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The Vehicle Recycling Partnership (VRP) initiated feasibility studies to evaluate the use of automated separation processes to recover plastics and polyurethane (PU) foams from shredder residue. One of the prevailing issues impeding the commercial success of these processes is contamination of the shredder materials. The contaminants include dirt, oils, glass, metal fines, polychlorinated biphenyls (PCBs) and heavy metals. The presence of PCBs and heavy metals was determined in a number of mixed plastics and PU foam samples separated using an automated separation process. An aqueous cleaning approach was investigated using various commercial surfactants to determine their effectiveness for removing oils, PCBs, and heavy metals. Mass balances of processed and cleaned materials were calculated to determine the cleaning efficiencies of the various surfactants.

A performance map for polyurethane energy managing foam is presented as a heuristic tool in the selection of appropriate formulation and density. Dynamic data was mapped to material characterization data. Material characterization was accomplished by quasi-static compression testing ASTM D-1621. The D-1621 data was correlated with 24.1 km/hr (15 mph) head impact data and 8.05 km/hr (5 mph) bumper impact data. For example, Head Injury Criterion (HIC) values were correlated with D-1621 compressive strengths which were mapped to polyurethane formulations and densities. The performance map can save time and money by identifying appropriate formulation and density.