Optimization of the high-pressure, near-critical liquid-based microsortation of recyclable post-consumer plastics

High-pressure, near-critical liquids were used as float-sink separation media for the microsortation of polyolefin mixtures and PET/PVC mixtures. Near-critical carbon dioxide was used for the refinement of the polyolefins, and sulfur hexafluoride was used to separate post-consumer PVC from PET. Preliminary experiments indicated that there was no overlap in the density ranges of post-consumer HDPE, LDPE and PP containers. There was no overlap in the PET and PVC densities, with the exception of a single PVC packaging material with a density in the PET range. These initial results indicated that a float-sink separation was a viable means of microsortation. Separations of 91% LDPE (1/8′ beads)/9% PP (1/8′ chopped strands) resin mixtures and mixed post-consumer polyolefin flakes were then conducted in a laboratory-scale, 1-I batch apparatus. This apparatus not only permitted the observation of the separation, but also enabled the separated fractions to be removed from the high-pressure environment. The results indicated that LDPE purity of greater than 98.9% was obtained in 3 min or less if (a) the fluid density was 0.018 g/cm³ greater than the PP density and only 0.002 g/cm³ less than the LDPE density, thereby providing the greatest buoyancy force for the removal of the PP, (b) the fluid was recirculated upward through the bed of mixed plastics, facilitating the upward movement of the PP, and (c) the loading was kept at levels below 40% by volume. HDPE purity of 99% was also attained with clean, dry, post-consumer mixed plastic flakes. The loadings for these separations were very low, however, due to the difficulty in agitating the mixed bed of plastics using fluid recirculation. An economic analysis of these microsortation processes indicated that the value of the sorted plastics relative to the mixed feed must increase by approx. $0.08/lb for the CO₂-based separation and approx. $0.27/lb for the SF₆-based separation to justify the implementation of these high-pressure processes.     

Sound management of brominated flame retarded (BFR) plastics from electronic wastes: State of the art and options in Nigeria

Management of flame retarded plastics from waste electrical and electronic equipment (WEEE) has been posing a major challenge to waste management experts because of the potential environmental contamination issues especially the formation of polybrominated-dioxins and -furans (PBDD/F) during processing. In Nigeria, large quantities of electronic waste (e-waste) are currently being managed—a significant quantity of which is imported illegally as secondhand electronics. As much as 75% of these illegal imports are never reused but are rather discarded. These waste electronic devices are mostly older equipment that contains brominated flame retardants (BFRs) such as penta-brominated diphenyl ethers (PBDEs), and polybrominated biphenyls (PBBs) which are presently banned in Europe under the EU WEEE and RoHS Directives. Risk assessment studies found both to be persistent, bio-accumulative and toxic. The present management practices for waste plastics from WEEE in Nigeria, such as open burning and disposal at open dumps, creates potential for serious environmental pollution. This paper reviews the options in the environmentally sound management of waste plastics from electronic wastes. Options available include mechanical recycling, reprocessing into chemicals (chemical feedstock recycling) and energy recovery. The Creasolv^® and Centrevap^® processes, which are the outcome of the extensive research at achieving sound management of waste plastics from WEEE in Europe, are also reviewed. These are solvent-based methods of removing BFRs and they presently offer the best commercial and environmental option in the sound management of waste BFR-containing plastics. Because these developments have not been commercialized, WEEE and WEEE plastics are still being exported to developing countries. The industrial application of these processes and the development of eco-friendlier alternative flame retardants will help assure sound management of WEEE plastics.     

Electronic waste recycling: A review of U.S. infrastructure and technology options

The useful life of consumer electronic devices is relatively short, and decreasing as a result of rapid changes in equipment features and capabilities. This creates a large waste stream of obsolete electronic equipment, electronic waste (e-waste).Even though there are conventional disposal methods for e-waste, these methods have disadvantages from both the economic and environmental viewpoints. As a result, new e-waste management options need to be considered, for example, recycling. But electronic recycling has a short history, so there is not yet a solid infrastructure in place.In this paper, the first half describes trends in the amount of e-waste, existing recycling programs, and collection methods. The second half describes various methods available to recover materials from e-waste. In particular, various recycling technologies for the glass, plastics, and metals found in e-waste are discussed. For glass, glass-to-glass recycling and glass-to-lead recycling technologies are presented. For plastics, chemical (feedstock) recycling, mechanical recycling, and thermal recycling methods are analyzed. Recovery processes for copper, lead, and precious metals such as silver, gold, platinum, and palladium are reviewed. These processes are described and compared on the basis of available technologies, resources, and material input–output systems.     

