of target foam elements in the product PRF1 may be 1 weight-% or more, preferably 2 weight-% or more, more preferably 5 weight-% or more, more preferably 15 weight-% or more, more preferably 30 weight-% or more, more preferably 40 weight-% or more, more preferably 60 weight-% or more, more preferably 80 weight-% or more, more preferably 90 weight-% or more, more preferably 95 weight-% or more; and/or the content of target foam elements in the product PRF1 may be 100 weight-% or less, preferably 95 weight-% or less, more preferably 90 weight-% or less, more preferably 50 weight-% or less, more preferably 25 weight-% or less, more preferably 10 weight-% or less. Preferably, the content is determined based on identity preservation and/or segregation and/or mass balance and/or book and claim chain of custody models, preferably based on mass balance, preferably the International Sustainability and Carbon Certification (ISCC) standard.

The publication Prior Art Disclosure; Issue 684; paragraphs [1000] to [8005]; ISSN: 2198-4786; published: February 12, 2024, will be regarded as Reference RF1 , which is incorporated herein by reference in its entirety. Preferably, the product PRF1 is a product as described in Reference RF1 ; paragraphs [1000] to [8005], Preferably, the method/process described herein is further a method/process for the production of a product, preferably product PRF1.

The converting step to obtain the product PRF1 preferably comprises one or more step(s) as described below and can be performed by conventional methods well known to a person skilled in the art. The converting step preferably comprises one or more step(s) selected from: recycling, preferably depolymerizing, gasifying, pyrolyzing, and/or steam cracking; and/or purifying, preferably crystallizing, (solvent) extracting, distilling, evaporating, hydrotreating, absorbing, adsorbing and/or subjecting to ion exchanger; and/or assembling, preferably foaming, synthesizing, chemical conversion, chemically transforming, polymerizing and/or compounding; and/or forming, preferably foaming, extruding and/or molding; and/or finishing, preferably coating and/or smoothing. In addition, the one or more step(s) are described in detail in Reference RF1 ; paragraphs [1000] to [8005],

The term "building block”, as used herein, comprises compounds, which are in a gaseous or liquid state under standard conditions of 0°C and 0.1 MPa. Building blocks are typically used in chemical industry to form secondary products, which provide a higher structural complexity and/or higher molecular weight than the building block on which the secondary product is based. The building block is preferably selected from the group consisting of hydrogen, carbon monoxide, carbon dioxide, ethylene oxide, ethylene glycols, syngas comprising a mixture of hydrogen and carbon monoxide, alkanes, alkenes, alkynes and aromatic compounds. The alkanes, alkenes, alkynes and aromatic compounds comprise in particular 1 to 12 carbon atoms, respectively.

The term "monomer”, as used herein, comprises molecules, which can react with each other to form polymer chains by polymerization. The monomer is preferably selected from the group consisting of (meth)acrylic acid, salts of (meth)acrylic acid; in particular sodium, potassium and zinc salts; (meth)acrolein and (meth)acrylates. (Meth)acrylates comprising 1 to 22 carbon atoms are preferred, in particular comprising 1 to 8 carbon atoms. The terms (meth)acrylic acid, (meth)acrolein or (meth)acrylate relate to acrylic acid, acrolein or acrylate and also to methacrylic acid, methacrolein or methacrylate, where applicable. Further, the monomer can be selected from hexamethylenediamine (HMD) and adipic acid. The building block can further be an intermediate compound. The term "intermediate compound”, as used herein, comprises organic reagents, which are applied for formation of compounds with higher molecular complexity. The intermediate compound can be selected for example from the group consisting of phosgene, polyisocyanates and propylene oxide. The polyisocyanates are in particular aromatic di- and polyisocyanates, preferably toluene diisocyanate (TDI) and/or diphenylmethane diisocyanate (MDI).

The building block and the monomer and typical converting step(s) to obtain the building block or monomer are described in more detail in paragraphs [1000] to [1012] of Reference RF1.

The term "polymer A”, as used herein, comprises thermoplastic, e.g., polyamide or thermoplastic polyurethane, thermoset, e.g., polyurethane, elastomer, e.g., polybutadiene, or a copolymer or a mixture thereof and is defined in more detail in paragraphs [2001] to [2007] of Reference RF1.

The term "polymer composition A”, as used herein, comprises all compositions comprising a polymer as described above and one or more additive(s), e.g. reinforcement, colorant, modifier and/or flame retardant, and is defined in more detail in paragraph [2008] of Reference RF1.

The term "polymer product A”, as used herein, comprises any product comprising the polymer A and/or polymer composition A as described above and is defined in more detail in paragraphs [2009] and [2010] of Reference RF1.

The step(s) to obtain the polymer, preferably polymer A, polymer composition, preferably polymer composition A or polymer product, preferably polymer product A is/are described in more detail in paragraph [2011] of Reference RF1.

The term "industrial use polymer”, as used herein, comprises rheology, polycarboxylate, alkoxy I ated polyalkylenamine, alkoxylated polyalkylenimine, polyether-based, dye inhibition and soil release cleaning polymers defined in more detail in paragraphs [3035] to [3044] of Reference RF1. The term "industrial use surfactant”, as used herein, comprises non-ionic, anionic and amphoteric industrial use surfactants defined in more detail in paragraphs [3008] to [3034] of Reference RF1. The term "industrial use descaling compound”, as used herein, comprises non-phosphate based builders (NPB) and phosphonates (CoP) described in more detail in paragraphs [3001] to [3005] of Reference RF1. The term "industrial use biocide”, as used herein, refers to a chemical compound that kills microorganisms or inhibits their growth or reproduction defined in more detail in paragraphs [3006] to [3007] of Reference RF1. The term "industrial use solvent”, as used herein, comprises alkyl amides, alkyl lactamides, alkyl esters, lactate esters, alkyl diester, cyclic alkyl diester, cyclic carbonates, aromatic aldehydes and aromatic esters defined in more detail in paragraphs [3045] to [3055] of Reference RF1. The term "industrial use dispersant”, as used herein, comprises anionic and non- ionic industrial use dispersants defined in more detail in paragraphs [3056] to [3058] of Reference RF1. The term "composition and/or formulation thereof” with reference to the industrial use polymers, industrial use surfactants, descaling compounds and/or industrial use biocides refers to industrial use compositions and/or institutional use products and/or fabric and home care products and/or personal care products defined in more detail in paragraph [3059] of Reference RF1. The converting step(s) to obtain the industrial use polymer, industrial use surfactant, descaling compound and/or industrial use biocide are defined in more detail in paragraph [3060] of Reference RF1. The converting steps to obtain the industrial use composition or formulation of the industrial use polymer, industrial use surfactant, descaling compound and/or industrial use biocide are defined in more detail in paragraph [3061] of Reference RF1.

