The hydraulic separator Multidune: preliminary tests on fluid-dynamic features and plastic separation feasibility

Recycling of plastic materials is a rapidly developing discipline because of environmental awareness, the need to conserve materials and energy, and the growing demand to increase the production economy. The main problem in plastics recovery and recycling is related to the variety of plastic wastes, even if selective collection occurs. Therefore, plastic materials can be recycled either as mixtures or as single types, separating the different typologies by their physical (size, specific mass, etc.) and/or chemical properties. However, separation of plastics in single typologies by traditional processes and devices is difficult due to their typical low variability in properties. This paper presents a new research development for recycling industry: the Multidune separator. This is a device constructed from a sequence of parallel semi-cylindrical tubes of transparent plastic welded together in a plane. The lower half is shifted laterally and then fixed relative to the upper half. Flow is then induced in the lateral direction normal to the axis of the tubes, creating a main flow channel and two recirculation zones. This apparatus creates a differential transport of particles of low specific mass, near to 1g/cm(3), allowing their separation. The flow field in the Multidune separator is studied via Particle Tracking Velocimetry (PTV). Eulerian analysis of the data is performed to gather information about the fluid-dynamics features established by different hydraulic heads at the inlet of the Multidune. Preliminary tests on monomaterial samples have been performed, varying several operative parameters to determine the best set of values. Therefore, separation tests have been executed on composite samples, obtaining satisfactory results in terms of plastic separation feasibility.     

Sink–float density separation of post-consumer plastics for feedstock recycling

The paper focuses on current mechanical waste processing technologies and out-of-the-box processes linked to the processing of coal and mineral resources, to ensure high-quality feedstock recycling of polyolefin-rich post-consumer plastic fractions. Moreover, the study aims to provide the basis for the technical and economic feasibility of the chemical recycling route of this plastic fraction. When evaluating common mechanical processes, either dry or wet ones, sink–float separation in a cylindrical centrifugal force separator achieves the best results. It combines the advantages of a simple, robust apparatus of low complexity and high capacity with selective separation through the accelerated settling of particles in the centrifugal field. Furthermore, the disconnection of the separation medium feed from the solid input increases residence times. Based on the above findings, a pilot-scale plant was constructed which consists of a centrifugal force separator and a hydro jig for the pre-separation of heavy waste components. Several test campaigns were conducted to separate polyolefins from various waste fractions. Two-stage processing in the centrifugal force separator rendered almost 90 wt% of polyolefin content in the produced lightweight fraction and of polyolefin recovery. One-stage processing, on the other hand, resulted in reduced polyolefin content in the lightweight fraction.

     

Rapid discrimination of plastic packaging materials using MIR spectroscopy coupled with independent components analysis (ICA)

Plastic packaging wastes increased considerably in recent decades, raising a major and serious public concern on political, economical and environmental levels. Dealing with this kind of problems is generally done by landfilling and energy recovery. However, these two methods are becoming more and more expensive, hazardous to the public health and the environment. Therefore, recycling is gaining worldwide consideration as a solution to decrease the growing volume of plastic packaging wastes and simultaneously reduce the consumption of oil required to produce virgin resin. Nevertheless, a major shortage is encountered in recycling which is related to the sorting of plastic wastes. In this paper, a feasibility study was performed in order to test the potential of an innovative approach combining mid infrared (MIR) spectroscopy with independent components analysis (ICA), as a simple and fast approach which could achieve high separation rates. This approach (MIR-ICA) gave 100% discrimination rates in the separation of all studied plastics: polyethylene terephthalate (PET), polyethylene (PE), polypropylene (PP), polystyrene (PS) and polylactide (PLA). In addition, some more specific discriminations were obtained separating plastic materials belonging to the same polymer family e.g. high density polyethylene (HDPE) from low density polyethylene (LDPE). High discrimination rates were obtained despite the heterogeneity among samples especially differences in colors, thicknesses and surface textures. The reproducibility of the proposed approach was also tested using two spectrometers with considerable differences in their sensitivities. Discrimination rates were not affected proving that the developed approach could be extrapolated to different spectrometers. MIR combined with ICA is a promising tool for plastic waste separation that can help improve performance in this field; however further technological improvements and developments are required before it can be applied at an industrial level given that all tests presented here were performed under laboratory conditions.     

