Flammability Properties of Virgin and Recycled Polycarbonate (PC) and Acrylonitrile–Butadiene–Styrene (ABS) Recovered from End-of-Life Electronics

Acrylonitrile–Butadiene–Styrene (ABS), Polycarbonate (PC) and their alloys are widely used in automotive industry, computer and equipment housings. With increasing disposal of end-of-life electronic equipment, there is also an increased demand for recycling of these materials so that they do not pose environmental challenge as solid waste. One of the recycling approaches is mechanical recycling of these thermoplastics where recycled plastic is melt blended with virgin materials to obtain a high quality product. Besides obtaining desirable mechanical properties, such blends should also conform to fire safety standards. In this work, a series of blends were prepared using PC and ABS recovered from discarded computers and virgin materials using a twin-screw extruder. Their flammability properties were evaluated using burner flammability tests and Ohio State University (OSU) release rate tests. It was found that the extinguishing time, burning extent and weight loss appears to progressively decrease with the addition of both virgin or recycled PC to virgin or recycled ABS. It was also seen that the addition of the 70% of PC, virgin or recycled, to ABS virgin or recycled, appears to significantly decrease heat release and smoke evolution. The results of this study indicate that recycled polycarbonate can be used as an additive for virgin or recycled ABS, as a means of giving flame resistance to ABS in high-value applications. This result is significant when related to the result obtained by a separate study indicating that up to 25% of recycled material can be used without degradation of mechanical properties in the presence of 15% short glass fiber reinforcement.     

Carbon accounting for Japanese petrochemicals

This paper discusses two bottom-up models for the estimation of carbon storage and CO₂ emissions related to the nonenergy use of fossil energy carriers. The models show how material flow accounting can be applied to policy making. The nonenergy use emission accounting tables model is a static model, while the chemical industry environmental strategy assessment program (CHEAP) model is a dynamic model of the flows of synthetic organic materials. Both models provide detailed and more accurate estimates of carbon storage in materials than the accounting method that is currently used in the framework of the Intergovernmental Panel on Climatic Change (IPCC) guidelines. The results for both models suggest that carbon storage in synthetic organic materials has been overestimated, and consequently CO₂ emissions have been underestimated. Japanese CO₂ emissions in 1996 were at least 1.9% higher than reported previously. The CHEAP model results indicate that the net carbon storage (storage − emissions in waste incineration) will decrease during the next few decades. This decrease is mainly driven by changing waste management practice. Received: December 8, 2000 / Accepted: August 15, 2001     

Recovery of PET from packaging plastics mixtures by wet shaking table

Recycling requires the separation of materials appearing in a mass of wastes of heterogeneous composition and characteristics, into single, almost pure, component/material flows. The separation of materials (e.g., some types of plastics) with similar physical properties (e.g., specific gravity) is often accomplished by human sorting. This is the case of the separation of packaging plastics in municipal solid wastes (MSW). The low cost of virgin plastics and low value of recycled plastics necessitate the utilization of low cost techniques and processes in the recycling of packaging plastics. An experimental study was conducted to evaluate the feasibility of production of a PET product, cleaned from PVC and PS, using a wet shaking table. The wet shaking table is an environmentally friendly process, widely used to separate minerals, which has low capital and operational costs. Some operational variables of the equipment, as well as different feed characteristics, were considered. The results show that the separation of these plastics is feasible although, similarly to the mineral field, in somewhat complex flow sheets.     

Evaluation of current material stock and future demolition waste for urban residential buildings in Jakarta and Bandung,Indonesia: embodied energy and CO<Subscript>2</Subscript> emission analysis

First, this paper evaluates the current building material stock and future demolition waste for urban residential buildings in the cities of Jakarta and Bandung using a material-flow analysis. The actual on-site building measurements were conducted in Jakarta (2012) and Bandung (2011), focusing particularly on unplanned houses, to obtain building material inventory data. A total of 297 houses were investigated in Jakarta, whereas 247 houses were measured in Bandung. Second, this paper analyses the embodied energy and CO₂ emissions of building materials through an input–output analysis. The results show that, overall, the total material input intensity for the houses is 2.67 ton/m² in Jakarta and 2.54 ton/m² in Bandung. Two scenarios with zero and maximum reuse/recycling rates were designed to predict future demolition waste and the embodied energy/CO₂ emissions of building materials in Jakarta. Closed- and open-loop material flows were applied. If the maximum reuse/recycling rates are applied to the closed- and open-loop material flows in Jakarta, then it would become possible to not only decrease the final disposal waste (from 123.9 to 2.1 million ton) but also reduce the corresponding embodied energy (from 247.8 to 192.1 PJ) and CO₂ emissions (from 24.3 to 19.2 million ton CO₂-eq) compared with the zero reuse/recycling scenario from 2012 to 2020.     

