Latest Developments on Plastics Recycling Technologies in Japan

Latest Developments on Plastics Recycling Technologies in Japan 1 August 30 2011 in Bangkok Yamawaki Takashi Plastic Waste Management Institute Contents 1.. Recycling technologies 3.1 Ex

Latest Developments on Plastics Recycling

Technologies in Japan

1

August 30 2011 in Bangkok Yamawaki Takashi

Plastic Waste Management Institute

Contents

1 Trend of waste plastic recycling in Japan

2 Containers and Packaging Recycling Law (CPRL)

3 Recycling technologies 3.1 Existing technologies for CPRL Blast furnace reducing agent, Coke oven fuel, Gasification, Liquefaction 3.2 Expecting technologies for CPRL

RPF

2

3.3 New recycling technologies and systems (1)Producing naphtha rich oil by catalyst cracking using spent FCC catalyst

(2)Highly efficient recycling technology for waste multilayer films (3)Mechanical Recycling Technology for Waste PVC wall covering based on High-speed Centrifugal Beating Technology

(4)Tray Tray to to Tray recycling by “FPCO system” Tray recycling by “FPCO system”

(5)Advanced separation technology of shredded plastic mixture from WEEE

(6)PET bottle to PET bottle by using mechanical process

Resin

Production

11,210

Domestic Consumption

8,430

Post-use Discharge 8,460

Total Discharge

9 120

Processing Waste 480

Mechanical Recycling 2,000(22%) Liquefaction, Gasification, Blast furnace 320(4%) Densified-refuse derived fuel 420(5%) Incineration with power generation 3,280(36%)

Utilized:7,230(79%)

Unit：1000t

1 Trend of waste plastics recycling in Japan

3

Figure-1 Flowchart of Plastic Products, Waste, and Recycling(2009)

9,120 Domestic Waste 4,440 Industrial Waste 4,680

Production Waste 180

Incineration with heat utilization facility 1,160(13%) Incineration without power generation or heat utilization facility 1,070(12%) Landfilling 880(10%)

Reclaimed

Products

540

Unutilized:2,710(21%)

Source : Plastic Waste Management Institute

Plastic utilization rate increased steadily reaching 79%(2009) of total plastic waste discharge.

65 70 75 80

4 40

45 50 55 60

Calender year

Figure-2

2 Containers and Packaging Recycling Law (CPRL)

Payment of

recycling

costs

Declaration for

Payment of recycling costs

Designated

manufactures/users Business entities utilizing

The Japan C&P Recycling Association

5

Consumers

Municipalities

Recyclers

of “items to meet sorting criteria”

Sorted

collection

Declaration for amount of sorting

price

Figure-3

Actual performance related to C&P plastics other than PET bottles

Figure-4

6

Trends in bidding for the various recycling methods for

C&P plastics other than PET bottles

Figure-5

7

JFE Steel (Chiba) Gasification: 20,000t Orix environmental resources

Gasification : 30,000t (Yorii)

Nihon Steel (Muroran) Coke Oven: 20,000t Mogami kiko (Shinjo) Liquefaction: 1,000t

Large Scaled Chemical Recycling Facilities

（complied with C&P recycling law, 2012)

16 Facilities:

Monomer 1 Blast furnace 3 Coke oven 6 Gasification 5 Liquefaction 1

(Total 500 Kt/y)

Figure-6

8 Kobe Steel (Kakogawa)

Blast furnace: 10,000t

Nihon Steel (Yahata) Coke Oven: 20,000t Nihon Steel (Oita) Cokes Oven: 25,000t Mizushima ecoworks (Mizushama) Gasification : 51,000t

Nihon Steel (Nagoya) Coke Oven: 50,000t

Nippon Steel (Kimitsu) Coke Oven: 50,000t JFE Steel (Fukuyama)