The term "agrochemical composition”, as used herein, typically relates to a composition comprising an agrochemically active ingredient and at least one agrochemical formulation auxiliary. Examples of agrochemical compositions, active ingredients and auxiliaries are described in more detail in Reference RF1 , paragraph [4001],

The agrochemical composition may take the form of any customary formulation. The agrochemical compositions are prepared in a known manner, e.g. described by Mollet and Grubemann, Formulation technology, Wiley VCH, Weinheim, 2001; or Knowles, New developments in crop protection product formulation, Agrow Reports DS243, T&F Informa, London, 2005. The converting step(s) to obtain the agrochemically active ingredients and auxiliaries may be conducted in analogy to the production step(s) of their analogues that are based on petrochemicals or other precursors that are not gained by recycling processes. In addition, conversion to compounds mentioned in sections "Polymer” and "Cosmetic surfactant, emollient, wax, cosmetic polymer, UV filter, further cosmetic ingredient or compositions or formulations thereof” may be performed as described in these sections as well as the respective paragraphs in Reference RF1.

The term "active pharmaceutical ingredients and/or intermediates thereof”, as used herein, comprises substances that provide pharmacological activity or other direct effect in the diagnosis, cure, mitigation, treatment, or prevention of disease, or to affect the structure or any function of the body. Intermediates thereof are isolated products that are generated during a multi-step route of synthesis of an active pharmaceutical ingredient. The term "pharmaceutical excipients”, as used herein, comprises compounds or compound mixtures used in compositions for various pharmaceutical applications, which are not substantially pharmaceutically active on itself. Active pharmaceutical ingredients and/or intermediates thereof and pharmaceutical excipients are defined in more detail in paragraph [5001] of Reference RF1.

The converting step(s) to obtain the active pharmaceutical ingredients and/or intermediates thereof and pharmaceutical excipients may comprise one or more synthesis steps and can be performed by conventional synthesis and techniques well known to a person skilled in the art. The terms "animal feed additives, human food additives, dietary supplements”, as used herein, comprises Vitamins, Pro-Vitamins and active metabolites thereof including intermediates and precursors, especially Vitamin A, B, E, D, K and esters thereof, like acetate, propionate, palmitate esters or alcohols thereof like retinol or salts thereof and any combinations thereof; Tetraterpenes, especially isoprenoids like carotenoids and xanthophylls including their intermediates and precursors as well as mixtures and derivates thereof, especially beta carotene, Canthaxanthin, Citranaxanthin, Astaxanthin, Zeaxanthin, Lutein, Lycopene, Apocarotenoids, and any combinations thereof; organic acids, especially formic acid, propionic acid and salts thereof, such as sodium, calcium or ammonium salts, and any combinations thereof, such as but not limited to mixtures of formic acid and sodium formiate, propionic acid and ammonium propionate, formic acid and propionic acid, formic acid and sodium formiate and propionic acid, propionic acid and sodium propionate and formic acid and sodium formiate; glycerides of carboxylic acids and short and medium chain fatty acids, conjugated linoleic acids, such as omega-6 fatty acid (C18:2) methyl ester and 1 ,2-propandiol and beverage stabilizers, such as polyvinylpyrrolidone-polymer or polyvinyli midazole/polyvi ny Ipyrrolidone-copolymer. Animal feed additives, human food additives and dietary supplements are defined in more detail in paragraph [5002] of Reference RF1.

The converting step(s) to obtain the animal feed additives, human food additives, dietary supplements may comprise one or more synthesis steps and can be performed by conventional synthesis and techniques well known to a person skilled in the art.

The terms "aroma chemical” and "aroma composition” as used herein, comprise a volatile organic substance with a molecular weight between 70-250 g/mol comprising a functional group with a carbon skeleton of C5- C16 carbon atoms comprising linear, branched, cyclic, for example with a ring size of C5-C18, bicyclic or tricyclic aliphatic chains and but not necessarily one or more unsaturated structural elements like double bonds, triple bonds, aromatics or heteroaromatics and preferably the one or more additional functional groups are selected from alcohol, ether, ester, ketone, aldehyde, acetal, carboxylic acid, nitrile, thiol, amine. In one aspect, the aroma chemical is a terpene-based aroma chemical, for example selected from monoterpenes and monoterpenoids, sesquiterpenes and sesquiterpenoids, diterpenes, triterpenes or tetraterpenes. Aroma chemicals can be combined with further aroma chemicals to give an aroma composition. Aroma chemicals and aroma compositions are defined in more detail in paragraph [5003] of Reference RF1.

The converting step(s) to obtain the aroma chemical and aroma composition may comprise one or more synthesis steps and can be performed by conventional synthesis and techniques well known to a person skilled in the art. The term "aqueous polymer dispersion”, as used herein, comprises aqueous composition(s) comprising dispersed polymer(s) and is defined in more detail in the section [6001] entitled "aqueous polymer dispersion” of Reference RF1. The dispersed polymer(s) may be selected from acrylic emulsion polymer(s), styrene acrylic emulsion polymer(s), styrene butadiene dispersion(s), aqueous dispersion(s) comprising composite particles, acrylate alkyd hybrid dispersion(s), polyurethane(s) (including UV-curable polyurethanes) and polyurethane - poly(meth)acrylate hybrid polymer(s). The term "emulsion polymer”, as used herein, comprises polymer(s) made by free-radical emulsion polymerization. Aqueous polyurethane dispersion(s) are defined in more detail in the section [6002] entitled "Polyurethane dispersions” of Reference RF1. UV-curable polyurethane(s) is/are defined in more detail in the section [6017] of Reference RF1. Polyurethane - poly(meth)acrylate hybrid polymer(s) is/are defined in more detail in the section [6016] of Reference RF1.

