Kunststoffrecycling: Herausforderungen einer neuen Industrie Chris Slijkhuis Director Sourcing

Transcription

1 8. Schweizer Sonderabfalltag. Olten, 7. Juni 2011 Kunststoffrecycling: Herausforderungen einer neuen Industrie Chris Slijkhuis Director Sourcing

2 Agenda The environmental aspects of plastics recycling from WEEE The legislative framework of plastics recycling Brominated Flame Retardants RoHS background and RoHS Re-Cast Other Environmental considerations Eco-Effective use of recycled plastics Plastics recycling from E-Waste

3 E-Waste Plastics

4 The Raw Materials

5 The avg. composition of the Sourcing Material EU Rubber 3% PVC 1% POM 1% PC-ABS & PC 6% PE 1% ABS-FR 3% Other Plastics 17% PPO 2% HIPS-FR 2% Ferrous & N-Ferrous 1% Wires & Elect Parts 4% Fluff/Foam 1% Wood Other Non-Plastics 3% Fines 1% 1% PP 3% ABS 24% HIPS 27%

6 Post-consumer plastics were mostly discarded Metals from durable goods recycled at 90+% rates Plastics have high intrinsic value but extremely low recycle rate Recyle Rates 120% 100% 80% 60% 40% 20% Glass Steel Paper Aluminum High Value Plastics 0%

7 The Sustainable Model of Re-Producing plastics Procurement Growing supply Land-filled/Incinerated Processing Mechanical mining process Selling Green products Virgin-like quality possible Self-replenishing < 10% of energy Sustainable and growing supply <10% of water consumption More sustainable business Save about 1-3 tons CO2/ton PCR plastics

8 CO2 Impact of MBA Polymers Recycling SOURCE: Extracted from EMPA Paper presented at IERC Conference Salzburg Jan 2010

9 A closer look at CO2 Emissions CO2 Emissions per Capita in MT/yr Austria 8,6 8,3 USA 18,8 18,9 Germany 9,9 9,6 China 4,6 4,9 SOURCE: Wikipedia

10 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 talks of developing a recycling society REACH creates the framework as the new EU Chemical Regulation 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

11 PCR Recycled Products already exist

12 Stable Properties with MBA Polymers Resins 10,0 MFR (200 C/5kg) in [g/10min] 9,0 8,0 7,0 6,0 5,0 MFR Analysis Type MBA PS , Samples RoHS Compliant Plastics

13 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

14 Printer Cover and Components Printer lid is made out of 100% MBA ABS Product packaging advertises % recycled content

15 Eco-Printy Stamps Trodat is world market leader office stamps Famous for their eco printy range Trodat substituted virgin ABS for home-and-on-the-move stamps MBA Polymers is supplier of these PCR plastics

16 The European legislation framework Waste Legislation The EU Waste Framework Directive The EU Waste Shipment Regulation The EU E-Waste Directive (WEEE Directive) The EU End-Of-Life Vehicle Directive (ELV Directive) And many other directives regarding waste, waste treatment, hazardousness of waste etc.etc. Product Legislation The EU General Product Safety Directive (GPSD) REACH Regulation Registration, Evaluation, Authorisation and Restriction of Chemical substances. The new law entered into force on 1 June Many sector specific product legislation And also RoHS EU Directive on the Restriction of Hazardous Substances for Electric and Electronic appliances implemented 2004.

17 Brominated Flame Retardants Some BFR s are indeed 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 POP listed These are all classified in REACH (threshold 1000 ppm each) Studies showed that these thresholds are not surpassed in WEEE plastics Deca-PBDE Deca PBDE not POP nor PIC listed nor classified under REACH In use for a long period of time in electronics and is very efficient Technically difficult to be replaced in some plastics Controversial EU court decision (ref exemption RoHS) EU court case is not based on toxicity, but only on procedural issues Many Brominated-Flame Retardants can still be used

18 History on RoHS RoHS = EU Directive 2002/95/EC on the restriction of the use of certain hazardous substances in electrical and electronic equipment RoHS was voted for Feb 2003 and took effect July Substances restricted: o Lead o Cadmium o Mercury o Hexavalent chromium o Polybrominated biphenyls (PBBs) not in use anymore at that moment o Polybrominated diphenyl ethers/oxides (PBDEs) widely used The PBDE ban has had significant impacts both upstream plastic material selection and downstream plastic material recycling RoHS Re-Cast in line with time of WEEE Re-Cast Owned by EU Greens