Blast furnace/Coke Oven : 40,000t Kyoei cycle（Onoda) Gasification: 25,000t

PET Reverse (Kawasaki) Monomer B to B: 27,500t

Showa Denko（Kawasaki) Gasification: 64,000t

JFE Steel (Kawasaki) 40,000t/30,000t Blast furnace/Coke Oven

(1)The flow seat of utilization for blast furnace reducing agents

3 Recycling technologies

Fe2O3+CH→Fe+CO2

+H2O

3.1 Existing recycling technologies for CPRL

9

Source: JFE Steel Co

Figure-7

(2)The flow seat of utilization for coke oven fuels

10

Source: Nippon Steel Co

Figure-8

Carbonization room

11

Source: Nippon Steel Co

Figure-9

(3) The flow seat of utilization for gasification

12

Source: Ube Industries Ltd

Figure-10

(4)The flow seat of utilization for liquefaction

13

Source: Sapporo Plastic Recycling

Figure-11

Figure-12

Waste Plastic, Spent Catalyst,

Slaked Lime

Coole r

Catalyst

Fixed

(1) Liquefaction by Catalyst Cracking using Spent FCC Catalyst

3.3 New recycling technologies

15

Oil/Gas Separator Heating

Furnace

Fuel

Air

Heater

Waste Catalyst Dechlorination Agent Residual Substance

Source: The University of Kitakyusyu Figure-13

Figure-14 Comparison of Liquefaction process

[existing cracking]

catalytic cracking

pretreatment melting

dechlorination cracking catalytic cracking product exhaust gas treatment

[this catalytic cracking]

product pretreatment

16

HCl gas feeder

melting dechlorination neutralization

vent

cracker

reflux condenser

product oil

air-heating furnace residue

feeder breaker waste plastic vent condenser

air-heating furnace

cracker

cracked oil heavy oil

Reduction

Results of PE Degradation using spent FCC Catalyst

Fig15 1：On the relationship between

0

20

40

60

80

100

120

Flow time [min]

425℃

PE-FCC 420℃

17

Free

catalyst [wt%]

Used catalyst [wt%]

Table1:Distribution ratio of products

Fig15-2:Distribution of carbon number of products

Free catalyzed Used Catalyst

Fig15-1：On the relationship between

outlet flow and flow time

0 10 20 30 40

Dr

Na a Ke ne de l he

y o

Free catalyst Used catalyst

WCCP Cracking (Bench Plant)

Ca(OH)2:50vol%

Temperature：420～480Ԩ Agitation：2～5rpm Reactor：300φ×1200L Feed：2～20kg/hr WCCP: waste container and packaging plastic

cracker

cracker

18

43.0 36.4 40.8

0.2 0.2 0.3 0.6 0.3 0.5 0.1 55.8 40.7

41.5

9.1 5.3 3.9 5.8 8.1 3.8 18.3

Number of run [-]

Heavy oil Diesel Naphtha LPG

Ca(OH)2

128 189 176

210

4047

0 1000 2000 3000 4000 5000

Number of run [-]

Start up feed Ca(OH) 2

Ca(OH) 2

Start up feed Ca(OH) 2

Figure-16-1

Figure-16-2

Figure-17＜Flow of Demonstration Plant＞

＜Demonstration Plant＞

DEMONSTRATION PLANT

OF WASTE PLASTIC CRACKING

Capacity : 80kg/h

Feed : C&P Home waste, Recycles of home electronics, ASR

大気放出

S002 排気筒 A001電動チェーンブロック

大気放出

S002 排気筒 A001電動チェーンブロック chain block

19

＜Cracker＞

廃水（産廃）

残渣排出

原料

B004排ガス誘引ブロワ

F001熱風発生炉

B003希釈空気ブロワ B002燃焼空気ブロワ

B001 生成ガスブロワ

P002払出しポンプ

T003払出しタンク T002

分解油タンク

P001分解油ポンプ

T004

水封タンク

R001

プラスチック液化装置

V001

材料受入ホッパ

V002

投入ホッパ

H001分解油冷却器

ＬＰＧ(補助燃料）

排気筒

廃水（産廃）

残渣排出

原料

B004排ガス誘引ブロワ

F001熱風発生炉

B003希釈空気ブロワ B002燃焼空気ブロワ

B001 生成ガスブロワ

P002払出しポンプ

T003払出しタンク T002

分解油タンク

P001分解油ポンプ

T004

水封タンク

R001

プラスチック液化装置

V001

材料受入ホッパ

V002

投入ホッパ

H001分解油冷却器

ＬＰＧ(補助燃料）

排気筒

feed

hopper

feeder

cracker

waste

catalyst

Waste water

oil cooler

blower

separator air blower

product oil

blower

air blower

LPG (supplement)

Background :

¾What is the multilayer film?

