Contents Trend of waste plastic recycling in Japan Containers and Packaging Recycling Law (CPRL) Recycling technologies 3.1 Existing technologies for CPRL Latest Developments on Plastics Recycling Technologies in Japan Blast furnace reducing agent, Coke oven fuel, Gasification, Liquefaction 3.2 Expecting technologies for CPRL RPF 3.3 New recycling technologies and systems (1)Producing naphtha rich oil by catalyst cracking using spent FCC August 30 2011 in Bangkok 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 Yamawaki Takashi Plastic Waste Management Institute 1 Trend of waste plastics recycling in Japan Mechanical Recycling Import Resin Production 11,210 Domestic Consumption 8,430 Post-use Discharge 8,460 Processing Waste 480 Total Discharge 120 9,120 Production Waste 180 Domestic Waste 4,440 2,000(22%) Liquefaction, Gasification, Blast furnace 80 320(4%) 75 Densified-refuse derived fuel 70 Reclaimed Products 540 Industrial Waste 4,680 Ut iliza tion t e（％） 420(5%) Unit：1000t Incineration with power generation 3,280(36%) Incineration with heat utilization facility 1,160(13%) Unutilized:2,710(21%) 65 60 55 50 Incineration without power generation or heat utilization facility 45 1,070(12%) Landfilling 40 880(10%) 1999 2000 Source : Plastic Waste Management Institute Figure-1 Flowchart of Plastic Products, Waste, and Recycling(2009) Plastic utilization rate increased steadily reaching 79%(2009) of total plastic waste discharge Utilized:7,230(79%) Export (4)Tray Tray to to 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 Figure-2 2001 2002 2003 2004 Calender year 2005 2006 2007 2008 Containers and Packaging Recycling Law (CPRL) Figure-4 Actual performance related to C&P plastics other than PET bottles Designated manufactures/users Business entities utilizing recycled products Payment of recycling costs The Japan C&P Recycling Association Supply Consumers Declaration for amount of sorting plastic waste Payment of recycling costs Bidding price Supply pp y Recyclers Municipalities Sorted collection Sorted discharge Transportation and recycling of “items to meet sorting criteria” Figure-3 Figure-6 Figure-5 Large Scaled Chemical Recycling Facilities Trends in bidding for the various recycling methods for C&P plastics other than PET bottles Nihon Steel (Muroran) Coke Oven: 20,000t 16 Facilities: Monomer Blast furnace Coke oven Gasification Liquefaction (Total 500 Kt/y) （complied with C&P recycling law, 2012) Mogami kiko (Shinjo) Liquefaction: 1,000t Orix environmental resources Gasification : 30,000t (Yorii) JFE Steel (Chiba) Gasification: 20,000t Nippon Steel (Kimitsu) Coke Oven: 50,000t JFE Steel (Fukuyama) Blast furnace/Coke Oven : 40,000t JFE Steel (Kawasaki) 40,000t/30,000t Blast furnace/Coke Oven Kyoei cycle（Onoda) Gasification: 25,000t Nihon Steel (Yahata) Coke Oven: 20,000t Showa Denko（Kawasaki) Gasification: 64,000t Nihon Steel (Oita) Cokes Oven: 25,000t Mizushima ecoworks (Mizushama) Gasification : 51,000t PET Reverse (Kawasaki) Monomer B to B: 27,500t Kobe Steel (Kakogawa) Blast furnace: 10,000t Nihon Steel (Nagoya) Coke Oven: 50,000t Recycling technologies (2)The flow seat of utilization for coke oven fuels 3.1 Existing recycling technologies for CPRL (1)The flow seat of utilization for blast furnace reducing agents Fe2O3+CH→Fe+CO2 +H2O Figure-7 Source: Nippon Steel Co 10 (3) The flow seat of utilization for gasification Carbonization room Figure-9 Figure-8 Source: JFE Steel Co Source: Nippon Steel Co 11 Figure-10 Source: Ube Industries Ltd 12 3.2 Expecting recycling technology for CPRL (4)The flow seat of utilization for liquefaction Source: Sapporo Plastic Recycling Last year, this plant was closed Figure-11 13 Figure-14 Comparison of Liquefaction process 3.3 New recycling technologies [existing cracking] (1) Liquefaction by Catalyst Cracking using Spent FCC Catalyst melting dechlorination pretreatment Waste Plastic, Spent Catalyst, Slaked Lime Fixed catalytic cracking product