The potential environmental gains from recycling waste plastics: Simulation of transferring recycling and recovery technologies to Shenyang, China

With the increasing attention on developing a low-carbon economy, it is necessary to seek appropriate ways on reducing greenhouse gas (GHG) emissions through innovative municipal solid waste management (MSWM), such as urban symbiosis. However, quantitative assessments on the environmental benefits of urban symbiosis, especially in developing countries, are limited because only a limited number of planned synergistic activities have been successful and it is difficult to acquire detailed inventory data from private companies. This paper modifies and applies a two-step simulation system and used it to assess the potential environmental benefits, including the reduction of GHG emissions and saving of fossil fuels, by employing various Japanese plastics recycling/energy-recovery technologies in Shenyang, China. The results showed that among various recycling/energy-recovery technologies, the mechanical waste plastics recycling technology, which produces concrete formwork boards (NF boards), has the greatest potential in terms of reducing GHG emissions (1.66 kg CO₂e/kg plastics), whereas the technology for the production of refuse plastic fuel (RPF) has the greatest potential on saving fossil fuel consumption (0.77 kgce/kg-plastics). Additional benefits can be gained by applying combined technologies that cascade the utilization of waste plastics. Moreover, the development of clean energy in conjunction with the promotion of new waste plastics recycling programs could contribute to additional reductions in GHG emissions and fossil fuel consumption.     

Life cycle assessment of integrated recycling schemes for plastic containers and packaging with consideration of resin composition

Many life cycle assessment studies have evaluated and compared the environmental performance of various technologies for recycling plastic containers and packaging in Japan and other countries. However, no studies have evaluated the combination of recycling technologies in consideration of the resin composition in terms of the quantity of each recycled product so as to maximize their environmental potential. In this study, 27 scenarios of recycling schemes for household waste plastic containers and packaging are developed through integrating a conventional recycling scheme with additional recycling schemes. The conventional recycling scheme involves municipal curbside collection and either the material recycling or feedstock recycling of waste plastics. The additional recycling schemes are feedstock recycling in steel works of the residue from conventional material recycling processes, and corporate voluntary collection and independent material recycling of specific types of plastic trays. Life cycle assessment based on the modeling of recycling processes considering the resin composition in terms of the quantity of each recycled product is applied to evaluate and compare these scenarios from the viewpoints of fossil resource consumption and CO₂ emission. The results show that the environmental loads are reduced in all scenarios including the additional recycling schemes compared with the conventional recycling scheme. However, the independent plastic tray recycling scheme exhibits lower additional environmental savings when the residue recycling scheme is integrated with the conventional material recycling scheme. This is because both additional recycling schemes aim to utilize polystyrene and polyethylene terephthalate, which would otherwise be incinerated as residue from material recycling processes. The evaluation of the environmental loads of plastic recycling with consideration of the resin composition in terms of the quantity of each recycled product makes it possible to investigate recycling schemes that integrate different technologies to maximize their environmental potential.     

Recycling of iron foundry sand and glass waste as raw material for production of whiteware.

The purpose of this study was to evaluate the production feasibility of triaxial whiteware using sand from cast iron moulds as a raw material instead of silica, and recycled glass in place of feldspar. Formulations were prepared using sand, glass waste, and white-firing clay such that only 50% of the composition was virgin material (clay). The ceramic bodies were formed by pressing and fired at different temperatures (between 1100 and 1300 degrees C). Specimens were characterized in terms of green density prior to firing; and their flexural strength, linear shrinkage, and water absorption were measured after firing. The microstructure was determined by scanning electron microscopy. Possible environmental impacts of this recycling process were also evaluated, through solubility and leaching tests, according to Brazilian standards. Gaseous emissions during the firing process were also analysed. The results showed that it is possible to produce triaxial ceramics by using such alternative raw materials.     

