From Supply Chain to Supply Cycle - HdK Dresden · 2 Impact of MBA Polymers Recycling SOURCE:...

Chris Slijkhuis

Director Sourcing

From Supply Chain to Supply Cycle

- Plastics meets its Re-Maker -

19. Seminar „Kunststoffrecycling in Sachsen“04. Mai 2010, 9.00 Uhr – 17.00 Uhr

Leibniz-Institut für Polymerforschung Dresden e.V., Hohe Straße 6, 01069 Dresden

Agenda

Why recycling of plastics from E-Waste?

Our supply chain becomes a supply cycle

The materials

MBA Polymers

Design implications for recycling

Brominated Flame Retardants – a technical debate

Questions & discussion

Plastics recycling from E-Waste

Post-consumer plastics were mostly discarded

0%

20%

40%

60%

80%

100%

120%

Glass Steel Paper Aluminum High Value Plastics

Recyle Rates

• Metals from durable goods recycled at 90+% rates• Plastics have high intrinsic value but extremely low recycle rate

•Self‐replenishing

•Sustainable and growing supply

•Growing supply

•Land‐filled/Incinerated

•< 10% of energy

•<10% of water 

•Save  1‐3 tons CO2/ton

•Mechanical ‘mining’process

•More sustainable business

•PCR plastics

•“Green” products

•Virgin‐like quality possible

The Sustainable Model of Re-Producing plastics

CO2 Impact of MBA Polymers Recycling

SOURCE: Extracted from EMPA Paper presented at IERC Conference Salzburg Jan 2010

Why recycling of tech plastics from/for electronics

Without plastics recycling EU recycling targets impossible• WEEE and ELV directives are clear in their targets• WEEE – 65 % for Small Domestic Appliances• ELV – 85 % as from 2015

Increasing pressure from the market and environment• NGO‘s like Greenpeace are putting industry under pressure to act• Consumers increasinlgly become aware and look for „green products“• EU Frame Work and other directives support this• REACH helps to create the framework as the new EU Chemical Regulat

Replacing virgin plastics with recycled makes sense• Recycled plastics were traditionally „down-cycled“• Best available technology now exists to recycle to high standards

Plastics recycling... huge environmental benefit

Agenda

Why recycling of plastics from E-Waste?

Our supply chain becomes a supply cycle

The materials

MBA Polymers

Design implications for recycling

Brominated Flame Retardants – a technical debate

Questions & discussion

Plastics recycling from E-Waste

Delivery

Integrated Supply Chain

Procurement

CustomerUse / Service

ManufacturingOperations

Take-back

Asset Recovery

Recycling

Waste Minimisation

Design For the Environment

Teaming up to get from Supply Chain to Supply Cycle……..

From Supply Chain to Supply Cycle

Build and Construct

Return toSuppliers

Deliver

Certified Reprocessing

Sort/Inspect

Customer Usage

RecyclingRemove

Disposal GoalZero

Return / Take Back

Certified Repair

Closed Loop Reprocessing

AlternativeUses

Materials forRecycling

Raw Materials

Global End-of-Life Material Return Growing

Millions of tons of durable goods are shredded every year to liberate and recover the ferrous and nonferrous metals

The E-Waste Supply Cycle focussing on plastics

Shredder Ferrous-Metals

Non-Ferrous-Metals

Smelters

Further Separation Plastic/non-Plastic

Non-FE Separations

Separate Non-Plastic Items

Size reduction, liberation and

separation

Mixed Plastic Rich E-Waste

De-Pollution

We work in the same Supply Cycle

E Waste Recyclers’ strengths

MBA Polymers strengths

Item collection and aggregation

Decon-tamination

Shredding and ferrous recovery

Non-ferrous concen-tration

Remove remaining metal-bearing

Remove remaining non-target materials

Plastics type sorting

Grade sor-ting

Com-poun-ding

Global sales, marketing & support

MBA Polymers

…………..and create Teamwork to Close the Loop for Plastics

Agenda

Why recycling of plastics from E-Waste?

Our supply chain becomes a supply cycle

The materials

MBA Polymers

Design implications for recycling

Brominated Flame Retardants – a technical debate

Questions & discussion

Plastics recycling from E-Waste

E-Waste Plastics

Tens of millions of tons of plastic-rich shredder residue that is mostly incinerated or land-filled

Plastics Rich Material Quantity Growing

The Raw Materials

The Raw Materials

The avg. composition of the Sourcing Material EU

HIPS27%

ABS24%

HIPS-FR2%

PPO2%

ABS-FR3%

PE1%

PC-ABS & PC6%

POM1%

PVC1%

Rubber3%

Other Plastics17%

Fluff/Foam

1% Wood

3%

PP3%

Fines1%

Ferrous & N-Ferrous1%

Wires & Elect Parts4%

Other Non-Plastics

1%

Agenda

Why recycling of plastics from E-Waste?

