Compositions containing solid waste material

Abstract

Compositions (e.g., composites) containing processed solid waste, products made from the compositions, and systems and methods for making the compositions and products, are provided herein. For example, composites containing solid waste compositions and one or more added polymers, fillers, or other compounds are provided herein.

What is claimed is: 
     
         1 . A composite comprising a combination of:
 a heat-treated solid waste composition comprising
 mixed plastics and 
 organic material, 
 wherein the heat-treated solid waste composition comprises less than about 3 wt. % water; and 
   one or more polymers in addition to the mixed plastics contained in the solid waste composition,   wherein the composite has a compressive strength of at least 1500 psi.   
     
     
         2 . The composite of  claim 1 , wherein at least a portion of the mixed plastics in the heat-treated solid waste composition form a plastic matrix within the solid waste composition. 
     
     
         3 . The composite of  claim 1 , wherein the solid waste composition comprises from about 40 wt. % to about 86 wt. % carbon, and from about 3 wt. % to about 20 wt. % hydrogen. 
     
     
         4 . The composite of  claim 1 , wherein the solid waste composition was sorted to remove glass and metal. 
     
     
         5 . The composite of  claim 1 , wherein the one or more polymers comprise a thermoset polymer. 
     
     
         6 . The composite of  claim 1 , wherein the composite comprises less than 5 wt. % water. 
     
     
         7 . The composite of  claim 1 , wherein the composite comprises about 5 wt. % to about 60 wt. % of the one or more polymers. 
     
     
         8 . The composite of  claim 1 , wherein the solid waste composition is derived from municipal solid waste, agricultural waste, or both. 
     
     
         9 . The composite of  claim 1 , further comprising one or more of a flame retardant, a biocide, or an additive selected from an added recycled plastic, polylactic acid (PLA), and wood waste. 
     
     
         10 . The composite of  claim 1 , further comprising a coating that forms an exterior surface of the composite. 
     
     
         11 . The composite of  claim 1 , wherein the composite is in the form of a board, a plank, a stud, a block, or a brick. 
     
     
         12 . The composite of  claim 1 , wherein the composite comprises one or more elongate solid polymer components extending within the composite. 
     
     
         13 . The composite of  claim 1 , wherein the composite comprises about 30 wt. % to about 70 wt. % of the solid waste composition, about 5 wt. % to about 70 wt. % of the one or more polymers, and about 0.01 wt. % to about 5 wt. % water. 
     
     
         14 . A method of making a composite, the method comprising:
 heating, in a process vessel, a solid waste composition comprising:
 mixed plastics; and 
 organic materials; 
   such that at least a portion of the mixed plastics in the solid waste composition becomes melted; and   during or after the heating, adding a polymer to the solid waste composition.   
     
     
         15 . The method of  claim 14 , wherein the composite comprises about 5 wt. % to about 70 wt. % of the polymer. 
     
     
         16 . The method of  claim 14 , wherein the polymer comprises a thermoset resin. 
     
     
         17 . The method of  claim 14 , further comprising, during or after the heating of the solid waste composition, adding an additive, a flame retardant, or a biocide. 
     
     
         18 . The method of  claim 14 , further comprising forming the composite into a selected shape, wherein the forming comprises molding the composite, and cooling the molded composite, wherein the molding comprises injection molding the composite, extrusion die molding the composite, or processing the composite with a conventional screw conveyor, a conveyor die, or both. 
     
     
         19 . The method of  claim 14  comprising, during or after at least a portion of the mixed plastics of the solid waste composition is melted, adding the polymer to the solid waste composition. 
     
     
         20 . The method of  claim 14 , wherein the polymer forms a support structure within the composite.