emerging and new technologies...emerging and new technologies by arnold black, resource efficiency...
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EMERGING AND NEW TECHNOLOGIES
By Arnold Black,
Resource Efficiency KTN,
www.resource-efficiency.org
Global Watch is a DTI service managed by Pera
WEEE Recovery – The European Story
Global Watch is a DTI service managed by Pera
WEEE Recovery – The European Story
Key finding and conclusions
• Recovery of the plastics fraction essential to meet the recovery targets
• Sophisticated Collection and handling facilities required
• Training of operators and senior staff through the supply chain.
• Developing solutions for anticipated problems
Global Watch is a DTI service managed by Pera
WEEE Recovery – The European Story
Dioxins and Furans in WEEE Plastics
• Incineration of plastics filled with Brominated Flame Retardants (BFR) creates Dioxins and Furans (PBDD/F) which can be above the threshold limits of German ChemVV
• Dioxins are also produced within hot shredder/granulation equipment when processing BFR plastics. The smaller the particle size of the plastics, the more Dioxins and Furans are produced
• Higher BFR levels were found in Monitor & TV housings than in Mixed Shredder residues
•Imports of plastics from Asia are raising the levels of BFRs in WEEE
Fraunhofer InstitutVerfahrenstechnikund Verpackung
IVV
Global Watch is a DTI service managed by Pera
WEEE Recovery – The European Story
The Creasolv® Process
• The Creasolv® Process can turn mixed plastics waste into polymers such as ABS and HIPS
• Flame retardants, Dioxins and Furans can be reduced by 70-93%
• Polymer product has properties similar to virgin polymers
• Currently on a lab scale, the Creasolv® process needs to be commercialised on an industrial scale
Fraunhofer InstitutVerfahrenstechnikund Verpackung
IVV
Global Watch is a DTI service managed by Pera
WEEE Recovery – The European Story
WEEE plastic fractions2 types of polymer fractions available
Manual dismantling(CRT glass)
Monitors & TV housing polymers >95% polymersFew polymer typesHigh BFR-levels
Mixed shredder residues~80% polymersMany polymer typesLower BFR-levels
Metal recovery,shredder
Fraunhofer InstitutVerfahrenstechnikund Verpackung
IVV
Global Watch is a DTI service managed by Pera
WEEE Recovery – The European Story
CreaSolv® processAim:
Recycling BFR-containing WEEE plastics to top quality technicalpolymers• free of other polymers
• free of contaminants
• genuine specifications
Polymer-recyclate
Plastic-waste
PretreatmentGrindingWashing
Recyclingof solvents
ConfectionCompressing
DryingCompounding
Dissolving
Cleaning
Precipitating
Fraunhofer InstitutVerfahrenstechnikund Verpackung
IVV
Global Watch is a DTI service managed by Pera
WEEE Recovery – The European Story
mg/kg OctaBDE DecaBDE TBBPA TBPE
Product 1. run
168 48 <30 130
Product 2. run
288 210 102 90
CreaSolv® Products from shredded TV-set casings(BFR fraction)
CreaSolv®
product
Regranulate
Elimination rates
95%96%97%98%99%
100%
OctaBDE DecaBDE TBBP A TBPE
Product 1 Product 2
Fraunhofer InstitutVerfahrenstechnikund Verpackung
IVV
Global Watch is a DTI service managed by Pera
WEEE Recovery – The European Story
Results of KERP Project:Pilot production on a small technical scale
Input100%
Yield of single process steps:Filtration ~85% BFR elimination ~95%
Products 80%
ABS/HIPS=6/4Mixed product
Purified polymers
By-products
20%
Fraunhofer InstitutVerfahrenstechnikund Verpackung
IVV
Global Watch is a DTI service managed by Pera
WEEE Recovery – The European Story
Results of KERP Project:RoHS compliance
TBBP Appm
OctaBDEppm
TBPEppm
DecaBDEppm
Br, calc ppm
Input 5428 861 1478 1198 5920
HIPS product 244 98 156 392 657
ABS product 295 111 155 323 639
Mix product 236 94 126 288 542
Threshold limit - 1000 - - -
Fraunhofer InstitutVerfahrenstechnikund Verpackung
IVV
Global Watch is a DTI service managed by Pera
WEEE Recovery – The European Story
Results of KERP Project:ChemVV compliance
Sum 4ppb
Sum 5ppb
HIPS product 0,16 < 0,30
HIPS MFI 0,48 < 0,65
Threshold limit 1 5
Fraunhofer InstitutVerfahrenstechnikund Verpackung
IVV
Global Watch is a DTI service managed by Pera
WEEE Recovery – The European Story
Introduction to Catalytic Depolymerisation
But what to do with the rest, But what to do with the rest, when the metals are gone?when the metals are gone?