Our supply chain becomes a supply cycle

The materials

MBA Polymers

Design implications for recycling

Brominated Flame Retardants – a technical debate

Questions & discussion

Plastics recycling from E-Waste

The MBA Polymers facility in Austria

A joint-venture betweenMBA Polymers and

Müller-Gutenbrunn

LocationKematen an der Ybbs

Danube vincinity

Near A1 Motorway

Easy access Western/ Eastern Europe

Capacity40 000 Tonnes per annum

Goods-In, Analysis & Pre-processing

Sourcing & Goods-In

• Material Handling

• Assaying

• Material Analysis

Pre-Processing

• Taking out remaining metals

• Cleaning material of minerals (glass, stones, dust)

• Eliminating organic fractions such as wood and rubber

Size reduction to a standard particle size

Conveying plastic material into high tech seperations

High Tech Separations & Extrusion/Compounding

Cleaning plastics

• Closed circuit water treatment

High-Tech Seperations

• Obtaining ABS and PS

• In three grades

• Injection Moulding

• Extrusion

• General Purpose

High quality extrusion and compounding

• RoHS compliant products

Laboratory services 24/24 hours

Incoming Material Analysis

• Yield & contaminations

Process Control

• Numerous checkpoints

• In-time feed-back cycles

• Purity control final products

Final products Quality Control

• Each big bag is quality controlled

• MFI, Izod and Tensile Strength

Creating a Global Footprint

California Austria

Guangzhou

UK

Also in the largest production center for electronics

A brief video on MBA Polymers

Why a High-Tech Global Footprint.......

Electronics OEM’s are Global and they demand: • Global Supply of Plastics

• Virgin-like quality of the tech plastics they use

• Large, dependable and consistent volumes

• Consistent technical specifications

• A global answer to their Waste Plastics

• Reliable service levels

to become designed in........

Agenda

Why recycling of plastics from E-Waste?

Our supply chain becomes a supply cycle

The materials

MBA Polymers

Products from recycling

Brominated Flame Retardants – a technical debate

Questions & discussion

Plastics recycling from E-Waste

Products – ABS, PS, PP as pellets & compounds

Stable Properties with MBA Polymers’ Resins

MFR Analysis Type MBA PS 3130

4,0

5,0

6,0

7,0

8,0

9,0

10,0

0 20 40 60 80 100 120 140 160Samples

MFR

(200

°C/5

kg) i

n [g

/10m

in]

RoHS Compliant Plastics

High Tech Applications for End-Products

100% Post-Consumer Plastic!

Some examples of recent green products

Europe - Electrolux

“Made with 55% recycled plastic, the Ultra Silencer Green from Electrolux is the most energy‐efficient cleaner on the market. Its new, high‐efficiency motor reduces the Ultra Silencer’s energy consumption by 33% compared to a standard 2,000 watt vacuum cleaner. Because Ultra Silencer Green is made out of recycled materials, it is only available in black, as this color allows to achieve the best looking finish and quality when using recycled materials. To signify Eco friendliness of the Green vacuum cleaner, Electrolux designers added signature elements of green on the graphics and buttons.”

SOURCE: Electrolux Pressrelease

Agenda

Why recycling of plastics from E-Waste?

Our supply chain becomes a supply cycle

The materials

MBA Polymers

Products from recycling

Brominated Flame Retardants – a technical debate

Questions & discussion

Plastics recycling from E-Waste

Which legislations became involved (1)

Waste Framework Directive• “The classification of waste as hazardous waste should be based on the

Community legislation on chemicals, in particular concerning theclassification of preparations as hazardous, including concentration limit values used for that purpose”

RoHS Directive• With threshold values for PBB and all PBDE‘s (1000 ppm for each group)• Controversial ECJ Ruling that exemption deca-PBDE will be deleted• But at same time a stakeholder consultation for deca-PBDE was started• Is RoHS overtaken by REACH? How about RoHS 2? 1000 amenments!

REACH Regulation• PPBs: Hexabromobiphenyl is banned in all products, • In EEC other PPBs are not allowed in textiles• OctaBDE: 0,1% max. concentration in products (0,5% in waste)• PentaBDE: 0,1% max. concentration in products (0,25% in waste)

Which legislations became involved (2)

WEEE Directive• Annex II – BFR‘s need to be removed (a simplification)• Does in itself not imply that all BFR‘s are hazardous• TAC guideline Annex II

• Manual, mechanical or other separation of Br-FR‘s • To result in environmentally safe treatment• Not necessarily at first stage of treatment• To result in an identifyable stream at end of process

Waste Transport Directive• PBB is only group of BFR‘s nomitavely mentionen in WSR• No other BFR is being mentioned

Unlevel paying field in Europe

Brominated Flame Retardants The Br-flame retardants that are Substances of Concern

• PBB Polybrominated Biphenyl – POP and PIC listed and restricted• PBB is chemically a different family of substances than PBDE‘s • Penta-BDE is POP listed (can hardly be found in electronics)• Octa- BDE – not yet POP or PIC listed• But listed in REACH (threshold 1000 ppm each), but not in WSR• It is possible to create REACH complaint plastics

Deca-PBDE – a BFR with quite some discussion still• Deca PBDE – not POP nor PIC listed• Has been in use for a long period of time in electronics and not in REACH• Technically difficult to be replaced in some plastics• Controversial EU court decision (ref exemption RoHS)• EU Stakeholder Consultation (RoHS) has been started, outcome will take time• Can be found in electronic wastes (mainly B2B manual disassembly & CRT‘s)

All other Brominated Flame Retardants are of no concern

Separating BFR‘s (REACH and RoHS) is possible

Teamwork

Teamwork to Close the Loop for Plastics