Resource Efficiency

7/27/2019 Resource Efficiency

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Resource efficiency: Best Practices forthe recovery of plastics waste in Europe

Aafko Schanssema - September 2007


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Best Practices for the recovery ofplastics

waste in Europe

Facts, experience, recommendations and guidelines

by PlasticsEurope, 2006

Outline:

- What are plastics and why use them?

- Life Cycle thinking: Plastics and resource efficiency- Recovery options for plastics

- Eco-efficiency

- Promoting recovery/best practices

- Conclusions & lessons learnt- Sources of information


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What are plastics ?

Materials made in a chemical reactionconnecting building

blocks in a long chain (polymers); these materials can bemoulded into shapes or films.

Usually the building blocks mainly containing hydrogen,carbon and often oxygen - are derived from fossil fuels (oiland gas), the so called hydrocarbon feedstocks

Conventional fossil fuel based polymers represent more than99% of plastics produced

There is increasing interest in the use ofrenewable rawmaterials as hydrocarbon feedstockfor plastics, butconventional plastics are expected to remain predominant


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Why use plastics?

They are versatile, light weight, resource efficient

materials, enabling quality of life. They contribute to energy savings and associated climate

change effects across the whole life-cycle of numerous

products Lightweight

Insulating properties

Design flexibility

Can be recovered as material and/or

energy at end-of-life


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Important question: Are plastics sustainable? Largely made of non-renewable

resource;

Oil refining and cracking is energyintensive;

Plastics waste often ends-up inlandfill or is littered

Question: What is sustainable use ofoil?


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Answer Yes: Life Cycle Thinking


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Cradle: Does plastic influence oil and gas

availability?Heat, electricity

and energy

42%

Transport45%

Plastics4%

Chem/

petrochem

feedstock

4%

Other (non-

energy use)

5%

NO!


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Increased resource efficiency in

production and processing

Almost all feedstocks are produced in efficient,

integrated petrochemical complexes

Continued innovation has ensured dramaticimprovements in resource efficiency for plastics raw

materials (the PP example is typical for all plastics)

Processing technologies developed to use minimum of

material, with more than 90% of production scrap beingrecycled (most plants have less then 2-3 % waste)


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Example Polypropylene

Propylene

Comonomer

Auxi liair ies

100%, 1185 kg1964

Atmosphere

4,4% average (52 kg)

Waste water

3,6% (43 kg)

Landfill

7,6% (90 kg)

PP 1000 kg

Propylene

Comonomer

Auxi liair ies100%, 1023 kg

1988

Waste gas to incinerator

1,7% average (17 kg)

Work-up of waste and

landfill 0,6% (6 kg)

Polymerization

PropyleneComonomer

Auxi liair ies

100%, 1005 1015 kg1999

Waste gas to incinerator

0,5 - 1,5% range (5-15 kg)

Polymerization

PP 1000 kg

PP 1000 kg

Polymerization

Yield

84 %

97 %

99 %

99.7 %Today:


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Plastics contribution to resource efficiency

during the use phase What were the net effects in Western Europe if

plastics did not exist?

Total energy to produce, use and recover plastics inWestern Europe is 3.900 Mill GJ/a

Substitution of plastics where possible would needadditional energy of 1.020 Mill GJ/a (+ 26%!)

Additional GHG emissions if plastics were substituted: 97Mt/a or 56% more than in total life cycle of all plasticproducts today

Source: GUA, Vienna for PlasticsEurope, 2005)


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Results are equivalent to ...

1.020 Mill GJ/a additional energy needed for

substitution of plastics is equivalent to:

22,4 Mill tonnes of crude oil or 43 ultra large crude oil tankers(a row of 20 km of ultra large crude oil tankers)

primary fuel input of 10 nuclear power plants with 1.000 MW

heating and warm water for 40 Million people (half of Germany)

97 Mt/a additional CO2 emissions are equivalent to:

30% of the Kyoto reduction target for the EU-15in the period 2000 2012 (319 Mt/a)

CO2 emissions from 90% of private cars in Germany


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Plastics and End-of-Life management

Plastics are designed for all end-of-life options: re-

use recycling recovery Re-use: both one-way and re-usable articles are used

Recycling: good examples are industrial films and PET

bottles Recovery: other recovery options like feedstock recycling,

or energy recovery should be used formixed/contaminated plastics and complex materials


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The recovery options of plastic waste

ReuseMechanical

recycling

Feedstock

recycling

EnergyRecovery/

generation

Landfill

Waste

Consumer products

Plastic materials

Raw material derived from oil/natural gas


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Why recover plastics waste?