exhaust gas treatment Fixed Coole r [this catalytic cracking] Fuel gas pretreatment product catalytic cracking vent Heater waste plastic condenser Oil/Gas Separator Fuel Heating Furnace feeder Waste Catalyst breaker reflux HCl gas feeder product oil cracker Residual Substance Source: The University of Kitakyusyu 15 vent condenser neutralization Dechlorination Agent Figure-13 cracking Spent Catalyst Rotational Dram Air 14 Figure-12 cracker Reduction melting dechlorination residue air-heating furnace air-heating furnace heavy oil 16 oil cracked WCCP Cracking (Bench Plant) Results of PE Degradation using spent FCC Catalyst Total outlet flow [wt%] cooler ＜Reaction Condition＞ 120 PE 425℃ PE-FCC 420℃ 100 80 Temperature：420～480Ԩ Agitation：2～5rpm Reactor：300φ×1200L Feed：2～20kg/hr WCCP: waste container and packaging plastic ＜Chlorine＞ 60 40 20 0 30 60 90 120 150 180 Flow time [min] 11.5 1～2 45.0 4000 3000 2000 39 210 176 47 Figure-16-1 17 17 ＜Demonstration Plant＞ Capacity : 80kg/h 47.6 41.5 46.0 50.1 3.9 18.3 39.9 5.3 43.0 36.4 52.8 58.1 40.9 47 12 13 189 128 20 Number of run [-] Start up feed Ca(OH)2 55.8 0.3 0.6 16 9.1 40.8 Heavy oil Diesel Naphtha Ca(OH)2 1000 3.8 8.1 5.8 4047 Fig15-2:Distribution of carbon number of products DEMONSTRATION PLANT OF WASTE PLASTIC CRACKING ＜Product Oil＞ 5000 Dr y Aromatic R esidua l C hlorine[ppm ] oi l i-Paraffin co ke 22.5 de se l 30 ga s Oreffin Used catalyst he av y 11.0 Free catalyst LP G 60 40 35 30 25 20 15 10 Used Catalyst Na ph th a Used catalyst [wt%] Percentage[wt%] n-Paraffin Free catalyzed Ke ro se ne Fig15-1：On Fig15 1：On the relationship between outlet flow and flow time Table1:Distribution ratio of products Free catalyst [wt%] hopper cracker Ca(OH)2:50vol% 40.7 0.5 12 Number of run [-] Figure-16-2 0.3 0.1 13 49.8 0.2 16 LPG 0.2 20 Ca(OH)2 Start up feed Ca(OH)2 18 (2) Introduction of development of highly efficient recycling technology for multilayer films Background : Feed : C&P Home waste, Recycles of home electronics, ASR 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 Figure-17＜Flow of Demonstration Plant＞ ¾Situation of waste treatment of the multilayer film 大気放出 chain block A001電動チェーンブロック Most of multilayer films have been being disposed of (incineration, or 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 S002 排気筒 原料 feed blower B004排ガス誘引ブロワ V001 材料受入ホッパ hopper V002 feeder 投入ホッパ 廃水（産廃） Waste water H001分解油冷却器 oil cooler R001 プラスチック液化装置 残渣排出 (産廃） Objective : B001 blower 生成ガスブロワ B003希釈空気ブロワ air blower ¾ Utilization of these multilayer films as recycled material by commpatibilization technology of different kinds of plastics ¾ Converting to economically advantageous sheet by achieving both compatibilization and molding to sheets from shredded flakes of mill end of multilayer films B002燃焼空気ブロワ air blower cracker waste catalyst ＜Cracker＞ F001熱風発生炉 T004 水封タンク LPG (supplement) ＬＰＧ(補助燃料） separator T003払出しタンク T002 分解油タンク product oil 生成油（産廃） P001分解油ポンプ P002払出しポンプ 19 19 20 Conventional process Compatibilizer shredding Multilayer film Figure-19 Effect of compatibilization Flake Modification and Kneading Pellet Pellet Sh t extruding Sheet t di Sh t Sheet New process SPE90A/JPP90A=75/25 Without compatibilizer Tensile strength=10MPa Elongation=10％ Two steps Compatibilizer shredding Multilayer film SPE90A/JPP90A=75/25 With 5％ of compatibilizer Tensile strength=10MPa Elongation=300％ Flake Modification, Kneading and Sheet extruding Sheet Direct sheet extrusion Figure-18 Comparison between the conventional process and the new process 21 Direct sheet extrusion system 22 The sheet which satisfies the following point, can be extruded directly with using shredded flake of multilayer film Big Tank Feeder System Acceptable range of wall thickness ‫ أ‬10％ Tensile strength ‫ ؤ‬10MPa（MD､TD） Fish eye or Foreign matter : Unidentified Compatibilizer Slot Gear Pump T-Die Figure-21 Target of direct sheet extrusion 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 