Solid wastes integrated management in Rio de Janeiro: input-output analysis

This paper analyzes the socioeconomic aspects of solid waste management in Rio de Janeiro. An "input-output" methodology was used to examine how the secondary product resulting from recycling is re-introduced into the productive process. A comparative profile was developed from the state of recycling and the various other aspects of solid waste management, both from the perspective of its economic feasibility and from the social aspects involved. This was done analyzing the greenhouse gas emissions and the decreased energy consumption. The effects of re-introducing recycled raw materials into the matrix and the ensuing reduction of the demand for virgin raw materials was based on the input-output matrix for the State of Rio de Janeiro. This paper also analyzes the energy savings obtained from recycling and measures the avoided emissions of greenhouse gases.     

Improved method for the formation of recycled resins from depolymerized products of waste fiber-reinforced plastics: simple and effective purification of recovered monomers by washing with water

The synthesis of recycled plastics from recovered monomeric materials obtained from the depolymerization reaction of fiber-reinforced plastics (FRP) was examined. The depolymerization reaction of FRP in the presence of N,N-dimethylaminopyridine (DMAP) smoothly yielded the corresponding monomers, which mainly consisted of dimethyl phthalates. The polymerization reaction with this monomer failed to form the corresponding unsaturated polyesters due to contamination by N-methyl-4-pyridone, a decomposition product of DMAP. An efficient purification of the recovered monomer was achieved by washing with water, and the purified monomer successfully yielded the corresponding polymers. A hardness test revealed that the polymers were as hard as the polyester made from virgin materials. The present modification provides a practical method for the preparation of recycled plastics from depolymerized plastics.     

Determination of nitrous oxide, methane, and ammonia emissions from a swine waste composting process

The amounts of harmful gas emissions from the process of composting swine waste were determined using an experimental composting apparatus. Forced aeration (19.2–96.1 l/m³/min) was carried out continuously, and exhaust gases were collected and analyzed periodically. With weekly turning and the addition of a bulking agent in order to decrease the moisture content and increase air permeability, the temperature of most of the contents rose to 70°C and composting was complete within 3–5 weeks. NH₃, CH₄, and N₂O emissions were high in the early stage of composting. About 10%–25% of the nitrogen in the raw material was lost as NH₃ gas during composting. The emission rate of NH₃ mainly depended on the aeration rate, so that as the aeration rate rose, the level of NH₃ emissions increased. The CH₄ and N₂O emissions could be kept lower with adequate treatment at more than 40 l/m³/min aeration. N₂O may be mainly the result of the denitrification of NO _x -N in the additional matured compost used as a composting accelerator. Received: September 11, 1998 / Accepted: November 8, 1999     

Resurrection of the iron and phosphorus resource in steel-making slag

 This research focused on the treatment of steel-making slags to recycle and recover iron and phosphorus. The carbothermal reduction behavior of both synthesized and factory steel-making slag in microwave irradiation was investigated. The slags were mixed with graphite powder and heated to a temperature higher than 1873 K to precipitate a lump of Fe–C alloy with a diameter of 2–8 mm. The larger the carbon equivalent (C_eq, defined in the text), the higher the fractional reduction of iron and phosphorus. An increase in the SiO₂ content of slag led to a considerable improvement in the reduction for both iron and phosphorus because of the improvement in the fluidity of the slags and an increase in the activity coefficient of P₂O₅ in the slags. The extraction behavior of phosphorus from Fe–P–C_satd alloy was also investigated at 1473 K by carbonate flux treatment. For all the experiments with a processing time longer than 10 min, the phosphorus in the fluxes could be concentrated to more than 9% (w/w) showing that it could be used as a phosphorus resource. Compared with K₂CO₃ flux treatment, that using Na₂CO₃ was more effective for the extraction of phosphorus, and this was attributed to the lower evaporation of Na₂CO₃. Finally, a recycling scheme for steel-making slag is proposed. Received: March 16, 2001 / Accepted: November 12, 2001     

Risk assessment of an old landfill regarding the potential of gaseous emissions – A case study based on bioindication,FT-IR spectroscopy and thermal analysis