Plastics much too valuable to be thrown away

All plastics can be recovered

To save materials and energy and contribute to

resource efficiency


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Landfill is least preferred option

Large quantities of Greenhouse Gas emissions

(food, bio waste) Waste of material and energy

resources (metals, plastics )

Extending recovery is main factor

(recycling, composting, energy recovery)


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Mechanical recycling is THE preferred option,

when

Homogeneous, clean waste streams

Can replace virgin on close to 1:1 basis

Markets exist or can be developed, and whenspecifications are met


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Be aware of high recycling cost of grades

from mixed plastics waste

Price

reduction

(Quality)

Price recycled

gradePrice Virgin

MaterialTo be paidLoss

Dismantling

Preparation

Compounding

Collection,

Transport

0

0.500

1.000

1.500

Euro / t

Contami

nated

/Com

plex

mixt

ures


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Feedstock or chemical recycling

Conversion via a chemical reactioninto an hydrocarbon

or mixture of hydrocarbons Often in an existing large industrial installation

Advantages:

Suitable for mixed or laminated plastics

Contamination less a problem

Secured emission controlExamples: Blast furnaces, Gasification to syngas, non-

ferrous smelters


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Feedstock recycling limitations and future

Today:

One commercial large scale gasification to methanol plant

in operation in Germany Germany and Austria rely very much on the blast furnace

option

Future: Many promising technologies, the result of many years of

innovative R&D

Technology allows further innovation in plastics materialdevelopment


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Eco-efficiency of plastics packaging recycling

Study: TNO for APME (2001)

EU scenarios of landfill versus increasing recyclinglevels combined with energy recovery from MSWI

Diversion from landfill single most important factor.

Increasing recycling from 15 50% has nosignificant environmental benefit but costs increase3X


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Eco-efficiency of plastics packaging waste

recovery options

Customer-

related

benefit:

Recovery of

1 kg plasticspackaging

waste from

industry and

households

Economic costs (in relative terms)

Enviro

nmentalimpact(inrelativeterms)

0

0,5

100,51

landf ill (100%)

now (70 % landfi ll)

15 % mechan. recyc.85 % energy recovery

increase of recycling;

decrease of energy

recovery

maximum recyc. (50%)

no landfilling:

1

2

3

45

6

Source: APME/TNO 2000

high environmental impact

high costs

low environmental impact

low costs


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Recovery options for plastics from end-of-life

vehicles + E&E

mechanical

recycling

sorting

dismantling of

large plastic

parts

shredder residue

treatment

large industrialtechnologies:

feedstock recycling

energy recovery


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Eco-efficiency of ELV plastics recovery

Options for various plastics parts in vehicles

Study: ko Institute for APME (2003)

Mechanical recycling best for large, accessible mono-

material parts For most parts energy recovery / feedstock recyclingroutes are most eco-efficient

Landfill is worst option

Energy savings during service life moreimportant than end-of-life recovery


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Heating value of plastics

05

10

15

2025

30

35

40

45

50

Gas Oil Plastics Coal Wood

MJ/kg


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Energy recovery includes a range of options

Municipal Waste Incineration

Co-combustion of Solid Recovered Fuel

(e.g. CEN Standards) Cement industry,

Coal fired power plants,

Pulp/paper industry

Low emissions covered by WID All provide environmental advantages over

power from coal (saving primary fuels and CO2)


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Future directions energy recovery

Increasing importance of standardised recovered fuels as

energy source (a tradable non-waste?) Increased acceptance of MSWI as essential component

of waste management options

Gasification technologies together with biomass as

clean fuel input to conventional power stations (or as

stand alone units)


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Waste treatment options -Economics

MSWI gasificationuse of CO/H2

Mechanical recyclingof post-consumer

power plant,cement kiln

landfill

?

Industrial films

Contaminated/Complexmixtures

Gate fees/costs


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0

1.000

2.000

3.000

4.000

5.000

6.000

7.000

1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005

x1.000

tonnes

Feedstock recycling (raw mater ial) Mechanical recycling Energy recovery

EU 15 + N/CH

Change from EU15+2 to EU25+2

19%

32%

15%

7%

Plastics recovery in W. Europe (1991 2004)

17%

22%


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0 20 40 60 80 100

Greece

Cyprus

Malta

Lithuania

Estonia

PolandLatvia

Hungary

Ireland

Slovenia

United Kingdom

Czechia

Finland

Slovakia

Spain

Portugal

Italy

France

Norway

Netherlands

Luxemburg

Aust ria

Belgium

Germany

Denmark

Sweden

Switzerland

Recycling (1 - 33%) Energy Recovery (0 - 83%)

Recycling varies much less than energy

recovery across EU25+2 (data 2004)