The term "polymeric dispersant”, as used herein, comprises preferably polymer(s) comprising polyether side chain, in particular polycarboxylate ether polymer(s) and polycondensation product(s) defined in more detail in paragraph [6020] entitled "Polymeric dispersant” of Reference RF1.

The converting (polymerization) step(s) to obtain the aqueous polymer dispersion(s) comprising emulsion polymer(s) is/are defined in more detail in the section [6003] entitled "Emulsion polymerization” of Reference RF1.

The converting (polymerization) step(s) to obtain the aqueous polyurethane dispersion(s) is/are defined in more detail in the section [6014] entitled "Process for the preparation of aqueous polyurethane dispersions” and section [6017] entitled "Aqueous UV-curable polyurethane dispersions, their preparation and use and compositions containing them” of Reference RF1.

Composition(s) and uses of aqueous polymer dispersion(s) and of polymeric dispersant(s) are defined in more detail in the following sections of Reference RF1 : section [6004] entitled "Uses of aqueous polymer dispersions”, section [6005] entitled "Binders for architectural and construction coatings” section [6006] entitled "Binders for paper coating” section [6007] entitled "Binders for fiber bonding” section [6008] entitled "Adhesive polymers and adhesive compositions” section [6015] entitled "Aqueous polyurethane dispersions suitable for use in coating compositions” section [6016] entitled "Aqueous polyurethane - poly(meth)acrylate hybride polymer dispersions suitable for use in coating compositions” section [6017] entitled "Aqueous UV-curable polyurethane dispersions, their preparation and use and compositions containing them” section [6018] entitled "Inorganic binder compositions comprising polymeric dispersants and their use” [6019] 100% curable coating compositions UV-crosslinkable poly(meth)acrylate(s) and its/their uses are defined in more detail in section [6009] entitled "UV-crosslinkable poly(meth)acrylates for use in UV-curable solvent-free hotmelt adhesives and their use for making pressure-sensitive self-adhesive articles” of Reference RF1.

Polyisocyanate(s), composition(s) comprising them and their uses are defined in more detail in section [6010] entitled "Polyisocyanates” of Reference RF1.

Hyperbranched polyester polyol(s) and its/their uses are defined in more detail in section [6011] entitled "Organic solvent based hyperbranched polyester polyols suitable for use in coating compositions” of Reference RF1. The converting step(s) to obtain the hyperbranched polyester polyols is/are defined in more detail in the section [6012] entitled "Preparation of organic solvent based hyperbranched polyester polyols” of Reference RF1. Coating composition(s) comprising hyperbranched polyester polyol(s), polyisocyanate(s) and additive(s) and substrate(s) coated therewith are defined in more detail in section [6013] entitled "Organic solvent based two component coating compositions comprising hyperbranched polyester polyols and polyisocyanates” of Reference RF1.

Unsaturated polyester polyol(s), solvent-based coating composition(s) comprising said unsaturated polyester polyol(s) and substrate(s) for coating with said coating composition(s) are defined in more detail in section [6018] entitled "Organic solvent based coating composition comprising unsaturated polyester polyols” of Reference RF1. 100% curable coating composition(s) is/are defined in more detail in section [6019] of Reference RF1. Polymeric dispersant(s) for inorganic binder compositions is/are defined in more detail in section [6020] of Reference RF1. The inorganic binder composition(s) comprising the polymeric dispersants and their use are defined in more detail in section [6021] of Reference RF1. The converting step(s) to obtain the polymeric dispersant(s) are defined in more detail in section [6020] of Reference RF1. The term "inorganic binder composition” comprising the polymeric dispersant(s), as used herein, comprises preferably in particular hydraulically setting compositions and compositions comprising calcium sulfate and is defined in more detail in section [6021] of Reference RF1 entitled "Inorganic binder compositions comprising the polymeric dispersant and their use”. Specific building material formulation(s) comprising polymeric dispersant(s) or building product(s) produced by a building material formulation comprising a polymeric dispersant are disclosed in more detail in section [6021] of Reference RF1.

The term "cosmetic surfactant”, as used herein, comprises non-ionic, anionic, cationic and amphoteric surfactants and is defined in more detail in paragraph [7002] of Reference RF1. The term "emollient”, as used herein, refers to a chemical compound used for protecting, moisturizing, and/or lubricating the skin and is defined in more detail in paragraph [7003] of Reference RF1. The term "wax”, as used herein, comprises pearlizers and opacifiers and is defined in more detail in paragraph [7004] of Reference RF1. The term "cosmetic polymer”, as used herein, comprises any polymer that can be used as an ingredient in a cosmetic formulation and is defined in more detail in paragraph [7005] of Reference RF1. The term "UV filter”, as used herein, refers to a chemical compound that blocks or absorbs ultraviolet light and is defined in more detail in paragraph [7006] of Reference RF1. The term "further cosmetic ingredient”, as used herein, comprises any ingredient suitable for making a cosmetic formulation. Several sources disclose cosmetically acceptable ingredients. E. g. the database Cosing on the internet pages of the European Commission discloses cosmetic ingredients and the International Cosmetic Ingredient Dictionary and Handbook, edited by the Personal Care Products Council (PCPC), discloses cosmetic ingredients. The term "composition and/or formulation thereof” with reference to the cosmetic surfactant, emollient, wax, cosmetic polymer, UV filter and/or further cosmetic ingredient refers to personal care and/or cosmetic compositions or formulations defined in more detail in paragraph [7007] of Reference RF1. The converting step(s) to obtain the cosmetic surfactant, emollient, wax, cosmetic polymer, UV filter or further cosmetic ingredient is/are defined in more detail in paragraph [7008] of Reference RF1.

The terms "polymer B”, "polymer composition B”, "coating composition”, "other functional composition”, "foil”, "molded body”, "coating” and "coated substrate” are well known to the person skilled in the art and are defined in more detail from paragraph [8000] to [8005] of Reference RF1.