Addressing the operational problems in a composting and recycling plant

The Istanbul composting and recycling plant, constructed in 2001, is one of the few composting plants in Turkey. During test operations of the plant, it was reported that the weight of the oversize materials (OM) above a 80-mm sieve was about 40% of the total incoming waste. They mainly consist of plastic bags that were full of garbage, which resulted in operational problems in the plant. In this paper, the composition of OM was determined and evaluated, particularly to find the economic losses in the plant. It was determined that approximately 58% of the OM transferred to the landfill area due to operational failures and interruptions could be used at the plant with improved operational conditions. Otherwise, the plant would realize an annual economic loss of about 640,800 US$. Compost quality in the plant has been satisfactory, but source separated collection, at least the separation of the wet from the dry fraction, is needed to increase the amount of compost and recovered materials.     

Efficient chemical recycling of waste fiber-reinforced plastics: use of reduced amounts of dimethylaminopyridine and activated charcoal for the purification of recovered monomer

We have achieved major improvements in the efficient chemical recycling of waste fiber-reinforced plastics (FRPs). The effects of reduction in the amounts of dimethylaminopyridine (DMAP) used for depolymerization were examined. The treatment of waste FRP in the presence of 1 or 2 wt% DMAP resulted in the successful recovery of monomeric materials that could be employed in the polymerization process to produce recycled plastic. The separation of linker units from glass fiber, however, was unsuccessful. The purity of the recovered monomeric material, when treated with activated charcoal, was improved to about 70%. This resulted in effective decoloration of the recovered monomer. Finally, the purified material, after undergoing repolymerization, provided high-quality recycled plastic comparable to new plastics produced from new monomers.     

Influence of RFID tags on recyclability of plastic packaging

The use of Radio Frequency IDentification Technology (RFID) in the packaging sector is an important logistical improvement regarding the advantages offered by this technology in comparison with barcodes. Nevertheless, the presence of these devices in plastic packaging, and consequently in plastic waste, can cause several problems in the recycling plants due to the materials included in these devices.In this study, the mentioned recycling constraints have been experimentally identified in a pilot scale recycling study consisting in three recycling tests with an increasing presence of RFID tags. Differences in each test were evaluated. Furthermore, the quality of the recycled material of each test was studied through the injection and testing of tests probes.The results of the pilot scale recycling tests did not show a decrease in the quality of the recycled plastic due to the presence of RFID tags. Nevertheless, several operational problems during the recycling process were observed such as the obstruction of the screens, which lessened the process yield and created process interruptions, as well as the loss of extruded plastic during the process.These recycling constraints cannot be directly extrapolated to the industrial plants due to the different working scales. Nevertheless, technological solutions are proposed in order to avoid these recycling constraints if they appear.     

Boiling treatment of ABS and PS plastics for flotation separation

A new physical method, namely boiling treatment, was developed to aid flotation separation of acrylonitrile–butadiene–styrene (ABS) and polystyrene (PS) plastics. Boiling treatment was shown to be effective in producing a hydrophilic surface on ABS plastic. Fourier Transform Infrared analysis was conducted to investigate the mechanism of boiling treatment of ABS. Surface rearrangement of polymer may be responsible for surface change of boiling treated ABS, and the selective influence of boiling treatment on the floatability of boiling treated plastics may be attributed to the difference in the molecular mobility of polymer chains. The effects of flotation time, frother concentration and particle size on flotation behavior of simple plastic were investigated. Based on flotation behavior of simple plastic, flotation separation of boiling treatment ABS and PS with different particle sizes was achieved efficiently. The purity of ABS and PS was up to 99.78% and 95.80%, respectively; the recovery of ABS and PS was up to 95.81% and 99.82%, respectively. Boiling treatment promotes the industrial application of plastics flotation and facilitates plastic recycling.     

New characterisation method of electrical and electronic equipment wastes (WEEE)

Innovative separation and beneficiation techniques of various materials encountered in electrical and electronic equipment wastes (WEEE) is a major improvement for its recycling. Mechanical separation-oriented characterisation of WEEE was conducted in an attempt to evaluate the amenability of mechanical separation processes. Properties such as liberation degree of fractions (plastics, metals ferrous and non-ferrous), which are essential for mechanical separation, are analysed by means of a grain counting approach. Two different samples from different recycling industries were characterised in this work. The first sample is a heterogeneous material containing different types of plastics, metals (ferrous and non-ferrous), printed circuit board (PCB), rubber and wood. The second sample contains a mixture of mainly plastics. It is found for the first sample that all aluminium particles are free (100%) in all investigated size fractions. Between 92% and 95% of plastics are present as free particles; however, 67% in average of ferromagnetic particles are liberated. It can be observed that only 42% of ferromagnetic particles are free in the size fraction larger than 20 mm. Particle shapes were also quantified manually particle by particle. The results show that the particle shapes as a result of shredding, turn out to be heterogeneous, thereby complicating mechanical separation processes. In addition, the separability of various materials was ascertained by a sink–float analysis and eddy current separation. The second sample was separated by automatic sensor sorting in four different products: ABS, PC–ABS, PS and rest product. The fractions were characterised by using the methodology described in this paper. The results show that the grade and liberation degree of the plastic products ABS, PC–ABS and PS are close to 100%. Sink–float separation and infrared plastic identification equipment confirms the high plastic quality. On the basis of these findings, a global separation flow sheet is proposed to improve the plastic separation of WEEE.     