Group of leading countries withrecovery rates above 80%

Source: PlasticsEurope


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Promoting general recovery -1

Learn from other countries experiences, but take accountof specific local conditions and infrastructure

Engage with all relevant stakeholders and collect properstatistics of wastes sent for recycling, energy recovery,landfill

Ensure existing landfill and incineration facilities meetrequirements of EU legislation

Promote diversion of high calorific waste including plasticswaste from landfill


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Aim for an integrated system of recovery options:recycling, composting, incineration/combustion, (landfill)

Size the solid waste incineration unit appropriately

Employ Combine Heat & Power generation where possiblein solid waste incineration plant

Actively promote the use of Solid Recovered Fuels (SRF),enhancing security of energy supply

Plan on the basis of proven technologies Plan on basis that waste will increase over time

Promoting general recovery -2


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Promoting plastics recovery (Packaging)

Encourage an integrated approach to municipal wastemanagement, creating a region sufficiently large to combine treatment and sorting

centres with an appropriately sized MSW Incineration plant. Where possible with combined heat & power (CHP), supplying local

infrastructure

Develop streams for recycling progressively

Focus recycling of plastics packaging on industrial filmpackaging and on bottles from household waste. The bottles should be integrated into the municipal waste collection

scheme together with collection of other packaging materials

Recognise importance of communication with public toincrease quality of waste streams

BP example implemented in Belgium


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Promoting plastics recovery (all plastics)

Landfill ban (since 2004) as supporting legislation

Separately collected films and bottles for mechanical recycling

Industry has increasing interest in alternative fuel

Mixed plastics separated from residual waste and shredderlight residue is utilised in cement works and blast furnace

(high calorific fraction) and pulp and fibre industry (mediumcalorific fraction)

Remaining residual waste (low calorific fraction) goes tomunicipal solid waste incineration plants with energy recovery

BP example implemented in Austria


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Promoting plastics recovery (ELV, WEEE)

Operations of dismantlers / shredders determine whetherplastics parts from cars/electronics are separated out forrecycling before shredding (e.g. bumpers)

Residual shredder light fraction used as solid recovered fuel,MSWI or low grade mechanical applications

For E&E waste possible recycling of large casings, but ifbrominated fire retardants present then should be incinerated

In general, limited possibilities for mechanical recycling ofplastic parts: driving force is ferrous and non-ferrous metal

recycling. Plastics can contribute as reducing agent

BP examples: The Netherlands, Sweden


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Promoting plastics recovery (B&C)

Determine in cooperation with converters the feasibility ofoptions for efficient recovery of building and demolition wasteplastics (e.g. PVC pipes, window frames)

Volumes currently low but will increase in the future

The PVC industry have made a Voluntary Commitment (Vinyl2010) to recycle certain quantities of PVC, and can assist indeveloping schemes.

Sometimes national legislation on demolition also promotesplastics recovery. Other separately collected plastics wastemay be suitable for conversion to SRF, but this not developed

BP examples: Denmark, The Netherlands


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Promoting plastics recovery (Agriculture)

Good source of homogeneous plastic PE films, althoughoften contaminated with soil

Substantial experience in several countries withvoluntary schemes (UK, NL, SWE, .)

Good performance with farmers delivering to collectionpoints

Potential critical issue are problems created by free-

riders

BP example: Spain


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Lessons learnt

No single country has all the best solutions for plasticswaste recovery Finding the right match between the realistic local conditions

and the best practices will increase efficiency

The strong EU legislative focus on mechanical recyclingtargets should be adapted where necessary:

to be consistent with the efficient use of resources and energyacross all phases of the life-cycle of materials, and to foster innovation

Diversion of plastics waste from landfill will increasingly

contribute to: savings of material and energy resources, in addition to the

savings made in the use phase of plastics products


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Conclusions

Minimize disposal of plastics waste to landfill Optimizesubstitution of primary resources

Use mix of all recovery options for eco-efficient wastemanagement appropriate balance between materialand energy recovery

Treatment and recovery of waste under definedenvironmental quality standards (e.g. IPPC)

Overall life cycle impact should be taken into account


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Sources of information

PlasticsEurope(www.plasticseurope.org)

Tecpol (www.tecpol.de)

European Plastics Converters (www.eupc.org)

European Plastics Recyclers (www.eupr.org)

Association of Cities & Regions for Recycling (www.acrr.org)

Confederation of European Waste-to-Energy Plants (www.cewep.com)

European Association of Plastics Recycling and Recovery (www.epro-plasticsrecycling.org)

Handbook for municipal waste prognosis and sustainabilityassessment of waste management systems (www.lca-iwm.net)


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Plastics

The material for the 21st century

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Resource Efficiency