23 Flake of multilayer film Outlet of first extruder Condition of sheet extrusion Figure-22 Situation of direct sheet extrusion 24 (3) Development of Mechanical Recycling Technology for Waste PVC wall covering based on High-speed Centrifugal Beating Technology 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 PVC wall covering Production 180 thousand tons PVC 32% rear： pulp Advantage : easy removable, recyclable use Plasti ｃizer 16% front：resin C CO3 CaCO 29% PULP 21% Figure-23 Construction site 25 Waste from  construction Production  waste Figure-24 Plywood covered by sheet Waste Figure-25 Waste from  dismantling 100 thousand tons Other 2% 26 26 Structure of High-speed Centrifugal Beating Machine System flow of this technology Shredding Waste Wall covering Pulverization Separation （recovery of pulp） pulp pulp new resin pulp new shredder beater Rotary separator Separation cyclone （recovery of resin） resin new Figure-26 27 Separation tower Figure-27 Vibrating sieve resin 28 28 PVC wall covering (4) Tray Tray to to Tray recycling by “FPCO system” Dining table Retail Delivery Consumers Supermarkets, etc Packaging wholesalers FPCO Structure of system using collaborating companies (FPCO System) Washing & drying Collection Storing Picking-up & recycling Pulp PVC resin Production Raw material Tasks of each player _ Supermarket Packaging Materials Collection FPCO box Sparkle Gleam Consumers are requested to separate used styrofoam trays from other garbage, and to wash and dry them Back paper for wall covering 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 temporarily store them on their premises When our trucks deliver trays to wholesalers, they bring the used 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 Items meeting sorting criteria Municipalities Floor mat for automobile Collection & sorting Form floor material * Designated corporation route: Collection route prescribed by the Containers and Packaging Recycling Law 29 Figure-28 Consolidation of final processes (improvement in quality of recycled raw materials) Outsourced treatment Designated corporation Japan Containers and Packaging Recycling Association 30 Figure-29 Source : FP CORPORATION Products from recycled materials (Tray-to-Tray) Washing water filter machine Alkaline concentration adjustment tank Eco hot water Hot water tank Alkalescent Heat exchanger supply system detergent tank Primary cleaning Secondary cleaning Rinsing Plant Mill-End Pellets Blend (70% plant mill-end, 30% collected tray pellets) Raw material Old line Recycled sheet Mold Raw film sheet Sheeting Process *Virgin raw material is not used at the sheet step Figure-30 31 FP CORPORATION Virgin film upper/lower laminate (film mass is 20% of tray mass) Oven Blowing agent Extruder Recycled Pellets of Collected Trays Cut Printed-pattern tray pellets PSP new washing line White-tray pellets zPSP: Into plants in Kanto, Shin-Chubu and Fukuyama Sold as construction raw materials (Pilings, artificial wood, wood flooring, etc.) Eco Tray Mill ends after cutting are used again to make pellets Vacuum suction Raw film Molded product sheet Molding Process Accounts for 20% of general-purpose trays circulating in the Market Eco trays have an eco symbol 32 Figure-31 FP CORPORATION (5) Advanced separation technology of shredded plastic mixture from WEEE Ensuring Eco Tray Safety WEEE ‹ 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 verify if that th t they th satisfy ti f the th corresponding di regulations and standards Vegetable case 【冷蔵庫 In refrigerator 野菜ｹｰｽ】 Hygiene Test Certificate Motor, Compressor Manual separation Vegetable case, Washing tank(Big plastic parts） Minute crushing Separation technology Shredding Fe, Cu, Al ( Metals) separation ‹ Both sides of Eco (recycled) Trays are laminated with virgin film in order to ensure additional product safety Shredded mix plastic Sandwiched by polystyrene film made from virgin raw material Recycled PSP 33 Figure-32 