Electrostatic separators of particles: Application to plastic/metal, metal/metal and plastic/plastic mixtures

Electrostatic separation is a generic term given to a significant class of technologies of industrial waste processing, widely used for the sorting of granular mixtures due to electric forces acting on particles whose average size is approximately 5mm. The focus of this paper is on three electrostatic processes of separation used for processing of different types of mixtures: (i) role-type electrostatic separator, used to sort mixtures containing metal/plastic particles (copper/PVC for example); (ii) plate-type electrostatic separator, used to sort mixtures containing metal/metal particles (copper/lead for example) and (iii) free-fall electrostatic separator, used to sort mixtures of plastic/plastic particles (PVC/PE for example). Experiments carried out on industrial samples using laboratory electrostatic separators confirm the efficiency of these processes and show that the processes can improve the recovery and purity of products resulting from industrial wastes.     

Estimation of residual MSW heating value as a function of waste component recycling

Recycling of packaging wastes may be compatible with incineration within integrated waste management systems. To study this, a mathematical model is presented to calculate the fraction composition of residual municipal solid waste (MSW) only as a function of the MSW fraction composition at source and recycling fractions of the different waste materials. The application of the model to the Lisbon region yielded results showing that the residual waste fraction composition depends both on the packaging wastes fraction at source and on the ratio between that fraction and the fraction of the same material, packaging and non-packaging, at source. This behaviour determines the variation of the residual waste LHV. For 100% of paper packaging recycling, LHV reduces 4.2% whereas this reduction is of 14.4% for 100% of packaging plastics recycling. For 100% of food waste recovery, LHV increases 36.8% due to the moisture fraction reduction of the residual waste. Additionally the results evidence that the negative impact of recycling paper and plastic packaging on the LHV may be compensated by recycling food waste and glass and metal packaging. This makes packaging materials recycling and food waste recovery compatible strategies with incineration within integrated waste management systems.     

Effect of informal recycling on waste collection and transportation: the case of Chiclayo city in Peru

This paper analyses the evolution of national solid waste policy in Peru and the increasing relevance of informal recycling. Despite this rise in relevance, source separation and incorporation of informal recyclers within municipal plans is still slow, and collection of mixed waste is being considered. Waste collection and transportation costs represent the main share in municipal budgets and this research calculates cost reductions as a result of informal recycling and waste picking. The city of Chiclayo in Peru is presented as a case study. The paper finds that so far, waste picking has resulted in a reduction of two collection rounds but not a reduction in the number of vehicles collecting waste. Looking to the future, recovery of the remaining materials will not have an effect on collection rounds and number of vehicles. The research concludes that synergy between municipal systems and informal recycling can be maximized if new operational conditions are implemented. It introduces the concepts of “critical work shift,” which is the time of the day when the system requires maximum quantity of resources (i.e. vehicle-hours), and “sensitivity to variations in waste amounts,” and proposes strategies to promote recycling based on these new operational concepts.     

Physical separation,mechanical enrichment and recycling-oriented characterization of spent NiMH batteries

Nickel–metal hydride (NiMH) batteries contain high amount of industrial metals, especially iron, nickel, cobalt and rare earth elements. Although the battery waste is a considerable secondary source for metal and chemical industries, a recycling process requires a suitable pretreatment method before proceeding with recovery step to reclaim all valuable elements. In this study, AA- and AAA-type spent NiMH batteries were ground and then sieved for size measurement and classification. Chemical composition of the ground battery black mass and sorted six different size fractions were determined by an analytical technique. Crystal structures of the samples were analyzed by X-ray diffraction. Results show that after mechanical treatment, almost 87 wt% of the spent NiMH batteries are suitable for further recycling steps. Size classification by sieving enriched the iron content of the samples in the coarse fraction which is bigger than 0.25 mm. On the other hand, the amounts of nickel and rare earth elements increased by decreasing sample size, and concentrated in the finer fractions. Anode and cathode active materials that are hydrogen storage alloy and nickel hydroxide were mainly collected in finer size fraction of the battery black mass.     

