DESIGN AND DEVELOPMENT OF A DEMONSTRATIVE PILOT PLANT FOR THE RECYCLING OF POLYVINYL BUTYRAL (PVB) GRANT AGREEMENT: LIFE09 ENV/ES/000501

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1 DESIGN AND DEVELOPMENT OF A DEMONSTRATIVE PILOT PLANT FOR THE RECYCLING OF POLYVINYL BUTYRAL (PVB) GRANT AGREEMENT: LIFE09 ENV/ES/000501

2 ANTECEDENTS AND PROBLEMS TO BE SOLVED PVB supposses almost 10% in weight of windshields, around 1 kg of PVB per windshield Nowadays only a small % of laminated glass is recycled. Mechanical methods are performed to separate glass from impure PVB. PVB impurified with glass dumping site or incineration After achieving successful results at labscale for the recycling and purification processes of PVB, and due to the novelty of the system, Lurederra get in 2009 a patent with title PROCEDURES FOR THE RECYCLING OF POLYVINYLBUTYRAL with expedient number WO/2009/ PROJECT: DESIGN AND DEVELOPMENT OF A DEMONSTRATIVE PILOT PLANT FOR THE RECYCLING OF POLIVINYL BUTYRAL (PVB)- (LIFE09 ENV/ES/000501)

3 PROJECT Project Objetives: Design, development and production of a demonstrative plant for the recycling of polyvinyl butyral (PVB) coming from laminated glass from automotive sector and construction, with a treatment capacity of 20 kg/hour. Provide an environmentally friendly solution for the current problem related to the recycling of PVB from laminated glass. Duration: September 2010 August 2013 (3 years) Project Partners: Coordinating Beneficiary : Centro Tecnológico Lurederra (España) Associated Beneficiaries: Bildu Lan S.Coop. (España), Glassdrive (España) Ingeniería Navarra Mecánica (España) 3 DR ZĄBER Sp. z o. o. (Polonia).

4 4 DEMONSTRATIVE PILOT PLANT

5 DEMONSTRATIVE PILOT PLANT MODULE I: EXTRACTION-SEPARATION Conventional Recycling EQUIPMENTS MODULE I Output Material: Glass Input Material: Wind Shields MODULE II 5 Output Material: PVB polluted with glass

6 DEMONSTRATIVE PILOT PLANT MODULE I: EXTRACTION-SEPARATION Input Line Grinding mills Vibrating tray Washing machine Storage silo 6

7 MODULE I: EXTRACTION-SEPARATION INPUT LINE: Waste impurities 7

8 MODULE I: EXTRACTION-SEPARATION GRINDING MILLS: Primary mill (slow) 8 Secondary mill (fast)

9 MODULE I: EXTRACTION-SEPARATION VIBRATING TRAY: 9

10 MÓDULO I: EXTRACCIÓN-SEPARACIÓN WASHING MACHINE: 10

11 MODULE I: EXTRACTION-SEPARATION STORAGE SILO: 11

12 DEMONSTRATIVE PILOT PLANT MODULE II: PURIFICATION Innovative own technology developed and patented by Lurederra EQUIPMENTS MODULE II MODULE III Input Material: PVB polluted with glass Output Material: PVB purified/recycled 12

13 DEMONSTRATIVE PILOT PLANT MODULE II: PURIFICATION 1. Reactor 1 Main process of separation of glass particles stuck to PVB. 2. Auxiliar Tank Recirculation of the solution to be cleaned through a filtering system. 3. Intermediate washing machine Cleaning of the PVB treated in Reactor Reactor 2 Second treatment for recovering PVB. 5. Final washing machine Cleaning of PVB treated in Reactor Centrifugal dryer Removal of humidity from purified PVB. 13

14 DEMONSTRATIVE PILOT PLANT MODULE II: PURIFICATION 14

15 DEMONSTRATIVE PILOT PLANT MODULE II: PURIFICATION 15

16 DEMONSTRATIVE PILOT PLANT MODULE III: PROCESSING Additives PVB flakes Recycled Recycled PVB Pellets 16

17 DEMONSTRATIVE PILOT PLANT MODULE III: PROCESSING Optimization of processing module parameters - Material humidity - Extrusion temperatures - Spindle speed - Feed speed - Pelletiser speed - Type of additives - Concentration of additives 17

18 DEMONSTRATIVE PILOT PLANT MODULE III: PROCESSING Analysis of Recycled PVB Properties PVB on the market Recycled PVB Density (g/cm 3 ) Hardness Tensile Strength (Kgf/cm 2 ) Elongation at break (%)

19 OBJECTIVES AND OBTAINED RESULTS Design, development and production of a demonstrative plant for the recycling of polyvinyl butyral (PVB) coming from laminated glass from automotive sector and construction, with a treatment capacity of 20 kg/hour Grinding and purification tests for PVB post-consumer coming from construction glass (300 Kg of PVB) and automotive sector (150 windshields) Obtaining of recycled PVB with the required technical properties to be used for the production of laminated glass. Contribution to the compliance of European Directive 2000/53/EC, establishing that the level of reused vehicles out of use must be 95% for the year

20 OBJECTIVES AND OBTAINED RESULTS Demonstration of the viability of the demonstrative pilot plant, using as raw material windshields coming from different sources: - ASSOCIATION OF VEHICLES REPAIR SHOPS OF NAVARRA - VOLKSWAGEN NAVARRA - GLASSDRIVE Through the relation with the Association of Vehicles Repair Shops of Navarra, contacts with political authorities of Navarra Government have been established to disseminate the recycling activity developed 20 - Jorge Miguel Indurain (General Director of Industry, Enterprise and Innovation Navarra Government) - Raúl Salanueva (Chief of the Waste Section Navarra Government)

21 DEMONSTRATIVE PILOT PLANT MODULE I Input Material: Wind Shields MODULE II Output Material Module I: PVB polluted with glass Output Material Module II: Recycled PVB 21

22 22 DEMONSTRATIVE PILOT PLANT