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The Best Practice on the Reduction of Plastic Waste. Development of New Recycling System for Used Plastics Kazuyuki Hirabayashi Showa Denko K.K. (Japan). About Showa Denko K.K. Showa Denko Group (at December 2005) Number of Group Companies 155 - PowerPoint PPT Presentation
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The Best Practice on the Reduction of Plastic Waste
Development of New Recycling System
for Used Plastics
Kazuyuki Hirabayashi
Showa Denko K.K. (Japan)
About Showa Denko K.K.
Showa Denko Group (at December 2005)• Number of Group Companies 155• Net Sales (Consolidated) 740.7 billions of yen• Operating Income (Consolidated) 52.1 billions of yen• Net Income (Consolidated) 7.6 billions of yen• Number of Employees (Consolidated) 11,166• Major products
Petrochemicals Sector (Olefins, Organic chemicals, Polyolefins, Plastic products)
Chemicals Sector (Chemicals, Gases and Specialty chemicals, Specialty resins)
Electronics Sector (Hard disks, Compound semiconductors, Rare earth magnetic alloys, Specialty gases for semiconductor processing, Electroceramic materials, Fine carbons and other electronic materials)
Inorganic Materials Sector (Ceramics and Carbons)Aluminum Sector (Aluminum metal, Sheets, Extruded products, Fabricated
products, building materials, engineering and others)
About Showa Denko K.K. Domestic Facilities
Oita Complex
Omachi Plant
Higashinagahara Plant
Chiba Plant
Kawasaki PlantYokohma Plant
Chichibu Plant
Tokuyama PlantOyama Plant
Hikone Plant
Sakai Plant
Kitakata PlantShiojiri Plant
About Showa Denko K.K.Global Subsidiaries
Overseas Production CompaniesP.T. Showa Esterindo IndonesiaTaiwan Showa Chemicals Manufacturing Co., LtdShowa Denko Carbon, Inc.Lianyungang Zaoling Abrasives Co.Ltd.SHOTIC Europa -Industria de Aluminio Lda.SHOTIC (Singapore) Pte. Ltd.Showa Aluminum Corporation of AmericaShowa Aluminium Czech s.r.o.Showa Aluminum (Thailand) Co., Ltd.P.T. Showa Aluminum IndonesiaShowa Aluminum Manufacturing Philippines CorporationBaotou Showa Rare Earth Hi-tech New Material Co., Ltd.Showa Denko (Dalian) Co., Ltd.Showa Denko HD (Malaysia) Sdn. Bhd.Showa Denko HD (Singapore) Sdn. Bhd.
Activity Guidelines regarding Responsible Care (Showa Denko, 1995)
(1) In the total life cycle of chemical substances, we should make our best effort to review and improve the business activities from the viewpoint of ensuring safety / health and protecting the environment.
(2) In the manufacturing activities, we should make best efforts to reduce the burden on the global environment not only by conventional approaches to environmental protection but also by promotion of raw material switching, energy conservation, wastes reduction and recycling, and reduction in the release of chemical substances.
(3) In new product development, new business development and establishment / increase / renewal of facilities, we should make our best effort to ensure safety / health and protect the environment.
(4) We should promote R & D and technology development which will contribute to the improvement of safety / health and protection of the environment. We should also promote marketing of alternative or new products.
(5) We should investigate the influences of the products and materials we handle on Safety / Health / Environment, and encourage our employees to have deep knowledge related to safe use and handling, and also provide our customers with such information.
(6) In overseas business activities, technology transfer and international trading of chemical products, we should give full consideration to ensuring safety / health and protecting the environment.
(7) We should comply with the international rules and domestic laws and regulations and make our best effort to cooperate with the relevant international organizations and foreign / domestic administrative agencies.
(8) We should positively participate in various activities related to environmental protection and make our best effort to communicate with society and communities for better understanding and trust.