Risk assessment of two sections (I and II) of an old landfill (ALH) in Styria (Austria) in terms of reactivity of waste organic matter and the related potential of gaseous emissions was performed using conventional parameters and innovative tools to verify their effectiveness in practice. The ecological survey of the established vegetation at the landfill surface (plant sociological relevés) indicated no relevant emissions over a longer period of time. Statistical evaluation of conventional parameters reveals that dissolved organic carbon (DOC), respiration activity (RA₄), loss of ignition (LOI) and total inorganic carbon (TIC) mostly influence the variability of the gas generation sum (GS₂₁). According to Fourier Transform Infrared (FT-IR) spectral data and the results of the classification model the reactivity potential of the investigated sections is very low which is in accordance with the results of plant sociological relevés and biological tests. The interpretation of specific regions in the FT-IR spectra was changed and adapted to material characteristics. Contrary to mechanically–biologically treated (MBT) materials, where strong aliphatic methylene bands indicate reactivity, they are rather assigned to the CH vibrations of plastics in old landfill materials. This assumption was confirmed by thermal analysis and the characteristic heat flow profile of plastics containing landfill samples. Therefore organic carbon contents are relatively high compared to other stable landfills as shown by a prediction model for TOC contents based on heat flow profiles and partial least squares regression (PLS-R). The stability of the landfill samples, expressed by the relation of CO₂ release and enthalpies, was compared to unreactive landfills, archeological samples, earthlike materials and hardly degradable organic matter. Due to the material composition and the aging process the landfill samples are located between hardly degradable, but easily combustible materials and thermally resistant materials with acquired stability.     

Studies on the dechlorination and oil-production technology of waste plastics

 Recycle technology for waste plastics containing polyvinyl chloride (PVC) has been developed in the Hokkaido National Industrial Research Institute for the production of solid and liquid fuel, and has established a recycling process which includes a dechlorination process for PVC plastics, and a two-stage catalytic pyrolysis process for plastics using zeolite catalysts. The dechlorination equipment consists of a two-axis screw extruder with a heating element, which can remove chlorine up to 99.9 wt. % from PVC containing plastics as hydrogen chloride. The product had about 44 000 kJ/kg calorific value and was fed into the next oil production process, although it could also be used as a solid fuel. Natural and synthetic zeolite were used as catalysts for the two-stage catalytic process, which produced a light oil with a boiling point which was between those of kerosene and gasoline. The yield of this oil reached 82 wt. %. The chemical type was analyzed using liquid chromatography, and was found to have many aromatic compounds. These technologies make it possible to produce a nonpolluting, high-calorie solid fuel and a liquid fuel very efficiently. Received: July 19, 2000 / Accepted: September 21, 2000     

Contribution to closing the loop on waste materials: valorization of bottom ash from waste-to-energy plants under a life cycle approach

Incineration has undergone several technology improvements, reducing air emissions and increasing the efficiency of energy and material recovery; however, there is still a long way to go. To analyze the environmental impacts of waste incineration, this study assessed 15 waste fractions that compose municipal waste in Spain, which are grouped as non-inert materials (plastics, paper, cardboard and organic matter), unburned materials (glass and Al) and ferrous materials. Additionally, this paper evaluates the valorization of bottom ash (BA) to produce steel, aluminum and cement in these recycled/recoverable waste fractions. The results depend on the input waste composition and the heating value (HHV) and showed that ferrous and unburned materials had the worst environmental performance due to the null HHV. The valorization of BA in steel, Al and cement production significantly reduced the environmental impact and the consumption of resources. BA recycling for secondary steel and Al production would improve the environmental performance of the combustion of unburned materials and ferrous materials, whereas the use of BA in cement production diminished the consumption of NR for non-inert materials. This is of great interest for organic matter and PC, waste with a low energy production and high heavy metal and sulfur content.     

The general utilization of scrapped PC board

The traditional burning process is used to recover copper from scrapped PC board (printed circuit board) but it causes serious environmental problems. In this research a new process was developed which not only prevents pollution problems, but also maximizes the utility of all the materials on the waste board. First, the scrapped PC board was crushed and grounded, then placed in the NH₃/NH₅CO₃ solution with aeration in order to dissolve copper. After distilling the copper NH₃/NH₅CO₃ solution and then heating the distilled residue of copper carbonate, pure copper oxide was obtained with particle size of about 0.2 μm and the shape elliptical. The remaining solid residue after copper removal was then leached with 6 N hydrochloric acid to remove tin and lead. The last residue was used as a filler in PVC plastics. The PVC plastics with PC board powder as filling material was found to have the same tensile strength as unfilled plastics, but had higher elastic modulus, higher abrasion resistance, and was cheaper.     