A third aspect of the present invention is directed to a pre-processing arrangement for pre-processing a scrap material for feeding a reactor of a recycling process for recovering raw materials. The pre-processing arrangement of the third aspect comprises at least one target foam selection unit that is configured to select, from the scrap material, target foam pieces comprising target foam that is suitable for the reactor. The target foam selection unit comprises a foam composition determination unit that is configured to perform a first analysis step for determining first composition data of a sample foam piece, the first composition data being indicative of a composition of the sample foam piece and to perform a second analysis step for determining second composition data of the same sample foam piece, the second composition data being indicative of the composition of the sample foam piece, and a processing unit configured to receive the first composition data and the second composition data and to determine that sample foam piece is a target foam piece when both the first composition data and the second composition data are indicative of the target foam material.

In an embodiment, the target foam selection unit is arranged in a single device. In a further embodiment, the foam composition determination unit is signally connected, e.g. via a wired or a wireless connection, to the processing unit. In yet another embodiment, the foam composition determination unit comprises a first device for performing the first analysis step and a second device for performing the second analysis step, both of which are signally connected (wired, or wirelessly) to the processing unit, which may be integrated with one of the devices or be an external processing unit. Depending on where the target foam selection unit is placed within the arrangement, a target foam selection unit according to the invention can be also used to perform a first analysis step for determining first composition data of a sample foam element, the first composition data being indicative of a composition of the sample foam element and to perform a second analysis step for determining second composition data of the sample foam element, the second composition data being indicative of the composition of the sample foam element. Here, the processing unit is configured to receive the first composition data and the second composition data and to determine that sample foam element is a target foam element when both the first composition data and the second composition data are indicative of the target foam material.

In another embodiment, the pre-processing arrangement of the third aspect further comprises a transporting unit that is configured to receive the selected target foam pieces and to transport the selected target foam pieces to a shredding unit; wherein the shredding unit is configured to shred the selected target foam pieces to form shredded foam elements for feeding to the reactor.

In yet another embodiment, the pre-processing arrangement of the third aspect additionally comprises a foam element selection unit that is configured to select, from the shredded foam elements, shredded target foam elements comprising target foam that is suitable for the reactor. The foam element selection unit is preferably configured as target foam selection unit in which the input material are foam elements provided by the shredding unit. In particular, in an embodiment, the foam element selection unit comprises a foam composition determination unit configured to perform an additional first analysis step for determining first composition data of a sample foam element, the first composition data being indicative of a composition of the sample foam element, and to perform an additional second analysis step for determining second composition data of the sample foam element, the second composition data being indicative of the composition of the sample foam element. Further, the processing unit, which can be a dedicated processing unit or the processing unit of the target foam selection unit, is configured to receive the first additional composition data and the second additional composition data and to determine that the sample foam element is a target foam element when both the first composition data and the second composition data are indicative of target foam.

The inclusion of two sorting steps, namely one for foam pieces and another one for foam elements, enables an optimal balance in terms of cost reduction and yield improvement compared to known pre-processing method or strategies. Also, the quality of the resulting products is improved.

In an embodiment, the target foam selection unit and/or the foam element selection unit comprise a first composition determination unit that is configured to determine the first com-position data and a second composition determination unit configured to determine the second composition data. Preferably, in an embodiment, the foam composition determination unit and/or the first composition determination unit and/or the second composition determination unit is, or are, selected from a group consisting of a near-infrared spectroscopy device, a medium-infrared spectroscopy device, a UV-VIS spectroscopy device, an optical camera, a Raman spectroscopy device, a THz spectroscopy device, a laser induced breakdown spectroscopy device and an X-ray fluorescence device.

According to a fourth aspect of the invention, a computer program is presented. The computer program comprises instructions which, when executed by a control unit of a target foam selection unit cause the target foam selection unit to perform the method of the first aspect of the invention. The control unit of the target foam selection unit can be a single processing unit located at the recycling facility or may be distributed among different processing units located at different locations and exchanging the necessary data for operation via suitable data network.

These and other aspects of the invention will be apparent from and elucidated with reference to the embodiments described hereinafter.

Detailed description

Further details and features of the invention result from the following description of preferred embodiments, in particular in conjunction with the dependent claims. The respective features may be realized individually or in combination with one another. The invention is not limited to the embodiments. The embodiments are shown schematically in the drawings. The drawings are to be understood as schematic representations. They do not represent a limitation of the invention, for example with regard to specific dimensions or design variants. Identical reference numerals in the individual drawings denote identical or functionally identical elements or elements corresponding to one another in terms of their functions. In the figures:

Fig. 1 shows a flow diagram of an exemplary method for pre-processing a scrap material that includes a method for selecting target foam pieces that comprise target foam material in accordance with a first embodiment of the invention.

Fig. 2 shows a flow diagram of another exemplary method for pre-processing a scrap material that includes a method for selecting target foam elements that comprise target foam material in accordance with a second embodiment of the invention.

Fig. 3 shows a flow diagram of an exemplary method for pre-processing a scrap material in accordance with a third embodiment of the invention. Fig. 4 shows a schematic block diagram of a pre-processing arrangement in accordance with a fourth embodiment of the invention.

Fig. 5 shows a schematic block diagram of a pre-processing arrangement in accordance with a fifth embodiment of the invention.

Fig. 6 shows a schematic block diagram of an exemplary target foam selection unit in accordance with a sixth embodiment of the invention.

Fig. 7 shows a schematic block diagram of another exemplary target foam selection unit in accordance with a seventh embodiment of the invention.

Fig. 1 shows a flow diagram of an exemplary method 100 for pre-processing a scrap material that includes a method 102 for selecting target foam pieces that comprise target foam material in accordance with a first embodiment of the invention. The following discussion will also make reference to the features of exemplary pre-processing arrangements that are shown in Fig. 4 and Fig. 5 and described below in more detail. The method 102 for selecting target foam pieces thus forms a first step of the method 100 for pre-processing the scrap material. The method 102 is suitable for selecting, from scrap material 202 comprising one or more foam pieces 206A, 206B, 203 (see Fig. 4), target foam pieces 206 that comprise target foam material 207 that is suitable for a predetermined recycling process. The method 102 comprises, in a first step 102A, performing a first analysis step for determining first composition data CD1 of a sample foam piece 202C (see e.g. Fig. 6 and the corresponding discussion below), the first composition data being indicative of a composition of the sample foam piece 202C. The method also comprises, in a step 102B, performing a second analysis step for determining second composition data CD2 of the sample foam piece 202C, the second composition data being indicative of the composition of the sample foam piece 202C, The method 102 also comprises, in a step 102C, selecting the sample foam piece 202C as a target foam piece 206 upon determining that the first composition data CD1 and the second composition data CD2 are indicative of the target foam material 207.