19 Original Report Jill Evans proposed ban on halogens Extended Ban on a number of substances proposed Part A o Lead (0,1%) o Mercury (0,1%) o Cadmium (0,01%) o Hexavalent chromium (0,1%) o Polybrominated biphenyls (PBB) (0,1%) o Polybrominated diphenyl ethers(pbde) (0,1%) Part B o Brominated flame retardants (0,1 %) o Chlorinated flame retardants (0,1 %) o Polyvinylchloride (PVC) (0,1 %) o Chlorinated plasticisers (0,1 %) o Bis (2-ethylhexyl) phthalate (DEHP) (0,1%) o Butyl benzyl phthalate (BBP) (0,1 %) o Dibutylphthalate (DBP) (0,1 %)

20 Where are the halogens Brominated Flame Retardants and PVC are widely used in o o o o Plastics, housings, enclosures Cables Printed Circuit Boards, connectors, fans Components (high power/heat) Non-RoHS substitutes exist o Non-brominated flame retardants such as inorganics (Aluminum, Magnesium, Phosphorus)- based But these can create problems in recycling o o No separation techniques available (yet) Phosphorous based FR s can create phosphoric acid... Legislator has not thought of impact of alternatives?

21 What we asked from legislators is simple The Recycling industry needs a re-casted RoHS Directive that Stimulates the development of a recycling industry Is fully aligned with REACH Does not contain an Annex III Does not restrict or list any other substances over & above REACH Recognizes the concept of a legacy of substances In order to recycle eco-effectively:

22 Current status of RoHS re-cast debate Annex III (request for urgent review) has been dropped There is a consensus between EU Council and parliament since November 2010 Parliament vote is now planned for June after many delays Recycling industry has tried to find exemption for legacy substances RoHS is not fully aligned with REACH but it is close RoHS close to being aligned with REACH

23 Other environmental considerations If half of WEEE plastics were recycled from the EU: Saving of nearly 2 million tons of CO 2 Saving of some10 million kilowatt hours of energy Representing over 7 million barrels of oil as feedstock WEEE recyclers would become more economic New jobs, as plastics recycling is more labor intensive EU manufacturers would have more sustainable materials, New standard for flat screens Cenelec introduced new standard Flame retardants for Flat Screens Candle Accessible Area Let industry deal with legacy: New POP s risk to have low thresholds These might be a next thread for industry 150 mm 10 mm Choose right priorities for eco effectiveness

24 Eco-Effective use of plastics for electronics Reduce the total number of plastic types, but several types are fine Use recyclable plastics that do not loose to much on IZOD (see EPEAT criteria) Some 60 % of the plastics used for electronics are ABS, HIPS and PP There are many exotic plastics in too low quantities to be recovered Exotic materials can they be recovered? Can they make recovery of major plastics more difficult. Avoid using: Unusual plastics that may not easily separate from common plastics Cross-linked thermosets Additives that are currently regulated Avoid using glass filled polymers or structural foamed plastics. Avoid using laminates. incompatible adhesives paints or metal coatings. For fasteners, use a comparable plastic type or a magnetic metal Magnetic material can be easily separated with magnet. Use compatible paints if absolutely necessary to use paints. Encourage the use of recycled plastics when possible.

25 Eco-effective use of PCR plastics Recycled plastics already contain pigments Design using blacks or grays Avoid white or intense and bright colors. Recycled plastics may contain small defects due to residual contaminants Avoid light colored parts (where defects are seen more easily) Design with textured or matt surfaces show less imperfections. Consider the properties of recycled plastics when designing moulds Recycled plastics have additional heat histories, MBA Polymers recommends slightly lower processing temp s. avoid use of hot runners at temperatures at or above the recommended processing temperature of the plastic avoid parts with weldline requiring high melt temperatures recycled plastics aren t always able to meet same impact properties as virgin Avoid stricter interpretation for substances than regulatory requirements Recycled plastics contain legacy additives, MBA Polymers can make RoHS and REACH compliant plastics Beyond these limits the costs for recycling quickly increase Not all BrFR s are regulated see chapter on BFR s e.g. EPEAT allows up to 3000 ppm for Br when using PCR content Regulators, allow for working out legacy

26 Let us not loose our teeth...

27 Teamwork to Close the Loop for Plastics