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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