Automobile Shredder Residues in Italy: characterization and valorization opportunities

At the moment Automobile Shredder Residue (ASR) is usually landfilled worldwide, but European draft Directive 2000/53/CE forces the development of alternative solutions, stating the 95%-wt recovery of an End of Life Vehicle (ELV) weight to be fulfilled by 2015. This work describes two industrial tests, each involving 250-300 t of ELVs, in which different pre-shredding operations were performed. The produced ASR materials underwent an extended characterization and some post-shredding processes, consisting of dimensional, magnetic, electrostatic and densimetric separation phases, were tested on laboratory scale, having as main purpose the enhancement of ASR recovery/recycling and the minimization of the landfilled fraction. The gathered results show that accurate depollution and dismantling operations are mandatory to obtain a high quality ASR material which may be recycled/recovered and partially landfilled according to the actual European Union regulations, with particular concern for Lower Heating Value (LHV), heavy metals content and Dissolved Organic Carbon (DOC) as critical parameters. Moreover post-shredding technical solutions foreseeing minimum economic and engineering efforts, therefore realizable in common European ELVs shredding plants, may lead to multi-purposed (material recovery and thermal valorization) opportunities for ASR reuse/recovery.     

Minimizing waste polymers in space

Waste polymers, essentially plastic packages, make up a significant fraction of solid wastes in a crewed space habitat. While logistic limitations preclude consideration of recovery/recycling technologies that have proven viable on Earth, the challenge in space is to provide materials and processes that minimize the volume of stored waste plastics and which allow recovery at the completion of a mission.     

Pyrolysis of municipal plastic wastes II: Influence of raw material composition under catalytic conditions

In this work, the results obtained in catalytic pyrolysis of three plastic waste streams which are the rejects of an industrial packing wastes sorting plant are presented. The samples have been pyrolysed in a 3.5 dm(3) reactor under semi-batch conditions at 440 °C for 30 min in nitrogen atmosphere. Commercial ZSM-5 zeolite has been used as catalyst in liquid phase contact. In every case, high HHV gases and liquids which can be useful as fuels or source of chemicals are obtained. A solid fraction composed of the inorganic material contained in the raw materials and some char formed in the pyrolysis process is also obtained. The zeolite has shown to be very effective to produce liquids with great aromatics content and C3-C4 fraction rich gases, even though the raw material was mainly composed of polyolefins. The characteristics of the pyrolysis products as well as the effect of the catalyst vary depending on the composition of the raw material. When paper rich samples are pyrolysed, ZSM-5 zeolite increases water production and reduces CO and CO(2) generation. If stepwise pyrolysis is applied to such sample, the aqueous liquid phase can be separated from the organic liquid fraction in a first low temperature step.     

Recovery of polypropylene and polyethylene from packaging plastic wastes without contamination of chlorinated plastic films by the combination process of wet gravity separation and ozonation

Wet gravity separation technique has been regularly practiced to separate the polypropylene (PP) and polyethylene (PE) (light plastic films) from chlorinated plastic films (CP films) (heavy plastic films). The CP films including poly vinyl chloride (PVC) and poly vinylidene chloride (PVDC) would float in water even though its density is more than 1.0 g/cm³. This is because films are twisted in which air is sometimes entrapped inside the twisted CP films in real existing recycling plant. The present research improves the current process in separating the PP and PE from plastic packaging waste (PPW), by reducing entrapped air and by increasing the hydrophilicity of the CP films surface with ozonation. The present research also measures the hydrophilicity of the CP films.In ozonation process mixing of artificial films up to 10 min reduces the contact angle from 78° to 62°, and also increases the hydrophilicity of CP films. The previous studies also performed show that the artificial PVDC films easily settle down by the same. The effect of ozonation after the wet gravity separation on light PPW films obtained from an actual PPW recycling plant was also evaluated. Although actual light PPW films contained 1.3% of CP films however in present case all the CP films were removed from the PPW films as a settled fraction in the combination process of ozonation and wet gravity separation. The combination process of ozonation and wet gravity separation is the more beneficial process in recovering of high purity PP and PE films from the PPW films.     

废弃印刷线路板中材料的资源化回收利用技术

废弃印刷线路板（WPCBs）既有污染环境的一面,又有可资源化回收利用的一面.通过机械物理法、热解、超临界流体氧化和离子液体溶解等方法对其进行分离和回收金属和非金属材料.初步分选的金属需要进一步提纯以实现高附加值.而非金属材料可以用热解法、微波处理、超临界流体技术、等离子技术等技术进行产气和能量回收,也可以通过制备建筑材料或填料和其它功能村料进行物料回收.总之,对WPCBs进行适当地处理不但可以减轻环境压力,还可以变废为宝,实现资源再生利用.     