Metals give the best revenuesMetals give the best revenues
Global Watch is a DTI service managed by Pera
WEEE Recovery – The European Story
The Inventor and the InventionInvention: Turn hydrocarbon waste into biodieselInventor: Christian KochProduct: KDV 500
Global Watch is a DTI service managed by Pera
WEEE Recovery – The European Story
Infeed Materials• All kinds of plastic, including PVC
• Rubber and car tyres
• Oil waste, wax and all kinds of grease
• Agricultural waste, animal leftovers and food waste
• Hospital waste that has been sterilized, dehydrated and dried
• Refinery waste, like bitumen, tar etc
Global Watch is a DTI service managed by Pera
WEEE Recovery – The European Story
Diesel Quality – Test Results• CDP diesel was tested in several laboratories
• Cetan-number > 56: Quality is higher than “normal”
• Specific weight: ok
• Water content: ok
• Other specs: ok
• No dioxins
• No bromides
• Good till – 16°C
• Result: The diesel is ok for use in motor engines
Global Watch is a DTI service managed by Pera
WEEE Recovery – The European Story
Summary and Advantages
• Diesel fuel from hydrocarbons, even from PVC waste • Production of clean “ready to use” diesel • Low costs (approx. EUR 0,23 per litre Diesel all in) • Reduced process temperature 270…350 °C• Unpressurized catalytic conversion (pressure -0.1 bar)• No dioxins and furans• Low energy consumption • Environment protecting process• High yield of process - approx. 90 % energy recovery! • Reduction of CO² emissions to the atmosphere
Global Watch is a DTI service managed by Pera
WEEE Recovery – The European Story
MBA Polymers• Can take mixed plastic shredder waste and
process to produce HIPS and ABS.
• Input capacity: 40 ktpa (Kematen, Austria)
• Infeed materials not containing BFR’s
Global Watch is a DTI service managed by Pera
WEEE Recovery – The European Story
Infeed conveyor
Global Watch is a DTI service managed by Pera
WEEE Recovery – The European Story
Test Piece
Global Watch is a DTI service managed by Pera
WEEE Recovery – The European Story
Inside Plant
Global Watch is a DTI service managed by Pera
WEEE Recovery – The European Story
About Resource Efficiency Knowledge Transfer Network
• Formerly Mini-Waste Faraday Partnership
• Expanded resource remit with no sector limits
• Retail/commercial partners now acceptable
• Strategic alliances with NISP
• Collaborating within the bigger KTN programme
Global Watch is a DTI service managed by Pera
WEEE Recovery – The European Story
Other areas of Funding• Future Technology Programme calls
– Towards Zero Emissions (November 2006 TBC)
• Carbon Trust– Eco-design type projects
• Grant for R&D– Small developmental projects
• WRAP– Focussed material based projects
Global Watch is a DTI service managed by Pera
WEEE Recovery – The European Story
Thanks for Listening!
• Contact DetailsArnold Black
Operations DirectorResource Efficiency Knowledge Transfer Network
+44 (0)151 347 [email protected]
www.resource-efficiency.org