The composite film which laminates PET, PA as the functional layer to give gas barrier property, pinhole resistant, and so on and PE, PP as the sealant layer

¾Situation of waste treatment of the multilayer film

Most of multilayer films have been being disposed of (incineration, or landfill), as these cannot be recycled to materials with required strength

(2) Introduction of development of highly efficient recycling technology for multilayer films

20

landfill), as these cannot be recycled to materials with required strength

The mill ends of these multilayer films of 15,000 t/month (estimate value) are discharged from printing factories in Japan

Objective :

¾Utilization of these multilayer films as recycled material by commpatibilization technology of different kinds of plastics

¾Converting to economically advantageous sheet by achieving both compatibiliza-tion and molding to sheets from shredded flakes of mill end of multilayer films

Conventional process

and Kneading

Pellet

shredding

Two steps

21 Figure-18 Comparison between the conventional process and the

new process

New process

and Sheet extruding

Pellet Sheet extruding

Compatibilizer

Sheet

Sheet

Direct sheet extrusion shredding

Figure-19 Effect of compatibilization

SPE90A/JPP90A=75/25 Without compatibilizer Tensile strength=10MPa Elongation=10％

22

SPE90A/JPP90A=75/25 With 5％ of compatibilizer Tensile strength=10MPa Elongation=300％

Big Tank Feeder System

Compatibilizer Slot

Gear Pump T-Die

Direct sheet extrusion system

23

First extruder : Co-Rotating Twin Screw Extruder equipped Screen Changer,

Screw Diameter 105mm

Second extruder : Single Screw Extruder equipped Screen Changer and

Gear Pump, Screw Diameter 100mm, L/D=28

Figure-20 Outline of direct sheet extrusion system

The sheet which satisfies the following point, can be extruded directly with using shredded flake of multilayer film

Acceptable range of wall thickness أ 10％

Tensile strength ؤ 10MPa（MD､TD）

Fish eye or Foreign matter : Unidentified

Figure-21 Target of direct sheet extrusion

24 Figure-22 Situation of direct sheet extrusion

Flake of multilayer film Outlet of first extruder Condition of sheet extrusion

Application example

Concrete panel

500 concrete panels (plywood covered by the sheet) are made for trial purposes,

and the performance assessment in the site is under way

Advantage : easy removable, recyclable use

25

Figure-23 Construction site Figure-24 Plywood covered by sheet

PVC wall covering

C CO

Plasti ｃizer 16%

PVC 32%

rear：

pulp front：resin

covering based on High-speed Centrifugal Beating Technology

26 26

Production  waste

Waste from  construction

Waste from  dismantling Other2%

PULP 21%

CaCO3

29%

Figure-25

Structure of High-speed Centrifugal Beating Machine

27

Figure-26

cyclone beater

new

Rotary separator

new

Pulverization

Shredding

pulp shredder

Waste Wall covering

resin System flow of this technology

28 28

Vibrating sieve Separation tower

new

resin resin

Figure-27

PVC wall covering

29

Floor mat for automobile Form floor material

Back paper for wall covering

Figure-28

Dining

Washing &

drying Collection Storing Picking-up & recycling

Tasks of each player

Raw material

Structure of system using collaborating companies (FPCO System)

((4 4)) Tray Tray to to Tray recycling by “FPCO system” Tray recycling by “FPCO system”

30

Gleam Sparkle _ Supermarket

Collection box

Packaging Materials FPCO

Consumers are requested to separate used styrofoam trays from other garbage, and to wash and dry them

Used trays brought in by consumers are accumulated in collection bins at supermarkets and other stores This makes for stronger ties between consumers and supermarkets

Packaging wholesalers use their trucks to pick up the used trays

on their way back from delivery runs to supermarkets, etc., and premises

When our trucks deliver trays to trays back with them on the return trip This method of collecting the used trays is unique to FPCO, which makes its own deliveries

Used trays are also recovered via municipalities and a designated corporation

Municipalities Collection & sorting

Designated corporation Japan Containers and Packaging Recycling Association

* Designated corporation route: Collection route prescribed

by the Containers and Packaging Recycling Law

Items meeting sorting criteria Outsourced treatment

Source : FP CORPORATION

Figure-29

Consolidation of final processes

(improvement in quality of recycled raw materials)

zPSP: Into 3 plants in Kanto, Shin-Chubu and Fukuyama

PSP new washing line

Eco hot water

supply system

Hot water tank

Heat exchanger

Washing water filter machine Alkaline concentration adjustment tank Alkalescent

detergent tank Primary cleaning Secondary cleaning Rinsing

31

FP CORPORATION

Old line

Figure-30

Products from recycled materials (Tray-to-Tray)

Recycled Pellets of Collected Trays

Plant Mill-End Pellets

Sold as construction raw materials (Pilings, artificial wood, wood flooring, etc.)