Energy or compost from green waste? – A CO2 – Based assessment

Green waste is increasingly extracted from the material recycling chain and, as a result of the financial subsidy arising from the German renewable energy law for the generation of energy from renewable raw materials; it is fed into the energy recovery process in biomass power stations. A reduction in climate relevant gases is also linked to the material recovery of green waste – in particular when using composts gained from the process as a new raw material in different types of potting compost and plant culture media as a replacement for peat. Unlike energy recovery, material valorisation is not currently subsidised. Through the analysis of material and energy valorisation methods for green waste, with particular emphasis on primary resource consumption and CO₂-balance, it could be determined that the use of green waste for energy generation and its recovery for material and peat replacement purposes can be considered to be on a par. Based on energy recovery or material oriented scenarios, it can be further deduced that no method on its own will achieve the desired outcome and that a combination of recycling processes is more likely to lead to a significant decrease of greenhouse gas emissions.     

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.     

A new approach to metal- and polymer-recovery from metallized plastic waste using mechanical treatment and subcritical solvents

Galvanized or “chromium-plated” plastics are well known to the consumer from the automotive sector and sanitary area. Polymers such as acrylonitrile butadiene styrene (ABS) are typically coated with a layer system of chromium, nickel and copper to obtain the characteristic optical surface and resistance properties. Due to the complex manufacturing process and high quality requirements, the production of these plastic metal composites generates 10–30% of rejects. We, therefore, developed an innovative process cascade for the recovery of both components (metal and polymer) applying established technologies (mechanical pre-treatment, classification, melt filtration, CreaSolv^® Process) and were able to obtain ABS regranulate having excellent properties regarding the characteristic values for strength but slight compromises in impact characteristics. Blends with different amounts of virgin ABS, virgin PC and recycled ABS material as well as the pure cases were successfully re-metallized, all of them passing adhesion test, thermal shock resistance and CASS test. The high purity of the recovered materials led to increased redemption prices for metal and polymer by a factor of 6 and 2.5, respectively. Thus, the value added of metallized plastic waste is maximized, revealing a highly positive economic prognosis of a commercial implementation of the developed process—even at moderate scale.     

Evaluating household waste treatment systems with specific examination of collection and transportation processes

To form a sustainable recycling society, control industrial waste, and reutilize resources from waste to the greatest extent possible, we evaluated the waste collection system in terms of CO₂ emissions, the energy consumed, the amount recycled, the final disposal amount, and cost, particularly addressing the collection and transportation processes of domestic waste and using LCA evaluation for multiple policies. The results showed that enforcement of a combination of five optimal policies (as assessed in terms of their evaluation indexes), i.e., the use of clean energy gas-powered vehicles, the station method, collection of waste segregated into 11 categories, collective collection, and simple pay-as-you-go charges, might cultivate residents’ sense of responsibility in terms of controlling waste discharge.     

Emission inventory of deca-brominated diphenyl ether (DBDE) in Japan

Atmospheric emissions of deca-brominated diphenyl ether (DBDE) in Japan were estimated based on the material flow of DBDE products and their emission factors. In 2002, the demand for DBDE in Japan was 2200 ton/year and the stock level was about 60 000 ton. The DBDE flow into the waste stream was estimated to be about 6000 ton/year and the flow out through second-hand product exports was more than 700 ton/year. Home appliance recycling facilities dismantle and crush domestic wastes containing about 600 ton of DBDE annually. Material recycling of crushed plastics is not commonly practiced as yet. Emission factors from plastics processing (2 × 10⁻⁹–1 × 10⁻⁷), textile processing (9 × 10⁻⁷), home appliance recycling (8 × 10⁻⁹–5 × 10⁻⁶), and waste incineration (1 × 10⁻⁷–2 × 10⁻⁶) were estimated using field measurement data. The DBDE emission rate through house dust during the service life of final products (2 × 10⁻⁷–9 × 10⁻⁷ per year) was estimated using the DBDE concentration in dust and the amount of dust in used televisions. Emission factors from previous studies were also used. The estimated total DBDE emission was 170–1800 kg/year. These results suggest the necessity of characterizing emissions during the service life of products, which is essential information for formulating an appropriate e-waste recycling strategy.