Once the target foam piece has been selected according to the method 102, the pre-processing method 100 of Fig. 1 further includes, in a step 104, transporting the selected target foam pieces to a shredding unit 210, in a step 106, shredding the selected target foam pieces 206 to form shredded foam elements 212 and, in an optional step 108, feeding the shredded foam elements 212 into the reactor 250.

The exemplary method 100 for pre-processing shown in Fig. 1 is especially favorable for a scrap material 202 that is obtained from dismantling a vehicle. The scrap material 202 may be, for example, a vehicle seat, a headliner, a dashboard or an interior panel that can be easily removed from the vehicle. Fig. 2 shows a flow diagram of another exemplary method 100B for pre-processing a scrap material 202 that includes a method 107 for selecting target foam elements 206 that comprise target foam material 207 in accordance with a second embodiment of the invention. In the method 100B of Fig. 2, performing the method 102 described above is optional, as indicated by the discontinuous line. If the method 102 is not performed, the foam pieces of the scrap material are all transported, in a step 104 to the shredding unit. If the method 102 is performed, only the selected target foam pieces are transported in the step 104. The foam pieces that reach the shredding unit are shredded, in a step 106 to form shredded foam elements. Now, the method 107 for selecting target foam elements, or in other words, foam elements comprising target foam material, is carried out before feeding the selected target foam elements the reactor in an optional step 108.

The method 107 comprises performing a first analysis step 107A for determining first composition data CD1 of a sample foam element 212B, the first composition data being indicative of a composition of the sample foam element 212B. The method also comprises performing a second analysis step 107B for determining second composition data CD2 of the sample foam element 212B, the second composition data being indicative of the composition of the sample foam element 212B. The method 107 also comprises, in a step 107C, selecting the sample foam element 212B as a target foam element 216 upon determining that the first composition data CD1 and the second composition data CD2 are indicative of the target foam material 207.

The exemplary method 100B for pre-processing shown in Fig. 2 is especially favorable for a scrap material 202 that is obtained from shredding a vehicle. The scrap material 202 may be, for example, an automotive shredder residue, a shredder light fraction (SLF) separated from automotive shredder residue, a shredder heavy fraction (SHF) separated from automotive shredder residue, or any combination thereof.

Fig. 3 shows a flow diagram of an exemplary method 100C for pre-processing a scrap material 202. The method 100C for pre-processing a scrap material 202, for example, for feeding a reactor 250 of a recycling process, in particular a chemical recycling process for recovering raw materials, comprises the following steps. In a step 102, the method 102 includes performing a first sorting step for selecting, from the scrap material 202, target foam pieces 206 that comprise target foam material 207 that is suitable for the reactor 250. This method step corresponds to the method for selecting a target foam piece described with reference to Fig. 1 above. The selected target foam pieces may, at this stage, also comprise other foam materials, such as foam materials that are not suitable for the reactor. Those foam pieces that are not selected are not further part of the pre-processing process and may, for example, be pressed and transported for another recycling process. The selected target foam pieces 206 are then transported, in a step 104, to a shredding unit 210. This transporting step 104 can be for instance carried out by means of a conveyor belt system, a sucking and/or blowing unit, by a road, rail, air or sea-based transport unit such as a truck, a train, an airplane or a ship, or by any combination thereof. The selected target foam pieces 206 are then shredded, in a step 106 to form shredded foam elements, also referred to as foam elements, and which are the result of shredding foam pieces or foam articles, and which have a similar size, in dependence on the used shredding unit. From the shredded foam elements, target foam elements 216 are then selected by performing a second sorting step 107. This second sorting step corresponds to the method 107 for selecting target foam elements as discussed with reference to Fig. 2 above. The selected target foam elements are then transported, in a step 110, to a milling unit. Those foam elements that, according to the second sorting step 107, do not qualify as target foam elements 216 are excluded from the subsequent steps to guarantee that they are not fed to the reactor. The selected target foam elements 216 are milled to form target foam flakes, which, in an optional step 114, are fed into the reactor 250 of the recycling process.

In cases where the first sorting step 102 and the shredding step 106 are performed in different facilities, a transporting step 104 of the selected target foam pieces by road, train, sea or air is required, and/or in cases where the second sorting step 107 and the milling step 112 are performed in different facilities, a transporting step 110 of the target foam elements by road, train, sea or air is required and/or in cases where the milling step 112 and the step of feeding 114 the target foam flakes to the reactor are performed in different facilities, a transport by road, train, sea or air is required. The method 100C therefore includes one, two or three pressing steps, namely a first pressing step 116A, wherein the selected target foam pieces 207 are pressed for forming pressed target foam pieces prior to the step of transporting 104 the selected target foam pieces 207, as pressed target foam pieces, to the shredding unit 210 and/or a second pressing step 116B, wherein the selected target foam elements 216 are pressed for forming pressed target foam elements prior to the step of transporting 110 the selected target foam elements 216 as pressed target foam elements to the milling unit 220, and/or a third pressing step 116C, wherein the target foam flakes 222 are pressed for forming pressed target foam flakes prior to the step of feeding the target foam flakes 222 as pressed target foam flakes to the reactor 250. In particular, the step of pressing the target foam flakes is preferably performed using an extruder. This is particularly advantageous for controlling dosage of target foam flakes into the reactor, especially when the reactor vessel of the reactor is pressurized.

Fig. 4 shows a schematic block diagram of a pre-processing arrangement 200 in accordance with a fourth embodiment of the invention. The pre-processing arrangement 200 is suitable for pre-processing a scrap material 202 for feeding a reactor 250 of a recycling process for recovering raw materials 252. The reactor 250 is exemplarily, but not necessarily, a chemical reactor for chemically recycling PU foam.