32

FP CORPORATION

Blend (70% plant mill-end, 30% collected tray pellets)

Recycled sheet

Sheeting Process

*Virgin raw material is not used at the sheet step.

Virgin film upper/lower laminate (film mass is 20% of tray mass)

Molding Process

Mill ends after cutting are used again to make pellets

Eco Tray

Accounts for 20% of general-purpose trays circulating in the Market.

Eco trays have an eco symbol.

Raw material

Extruder Blowing agent

Mold Raw film sheet

Raw film sheet

Oven Cut

Vacuum suction Molded product

Figure-31

Hygiene Test Certificate

Ensuring Eco Tray Safety

‹ A standards inspection of recycled raw

material is performed monthly by the

Japan Inspection Association of Food and

Food Industry Environment at every

recycling plant

‹ The Japan Food Research Laboratories are

requested to test the Eco (recycled) Trays to

33

FP CORPORATION

Recycled PSP

Sandwiched by polystyrene film made from virgin raw material

verify that they satisfy the corresponding

regulations and standards

‹ Both sides of Eco (recycled) Trays are

laminated with virgin film in order to ensure

additional product safety

Figure-32

((5 5) Advanced separation technology of shredded plastic ) Advanced separation technology of shredded plastic

mixture from WEEE

【冷蔵庫 野菜ｹｰｽ】

Minute crushing

Manual separation

WEEE

Motor, Compressor Vegetable case, Washing tank(Big plastic parts）

Vegetable case

In refrigerator

34 Rough crushing（50～150mm） Minute crushing（5～10mm）

Separation technology Shredding

separation Fe, Cu, Al ( Metals)

Shredded mix plastic

Source: Mitsubishi electric Figure-33

X-ray analysis selection

③

The selection flow of shredded plastic mixture shredded plastic mixture

Selection by

specific gravity

Electrostatic separation

35

Mixed

plastics

ＡＢＳ／ＰＳ

mixture

ＰＰ

Heavy

gravity

plastics

ＡＢＳ

ＰＳ

High purity

ＡＢＳ

High purity

ＰＰ

High purity

ＰＳ

Cement raw material

Source: Mitsubishi electric Figure-34

①Separation by specific gravity of plastic mixture

●Principle

【Separation by specific gravity】

Buoyancy

PP

36

PP (specific gravity 0.91-0.98) that

is lighter than water float to surface

by using water for the medium, and ABS and PS (specific gravity 1.04-1.10) that is heavier than water sink

to bottom, as a result , they can be separated

Light gravity plastic Heavy gravity plastic

Gravity

Source: Mitsubishi electric ABS,PS

Figure-35

②Separation by static electricity of plastic

mixture

The piece of PS and ABS

is rubbed, then matched

by rotating the

electrification cylinder,

and static electricity is

PS,ABS mixture

plastics piece

＋

－

37

caused

－Electrode

＋Electrode

＋

－

－

－

PS: Polystyrene

ABS: Acrylonitrile－butadiene－styrene

Source: Mitsubishi electric

Figure-36

③ X-ray analysis selection system

（under testing）

X ray

Controller

2010 Fiscal year The minister of the environment prize

Figure-37

38

X-ray penetration image

Detector

Brominated flame retardant content plastic

Brominated flame retardant content plastic Brominated flame retardantfree plastic

(6) PET bottle to PET bottle by mechanical recycling

High level safety

・By alkali depolymeriziation, surface PET which is contact

with food is removed

②Removal of residue foreign substance by vacuum and

high temp and polymerize

39

・Under vacuum and high temp state, almost low molecular

organic substances are removed and a polymerization is

occurred simultaneously.

Certification of safety

food contact packaging criterion.

・The regulated substances (heavy metals, chemicals) are

Conveyer Opener Feeder Separator

Color bottle  crasher

Manual  separation First crasher Non ferrous Second crasher

Metal remover

Label separator

Label

Process flow of flake production

Color PVC

Label separator

①Separation of foreign substance

(color bottle, label etc.)

Source: Kyoei industry

Resource from municipality

40 p

Alkali washer

First dehydrator Hydro cyclone Rinse Second dehydrator Heater Wind separator

Vibrating  sieve

Magnetic 

Flake

Dehydrator Cap Sieve PO

Removal of surface Foreign substance

②Removal of surface foreign substance by alkali

Figure-38