Showa Denko Kawasaki Plant
- a HFC-125HFC 134 ・
Civil EngineeringMaterials
Derivativematerials
by products
DMOD
Hospitane C
Alanine
GLDA
PAS
EDTA
Glycine
Terephthalonitrile
isophthalonitrile
Acrylonitrile
SHOPRENE
ELASLEN
Vapor Grown CarbonFiber
Special clean gas
Clean S
Pollution preventivecylinders/devices
6FCー14・FC-11
Liquid Ammonia
Nitrous oxide
Ammonium thiosulfate
Liquefied sulfurous acid
Sodium bisulfite
Sodium hypochlorite
Hydrochloric aide
Epitaxial wafer
High purity gas for semi-conductor processing
High purity NH3 CH2 Hbr and BCL3 gas and clean cylinders for them
Surface treatment
Absorption decomposition and recycling
Column for high-speed liquidchromatography
Products flow in the KawasakiPlant
Keihin Industrial Complex
Independent power produce
common salt
Air
Air
Naphtha
Waste plastic
Town gas
Propylene
Special gases
D/L Cystine
HYD
BEH
BHD
APS
SHODEX
APM
Fluorine
Trichloroethylene/TetrachloroethyleneHydrogen Fluoride
Argon
Oxygen
Nitrogen
Caustic Soda
Chlorine
Hydrogen
Wire coating/PVC Rubber modifier
Agrichemical materials/Daconyl
Raw materials for agricultural chemicals
Fodder addotoves
Food additive/VB materials
Food additive
Chelating agent
Biodegradable chelating agent
Cataplasm
Food additives and Aspartame
Photographic chemicals
Photographic chemicals
Cosmetics and high grade permanent wave
Cosmetics and whitening agent
Cosmetics and whitening agent
Decomposed gas
Ammonia
Carbon dioxide
※
*
*
*
※ *
Chloroprene rubber
Photographic chemicals
* * * *
Chemical Recycling of Waste Plastic
for Ammonia Production
Chemical recycling(3% )
Liquefaction
Blast furnace feed
Coke oven feed
Recycling(55 % )
Material recycling(15% )
Thermal recycling(37% )
Incineration without power generation(18% )
Landfill(28% )
<Showa Denko Plant >
Perfect Chemical recycling
Recycling as chemical raw materials
( H2,CO,CO2,Cl,S, etc.)
Gasification
Waste Plastics
(10mil ton/year)
Disposal(45 % )
Waste Plastics recycling and disposal in Japan
計画地
Location
凡 例Pre-treatment
gasification
Kawasaki plant
N
Ammonia plant
195T/D
175T/D
(1) Scale
(2) Plant plot
(1)Pre-treatment plant Showa Denko K.K. kawasaki plant Area ; 6 , 590m2
(2)Gasification plant Showa Denko K.K. kawasaki plant Area ; 7 , 400m2
SHOWA DENKO PLANT
・ Hydrogen 346,000Nm3/D
・Waste plastics
・ Ammonia
Waste Plastics treatment process flow
Recovered
Metal
Law-temperature
gasifier
Scrubber
Neutralization
Slag treatment
De-sulfur
CO shift
GasCompressor
High-temperature
gasifier
Construction
materials
Caustic sodaraw materials
Sodium sulfite(NaHSO3)
Dry iceLiquefied CO2
Ammonia
Waste PlasticsStorage
Crusher
Separator
Feeder
Extruder
Metal
RPF ( Recycle Plastic Fuel )
H2 business
Pre-treatment plant Gasification plant
RPF
Metal
Slag
NaCl
S
CO2
H2
WastePlastics
Pre-treatmentplant
Gasification Scrubber CO shift De-sulfur
H2CO2NaClSlag
RecoveredMetal
Boiler
Dry iceLiquefied CO2
Metal
Construction
materials
Slag treatment
CausticSoda
GasCompressor
195T/D
175T/D430T/D
Sodium sulfite(NaHSO3)
0.65 T/D8.2 T/D5.8 T/D5.8 T/D
NaOH
Law-temperatureHigh-temperature
Component of Waste Plastics (Example)C H O N Cl S Metal Slag Total
74.2 10.7 6.3 0.4 2.5 0.1 2.9 2.9 100wt%144.7 20.9 12.3 0.8 4.9 0.2 5.6 5.6 195T/D
Process Flow to produce Ammonia Gas from Waste Plastic
AmmoniaH2 business
S
Japanese Containers and Packaging Recycling System
Flow of Containers and Packaging Recycling
Consumers
The Japan Containers and Packaging
Recycling Association
Showa Denko
Recycler
Specified business entities
Manufacturing orselling companies
Municipapalities(pressing and stock)
Selective discard
Selective
collection
Selling container or packaging
Payment of recycling feePayment of fees for recycling
Bidding
8% 92%
Payment for recycle fee
Transport
Plastic containers
Pre-Treatment process
Waste Plastic
Crasher
Extruder
RPF (Recycle Plastic Fuel for Gasification)
Gasification Plant
Gasification Plant
O2 + Steam
Metal
Law-temperature gasifier(fluidized-bed type)
High-temperature gasifier(swirling type)
Slag
ScrubberCO shiftDe-sulfur
H2
CO2
RPF
Caustic sodaraw material
Gasification plant outline
Silo
Perfect Chemical Recycling (zero-emission)
From Pre-treatment plant
O2 + Steam
Quench
Sodium sulfiteraw material
Thank You