FP CORPORATION ② Figure-33 34 Rough crushing（50～150mm） Minute crushing（5～10mm） ①Separation by specific gravity of plastic mixture The selection flow of shredded plastic mixture ① Source: Mitsubishi electric ③ 【Separation by specific gravity】 Selection by specific gravity ＡＢＳ／ＰＳ mixture Mixed plastics ＰＰ Heavy gravity plastics Figure-34 Electrostatic separation X-ray analysis selection ＡＢＳ High purity ＡＢＳ ＰＳ High purity ＰＳ High purity ＰＰ PP ●Principle 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 1.041.10) that is heavier than water sink to bottom, as a result , they can be separated Cement raw material 35 Source: Mitsubishi electric Figure-35 Buoyancy y y ABS,PS Light gravity plastic Heavy gravity plastic Gravity 36 Source: Mitsubishi electric Source: Mitsubishi electric ②Separation by static electricity of plastic mixture PS,ABS mixture plastics piece The piece of PS and ABS is rubbed, then matched by rotating the electrification cylinder, and static electricity is caused － X ray Air gun Conveyer ABS Figure-37 ＋ PS: Polystyrene ABS: Acrylonitrile－butadiene－styrene － Source: Mitsubishi electric Controller ＋ PS 2010 Fiscal year The minister of the environment prize ③ X-ray analysis selection system （under testing） Electrode － － PS(-) －Electrode Detector Brominated flame retardant content plastic ＋ ＋ ABS(+) 37 Figure-36 Brominated flame retardant Brominated flame retardant 38 free plastic content plastic X-ray penetration image Source: Kyoei industry (6) PET bottle to PET bottle by mechanical recycling 39 Label separator ①Separation of foreign substance (color bottle, label etc.) Label separator Color bottle  crasher Label Resource from municipality PVC Conveyer Opener Feeder Color Manual  separation p Separator Non ferrous Second crasher Metal remover First crasher ②Removal of surface foreign substance by alkali Removal of surface Foreign substance Vibrating  sieve Magnetic  separator Cap Dehydrator Sieve Figure-38 Flake Wind separator Heater Second dehydrator Rinse PO High level safety ①Removal of surface foreign substance by alkali ・By alkali depolymeriziation, surface PET which is contact with food is removed ②Removal of residue foreign substance by vacuum and high temp and polymerize ・Under vacuum and high temp state, almost low molecular organic substances are removed and a polymerization is occurred simultaneously Certification of safety ・By the fraunhofer test results, FDA permitted to pass a food contact packaging criterion ・The regulated substances (heavy metals, chemicals) are not detected Source: Kyoei industry Process flow of flake production Hydro cyclone First dehydrator Alkali washer 40 10 Source: Kyoei industry Process flow of pellet production ③Removal of residue foreign substance by vacuum and high temp and polymerize Vacuum, High temp Flake Hopper Polymerization  and Remove of foreign substance Thank you for your attention Weight meter First reactor Figure-39 Second reactor Extruder Filter Cooling  tank Pelletizer Vibrating  sieve 41 Polymerization plant Plastic Waste Management Institute Sumitomorokko Bldg.,1-4-1 Shinkawa,Chuo-ku,Tokyo 104-0033,Japan Tel;81-3-3297-7511 Fax;81-3-3297-7501 Web site http://www.pwmi.or.jp 42 Recycled pellet 11 [...]...Source: Kyoei industry Process flow of pellet production ③Removal of residue foreign substance by vacuum and high temp and polymerize Vacuum, High temp Flake Hopper Polymerization  and Remove of foreign substance Thank you for your attention Weight meter First reactor Figure-39 Second reactor Extruder Filter Cooling  tank Pelletizer Vibrating  sieve 41 Polymerization plant Plastic Waste Management Institute... meter First reactor Figure-39 Second reactor Extruder Filter Cooling  tank Pelletizer Vibrating  sieve 41 Polymerization plant Plastic Waste Management Institute Sumitomorokko Bldg.,1-4-1 Shinkawa,Chuo-ku,Tokyo 104-0033 ,Japan Tel;81-3-3297-7511 Fax;81-3-3297-7501 Web site http://www.pwmi.or.jp 42 Recycled pellet 11