Enhancement of the recycling of waste Ni-Cd and Ni-MH batteries by mechanical treatment

A serious environmental problem was presented by waste batteries resulting from lack of relevant regulations and effective recycling technologies in China. The present work considered the enhancement of waste Ni-Cd and Ni-MH batteries recycling by mechanical treatment. In the process of characterization, two types of waste batteries (Ni-Cd and Ni-MH batteries) were selected and their components were characterized in relation to their elemental chemical compositions. In the process of mechanical separation and recycling, waste Ni-Cd and Ni-MH batteries were processed by a recycling technology without a negative impact on the environment. The technology contained mechanical crushing, size classification, gravity separation, and magnetic separation. The results obtained demonstrated that: (1) Mechanical crushing was an effective process to strip the metallic parts from separators and pastes. High liberation efficiency of the metallic parts from separators and pastes was attained in the crushing process until the fractions reached particle sizes smaller than 2 mm. (2) The classified materials mainly consisted of the fractions with the size of particles between 0.5 and 2 mm after size classification. (3) The metallic concentrates of the samples were improved from around 75% to 90% by gravity separation. More than 90% of the metallic materials were separated into heavy fractions when the particle sizes were larger than 0.5 mm. (4) The size of particles between 0.5 and 2 mm and the rotational speed of the separator between 30 and 60 rpm were suitable for magnetic separation during industrial application, with the recycling efficiency exceeding 95%.     

Automotive shredder residue (ASR) characterization for a valuable management

Car fluff is the waste produced after end-of-life-vehicles (ELVs) shredding and metal recovery. It is made of plastics, rubber, glass, textiles and residual metals and it accounts for almost one-third of a vehicle mass. Due to the approaching of Directive 2000/53/EC recycling targets, 85% recycling rate and 95% recovery rate in 2015, the implementation of automotive shredder residue (ASR) sorting and recycling technologies appears strategic. The present work deals with the characterization of the shredder residue coming from an industrial plant, representative of the Italian situation, as for annual fluxes and technologies involved. The aim of this study is to characterize ASR in order to study and develop a cost effective and environmentally sustainable recycling system. Results show that almost half of the residue is made of fines and the remaining part is mainly composed of polymers. Fine fraction is the most contaminated by mineral oils and heavy metals. This fraction produces also up to 40% ashes and its LHV is lower than the plastic-rich one. Foam rubber represents around half of the polymers share in car fluff. Moreover, some chemical–physical parameters exceed the limits of some parameters fixed by law to be considered refuse derived fuel (RDF). As a consequence, ASR needs to be pre-treated in order to follow the energy recovery route.     

Enrichment of the metallic components from waste printed circuit boards by a mechanical separation process using a stamp mill

Printed circuit boards incorporated in most electrical and electronic equipment contain valuable metals such as Cu, Ni, Au, Ag, Pd, Fe, Sn, and Pb. In order to employ a hydrometallurgical route for the recycling of valuable metals from printed circuit boards, a mechanical pre-treatment step is needed. In this study, the metallic components from waste printed circuit boards have been enriched using a mechanical separation process. Waste printed circuit boards shredded to <10mm were milled using a stamp mill to liberate the various metallic components, and then the milled printed circuit boards were classified into fractions of <0.6, 0.6-1.2, 1.2-2.5, 2.5-5.0, and >5.0mm. The fractions of milled printed circuit boards of size <5.0mm were separated into a light fraction of mostly non-metallic components and a heavy fraction of the metallic components by gravity separation using a zig-zag classifier. The >5.0mm fraction and the heavy fraction were subjected to two-step magnetic separation. Through the first magnetic separation at 700 Gauss, 83% of the nickel and iron, based on the whole printed circuit boards, was recovered in the magnetic fraction, and 92% of the copper was recovered in the non-magnetic fraction. The cumulative recovery of nickel-iron concentrate was increased by a second magnetic separation at 3000 Gauss, but the grade of the concentrate decreased remarkably from 76% to 56%. The cumulative recovery of copper concentrate decreased, but the grade increased slightly from 71.6% to 75.4%. This study has demonstrated the feasibility of the mechanical separation process consisting of milling/size classification/gravity separation/two-step magnetic separation for enriching metallic components such as Cu, Ni, Al, and Fe from waste printed circuit boards.