The pre-processing arrangement 200 comprises a target foam selection unit 204, configured to select, from the scrap material 202, target foam pieces 206 comprising target foam material 207 that is suitable for the reactor 250. An exemplary target foam selection unit 204 is shown in Fig. 6. The target foam selection unit 204 of Fig. 6 comprises a foam composition determination unit 205 that is configured to perform a first analysis step (see 102A) for determining first composition data CD1 of a sample foam piece of the scrap material 202, the first composition data being indicative of a composition of the sample foam piece, i.e. the foam piece currently under analysis, and to perform a second analysis step (see 102B) for determining second composition data CD2 of the sample foam piece, the second composition data being indicative of the composition of the sample foam piece. The target foam selection unit 204 also comprises a processing unit processing unit 209 that is configured to receive the first composition data CD1 and the second composition data CD2 and to determine that sample foam piece is a target foam piece 206 when both the first composition data and the second composition data are indicative of target foam. If the first composition data CD1 and the second composition data CD2 are not indicative of the target foam material 207 the sample foam piece (see 203) is not selected and is removed from the pre-processing arrangement 200.

Preferably, the first composition data CD1 is indicative of a type of foam, in particular of a type of polyurethane foam of the sample foam piece, and the second composition data is indicative of a type of additive of the sample foam piece, in particular indicative of one or more additives, selected from a group consisting of water, inorganic fillers, flame retardants, styrenes (in particular styrene acrylonitrile), silicon stabilizers, crosslinker, chain extenders, monools, antioxidants, defoamers, catalysts and dyes. Additionally, or alternatively, the first composition data and/or the second composition data is indicative of the presence of an impurity or contamination, such as unacceptable dirt, dust, or microbial or fungal layers.

The pre-processing arrangement 200 further comprises a transporting unit 208 that is configured receive the selected target foam pieces 206 and to transport the selected target foam pieces 206 to a shredding unit 210, wherein the shredding unit 210 is configured to shred the selected target foam pieces 206 to form shredded foam element 212 for feeding to the reactor 250.

Fig. 5 shows a schematic block diagram of a pre-processing arrangement 200B in accordance with another embodiment of the invention. The pre-processing arrangement 200B is also suitable for pre-processing a scrap material 202, for example a flexible foam mix, in particular a polyurethane (PU) mix for feeding a reactor 250 of a recycling process, for instance a chemical recycling process for recovering raw materials 252. The raw materials to be recovered are typically TDA and polyols in the case of TDI-based PU foam. In the case of a MDI-based PU foam or a TDI/MDI mixed foam, then MDA is also obtained. Typically, in the recycling process, the amine is converted to the corresponding isocyanate in a downstream step, generally after a dedicated reprocessing and purification chain.

The pre-processing arrangement 200B comprises a first sorting unit 204A that is configured to select, from the scrap material 202 that comprises one or more foam pieces 203, 206A, 206B, probably comprising different types of foam materials, those foam pieces 206A, 206B comprising target foam material 207 that is suitable for the reactor 250, and which are referred to as target foam pieces. The first sorting unit 204A corresponds to the target foam selection unit 204 described with reference to Fig. 4. The foam composition determination unit 205 of the target foam selection unit 204 can comprise, for instance, a near-infrared spectroscopy device 204.1 , a medium-infrared spectroscopy device 204.2, a UV-VIS spectroscopy device 204.3, an optical camera 204.4, a laser induced breakdown spectroscopy device 204.5, a Raman spectroscopy device 204.6, an X-ray fluorescence device 204.7 or a THz spectroscopy device 204.8. The foam composition determination unit 205 of the target foam selection unit 204A may also comprise two of the above-mentioned devices, each configured to determine a respective one of the first and the second composition data.

The selected target foam pieces 206 which have been selected based on its content of target foam material

207 are then transported by a first transporting unit 208 that is configured to receive the selected target foam pieces 206 and to transport the selected target foam pieces 206 to a shredding unit 210. The transporting unit

208 of Fig. 5 is exemplarily configured as a conveyor belt. The shredding unit 210 is configured to shred the selected target foam pieces 206 to form shredded foam elements 212. The shredding unit 210 may for instance comprise a cylindrical chamber with a cylindrical rotating element co-axial ly arranged inside the chamber to rotate along the common longitudinal axis. The rotating element has cutting and/or gripping elements distributed along its surface. The inner wall of the cylindrical chamber may also comprise cutting and/or gripping elements. A gap between the inner wall of the chamber and the rotating element allows the introduced foam piece to move. When engaged by the cutting or gripping elements, the foam pieces are cut or tore. A filtering mesh allows those shredded pieces with a predetermined size to exit the shredding unit 210. These are referred to as foam elements 212.

The foam elements 212 are provided to a second sorting unit 204B configured to select target foam elements 216 from the shredded foam elements 212. The second sorting unit can be also configured as a target foam selection unit, such as the one described with reference to Fig. 4 204A.

Due to its position in the pre-processing arrangement 200B of Fig. 5, the second sorting unit 204B is referred to as a foam element selection unit 204B and comprises a foam composition determination unit (analogous to the foam composition determination unit 205 of Fig. 4) that is configured to perform an additional first analysis step (see 107A) for determining first composition data CD1 of a sample foam element, i.e. a foam element under currently under analysis. The first composition data CD1 is indicative of a composition of the sample foam element. It is also configured to perform an additional second analysis step (see 107B) for determining second composition data CD2 of the sample foam element, the second composition data being indicative of the composition of the sample foam element. The foam element selection unit 204B also comprises a processing unit (analogous to the processing unit 209 of Fig. 4) configured to receive the first composition data CD1 and the second composition data CD2 and to determine that sample foam element is a target foam element 216 when both the first composition data CD1 and the second composition data CD2 are indicative of target foam 207. Since the target foam pieces 206 may still comprise foam material 211 other than the suitable target foam material 207, some of the shredded foam elements that undergo the analysis of the second sorting unit may not qualify as target foam elements 216 and are separated.

As in the case of the first sorting unit 204A, the second sorting unit 204B can comprise, for instance, a nearinfrared spectroscopy device 204.1 , a medium-infrared spectroscopy device 204.2, a UV-VIS spectroscopy device 204.3, an optical camera 204.4, a laser induced breakdown spectroscopy device 204.5, a Raman spectroscopy device 204.6, an X-ray fluorescence device 204.7 or a THz spectroscopy device 204.8. The first sorting unit does not have to be the same type of device as the second sorting unit.

A second transporting unit 218 is configured to receive the selected target foam elements 216 and to transport the selected target foam elements 216 to a milling unit 220. The milling unit 220 is configured to mill the selected target foam elements 216 to form target foam flakes 222 that are suitable, both in size and in composition, to be fed to the reactor 250.

The milling unit and the shredding unit can be based on a similar technology, although the average size of the target foam flakes is smaller than the average size of the shredded foam elements. Preferably, the milled target foam flakes have a maximum dimension smaller than 120 mm, preferably smaller than 90 mm, even more preferable smaller than 70 mm.

The arrangements 200 and 200B can be configured as pre-processing arrangements for pre-processing a scrap material 202 that is favorably obtained from dismantling a vehicle. The scrap material 202 may be, for example, a vehicle seat, a headliner, a dashboard or an interior panel that can be easily removed from the vehicle.

Fig. 6 shows a schematic block diagram of an exemplary target foam selection unit 204A or foam element selection unit 204B in accordance with a sixth embodiment of the invention.

The target foam selection unit 204A or foam element selection unit 204B comprise a foam composition determination unit 205 that configured to perform the first analysis step (102A or 107A) for determining first composition data CD1 of a sample foam piece 202C or of a sample foam element 212B. Again, the first composition data CD1 is indicative of a composition of the corresponding sample foam piece 202C or element 212B under analysis. The foam composition determination unit 205 is also configured to perform a second analysis step (see 102B or 107B) for determining second composition data CD2 of the sample foam piece 202C or element 212B, where the second composition data CD2 is indicative of the composition of the sample foam piece 202C or element 212B under analysis. The first and second composition data CD1 and CD2 are sent to the processing unit 209, which is configured to receive the first composition data CD1 and the second composition data CD2 and to determine that sample foam piece 202C or the sample foam element 212B is a target foam piece 206 or a target foam element 216, when both the first composition data CD1 and the second composition data CD2 are indicative of target foam material 207.

In the exemplary case shown in Fig. 6, the target foam selection unit 204A or foam element selection unit 204B comprise a first composition determination unit 205A configured to determine the first composition data CD1 and a second composition determination unit 205B configured to determine the second composition data CD2. Optionally, the target foam selection unit 204A or foam element selection unit 204B may comprise at least a third composition determination unit 2050 configured to determined third composition data CD3. The first composition determination unit 205A and/or the second composition determination unit 205B can be selected from a group consisting of a near-infrared spectroscopy device, a medium-infrared spectroscopy device, a UV-VIS spectroscopy device, an optical camera, a Raman spectroscopy device, a THz spectroscopy device, a laser induced breakdown spectroscopy device and an X-ray fluorescence device.

Preferably, the first composition data CD1 is indicative of a type of foam, in particular of a type of polyurethane foam PUx of the sample foam piece 202C or of the sample foam element 212B and the second composition data is indicative of a type of additive Ax of the sample foam piece 202C or of the sample foam element 212B. The second composition data can also be indicative of an impurity or a contamination.

Preferably, the first and the second composition data are obtained from a common location on the sample under analysis, as it is shown in Fig. 4. In an alternative embodiment more than one non-overlapping locations of the sample foam piece 202C and/or the sample foam element 212B are analysed to obtain a better spatial resolution.

Fig. 7 shows a schematic block diagram of another exemplary target foam selection unit or foam element selection unit 204C in accordance with a seventh embodiment of the invention. In the target foam selection unit or foam element selection unit 204C the individual composition determination units 205A, 205B, and, if applicable, 205C, are independent devices, that communicate the determined composition data to the processing unit 209 via a wired or wireless connection.

In summary, the invention is directed to a method for selecting target foam pieces that comprise target foam material that is suitable for a predetermined recycling process, the method comprising the steps of providing a scrap material obtained by dismantling and/or shredding a vehicle, the scrap material comprising one or more foam pieces, performing a first analysis step for determining first composition data of a sample foam piece, the first composition data being indicative of a composition of the sample foam piece, performing a second analysis step for determining second composition data of the sample foam piece, the second composition data being indicative of the composition of the sample foam piece; and selecting the sample foam piece as a target foam piece upon determining that the first composition data and the second composition data are indicative of the target foam material.

Other variations to the disclosed embodiments can be understood and effected by those skilled in the art in practicing the claimed invention, from a study of the drawings, the disclosure, and the appended claims.

A single unit or device may fulfill the functions of several items recited in the claims. The mere fact that certain measures are recited in mutually different dependent claims does not indicate that a combination of these measures cannot be used to advantage.

Any reference signs in the claims should not be construed as limiting the scope.

Claims

1. A method for selecting target foam pieces (206, 206A, 206B) that comprise target foam material (207) that is suitable for a predetermined recycling process, the method (102) comprising the steps of:

- providing a scrap material (202) obtained by dismantling and/or shredding a vehicle, the scrap material (202) comprising one or more foam pieces (202);

- in a first analysis step (102A), determining first composition data (CD1) of a sample foam piece (202C) by means of a first analysis setting, the first composition data being indicative of a composition of the sample foam piece (202C);

- in a second analysis step (102B), determining second composition data (CD2) of the same sample foam piece (202C) by means of a second analysis setting, the second composition data being indicative of the composition of the sample foam piece (202C); and

- selecting (102C) the sample foam piece (202C) as a target foam piece (206) upon determining that the first composition data (CD1) and the second composition data (CD2) are indicative of the target foam material (207).

2. The method of claim 1 , further comprising performing at least a third analysis step for determining at least a third composition data (CD3) indicative of a composition of the sample foam piece (202C) and selecting the sample foam piece (202C) as a target foam piece (206) upon determining that at least a predetermined number of the determined composition data, in particular all of the determined composition data (CD 1 , CD2, CD3), is indicative of the target foam material (207).

3. The method of claim 1 or 2, wherein the first analysis step (102A) for determining the first composition data (CD1) and the second analysis step (102B) for determining the second composition data (CD2) are performed using different analytical methods.

4. The method of any one of claims 1 to 3, wherein the first composition data (CD1) is indicative of a type of foam, in particular of a type of polyurethane foam (PUx) of the sample foam piece (202C) and the second composition data is indicative of a type of additive (Ax) and/or impurity of the sample foam piece (202C).

5. The method of claim 4, wherein the second composition data (CD2) is indicative of one or more additives (Ax) selected from a group consisting of water, inorganic fillers, flame retardants, styrenes (in particular styrene acrylonitrile), silicon stabilizers, crosslinker, chain extenders, monools, antioxidants, defoamers, catalysts and dyes and/or wherein the second composition data (CD2) is indicative of one or more impurities selected from a group consisting of dust, dirt, microbial contamination and fungal contamination.

6. The method of any one of claims 1 to 5, wherein the first analysis step (102A) for determining the first composition data (CD1) and/or the second analysis step (102B) for determining the second composition data (CD2) is performed by one or more analytical methods selected from the group consisting of a near-infrared spectroscopy based method, a medium-infrared spectroscopy based method, a Raman spectroscopy based method, a THz spectroscopy based method, a UV-VIS spectroscopy based method, an optical-cameras based method, a laser induced breakdown spectroscopy method and an X- ray fluorescence based method.

7. The method of any one of claims 1 to 6, wherein the scrap material (202) comprises a vehicle seat, a headliner, a dashboard, an interior panel, an automotive shredder residue, a shredder light fraction (SLF) separated from automotive shredder residue, a shredder heavy fraction (SHF) separated from automotive shredder residue, or any combination thereof.

8. A method (100, 100B, 100C) for pre-processing a scrap material (202) for feeding a reactor (250) of a recycling process, the method (100, 100B, 100C) comprising the steps of:

- performing the method (102) of any of the preceding claims 1 to 7 for selecting target foam pieces (206) from the scrap material (202);

- transporting (104) the selected target foam pieces (206) to a shredding unit (210);

- shredding (106), at the shredding unit (210), the selected target foam pieces (206) to form shredded foam elements (212); and

- optionally feeding (108) the shredded foam elements (222) to the reactor (250) for recovering raw materials (252); or comprising the steps of:

- transporting the scrap material (202) comprising one or more foam pieces (206A, 206B, 203) to a shredding unit (210);

- shredding (106), at the shredding unit (210), the foam pieces to form shredded foam elements (212);

- performing the method (107) of any of the preceding claims 1 to 7 on the shredded foam elements for selecting shredded target foam elements upon determining that the first composition data (CD1) and the second composition data (CD2) are indicative of target foam material (207); and optionally feeding (108) the selected shredded target foam elements (222) to the reactor (250) for recovering raw materials (252); or comprising the steps of:

- performing the method (102) of any of the preceding claims 1 to 6 for selecting target foam pieces from the scrap material (202);

- shredding (106), at the shredding unit (210), the selected target foam pieces (206) to form shredded foam elements (212);

- performing the method (107) of any of the preceding claims 1 to 7 on the shredded foam elements for selecting shredded target foam elements upon determining that the first composition data (CD1) and the second composition data (CD2) are indicative of target foam material (207); and

- optionally feeding (108) the selected shredded target foam elements (222) to the reactor (250) for recovering raw materials (252).

9. A method, preferably according to any one of claims 1 to 8, comprising the step:

- converting the target foam pieces (206) obtainable by or obtained by the method according to any one of claims 1 to 7, and/or the shredded target foam elements (222) and/or the raw materials (252) obtainable by or obtained by the method according to claim 8 to obtain a product PRF1.

10. Pre-processing arrangement (200, 200B, 200c) for pre-processing a scrap material (202) for feeding a reactor of a recycling process for recovering raw materials, the pre-processing arrangement (200) comprising at least one target foam selection unit (204, 204B) configured to select, from the scrap material (202), target foam pieces (206A, 206B) comprising target foam (207) that is suitable for the reactor (250), the target foam selection unit (204) comprising:

- a foam composition determination unit (205) configured to perform a first analysis step (102A) for determining first composition data (CD1) of a sample foam piece (202C), the first composition data being indicative of a composition of the sample foam piece (202C) and to perform a second analysis step (102B) for determining second composition data (CD2) of the same sample foam piece (202C), the second composition data being indicative of the composition of the sample foam piece (202C); and

- a processing unit (209) configured to receive the first composition data (CD1) and the second composition data (CD2) and to determine that sample foam piece (202C) is a target foam piece when both the first composition data and the second composition data are indicative of target foam.

11. The pre-processing arrangement of claim 10, further comprising:

- a transporting unit (208) configured to receive the selected target foam pieces (206) and to transport the selected target foam pieces (206) to a shredding unit (210); wherein

- the shredding unit (210) is configured to shred the selected target foam pieces (206) to form shredded foam elements (212) for feeding to the reactor.

12. The pre-processing arrangement of claim 10 or 11 , further comprising a foam element selection unit (204B) that is configured to select, from the shredded foam elements (212), shredded target foam elements (216) comprising target foam (207) that is suitable for the reactor (250).

13. The pre-processing arrangement of claim 12, wherein the foam element selection unit (204B) comprises:

- a foam composition determination unit (205) configured to perform an additional first analysis step (107A) for determining first composition data (CD1) of a sample foam element (212B), the first composition data being indicative of a composition of the sample foam element (212B), and to perform an additional second analysis step (107B) for determining second composition data (CD2) of the sample foam element (212B), the second composition data being indicative of the composition of the sample foam element (212B); and

- a processing unit (209) configured to receive the first composition data (CD1) and the second composition data (CD2) and to determine that sample foam element (212B) is a target foam element (216) when both the first composition data (CD1) and the second composition data (CD2) are indicative of target foam (207).

14. The pre-processing arrangement of claim 10 or 13, wherein the target foam selection unit (204A) and/or the foam element selection unit (204B) comprise:

- a first foam composition determination unit (205A) configured to determine the first com-position data (CD1); and

- a second foam composition determination unit (205B) configured to determine the second composition data (CD2).

15. The pre-processing arrangement of any one of claims 10 or 13-14, wherein the foam composition determination unit (205) and/or the first composition determination (205A) unit and/or the second foam composition determination unit (205B) is or are selected from a group consisting of a near-infrared spectroscopy device (204.1), a medium-infrared spectroscopy device (204.2), a UV-VIS spectroscopy device (204.3), an optical camera (204.4), a Raman spectroscopy device (204.5), a THz spectroscopy device (204.6), a laser induced breakdown spectroscopy device (204.7) and an X-ray fluorescence device (204.8).

16. Computer program comprising instructions which, when executed by a control unit of a target foam selection unit, cause the target foam selection unit to perform the method of any one of claims 1 to 7.