Mechanical separation-oriented characterization of electronic scrap

The ever-increasing amount of electronic scrap and the steadily-decreasing contents of the precious metals used in electronics, as well as the ever-growing environmental awareness, challenges such conventional precious-metal-oriented recycling techniques as pyrometallurgy. Separation and beneficiation of various materials encountered in electronic scrap might provide a correct solution ahead. In this context, mechanical separation-oriented characterization of electronic scrap was conducted in an attempt to evaluate the amenability of mechanical separation processes. Liberation degrees of various metals from the non-metals, which are crucial for mechanical separation, were analyzed by means of a grain counting approach. It is found that the metallic particles below 2 mm achieve almost complete liberation. Particle shapes were also quantified through an image processing system. The results obtained show that the shapes of the particles, as a result of shredding, turn out to be heterogeneous, thereby complicating mechanical separation processes. In addition, separability of various materials was ascertained by a sink–float analysis. It has been shown that density-based separation techniques shall be viable in separating metals from plastics, light plastics (ABS, PS and PVC, etc.) from glass fiber reinforced resins and aluminum from heavy metals. Specifically, a high quality copper concentrate can be expected by density-based separation techniques. Moreover, FT-IR spectra of plastics pieces from the light fractions after the sink–float testing show that PC scrap primarily contains ABS, PS and PVC plastics with the density range of +1.0–1.5 g/cm³, whereas PCB scrap mainly contains glass fiber reinforced epoxy resins plastics with the density range of +1.5–2.0 g/cm³.     

Selective flotation separation of plastics by chemical conditioning with methyl cellulose

The floatability of seven plastics (POM, PVC, PET, PMMA, PC, PS and ABS) in the presence of methyl cellulose (MC) and separation of plastics mixtures were investigated in this paper. It was found that the seven plastics can be separated into three groups by using the wetting agent MC. Group one includes POM and PVC. They are depressed at very low MC concentrations. Group two, including PET, PMMA and PC, has an intermediate floatability. Group three (ABS and PS) has a high floatability. They are almost not depressed within the given MC concentration range. In order to understand the mechanism of selective flotation of plastics and the chemical conditioning process, surface chemical factors, such as wettability of plastics and surface tension of flotation medium, and gravity factors, such as particle density and shape, were studied. It was found that the depressing effect of MC on plastics is ascribed mainly to its adsorption on the plastics surfaces. The MC molecules absorbed on plastics expose some of their polar groups oriented towards the aqueous phase, hence making the plastics surfaces hydrophilic. In addition, flotation selectivity for the plastics is dominated not only by wettability of plastics, but also by particle size, density and shape.     

Closed loop recycling of plastics containing Flame Retardants

Annually 2.7 million tonnes of plastics containing Flame Retardants (FRs) are globally discarded in Waste Electrical and Electronic Equipment (WEEE). Little is known on the feasibility of closing material loops for FR plastics. Therefore, series of experiments were set up to analyze the feasibility of separating plastics containing FRs from one specific product category, namely End-of-Life (EoL) Liquid Crystal Display (LCD) TVs. The characterization of the housings of this waste stream indicated a concentration of 18 wt% Bromine based (Br) FRs and 31 wt% Phosphor based (P) FRs, the remainder not containing FRs. With practical tests it was demonstrated that, after disassembly and plastic identification, the co-polymer poly-carbonate (PC)/acrylonitrile-butadiene-styrene (ABS) containing PFR can be recycled in a closed loop system. Based on the determined plastic density distributions and separation efficiencies of optical sorters, a purity of 82% was calculated for PFR PC/ABS separated from EoL LCD TVs after size-reduction (shredding). Performed miscibility tests indicated that for this fraction at least a factor 10 dilution with virgin material is required. In addition, higher waste volumes are required for a size-reduction based treatment to become economically viable and technical challenges still need to be faced, whereas closed loop recycling of PFR PC/ABS from the current waste stream of EoL LCD TVs of different brands in a disassembly based treatment is found to be technically feasible and economically viable under European boundary conditions.     

Intermediate storage of carbon dioxide in geological formations: A technical perspective

Enhanced oil recovery (EOR) through CO₂ flooding has been practiced on a commercial basis for the last 35 years and continues today at several sites, currently injecting in total over 30 million tons of CO₂ annually. This practice is currently exclusively for economic gain, but can potentially contribute to the reduction of emissions of greenhouse gases provided it is implemented on a large scale. Optimal operations in distributing CO₂ to CO₂-EOR or enhanced gas recovery (EGR) projects (referred to here collectively as CO₂-EHR) on a large scale and long time span imply that intermediate storage of CO₂ in geological formations may be a key component. Intermediate storage is defined as the storage of CO₂ in geological media for a limited time span such that the CO₂ can be sufficiently reproduced for later use in CO₂-EHR. This paper investigates the technical aspects, key individual parameters and possibilities of intermediate storage of CO₂ in geological formations aiming at large scale implementation of carbon dioxide capture and storage (CCS) for deep emission reduction. The main parameters are thus the depth of injection and density, CO₂ flow and transport processes, storage mechanisms, reservoir heterogeneity, the presence of impurities, the type of the reservoirs and the duration of intermediate storage. Structural traps with no flow of formation water combined with proper injection planning such as gas-phase injection favour intermediate storage in deep saline aquifers. In depleted oil and gas fields, high permeability, homogeneous reservoirs with structural traps (e.g. anticlinal structures) are good candidates for intermediate CO₂ storage. Intuitively, depleted natural gas reservoirs can be potential candidates for intermediate storage of carbon dioxide due to similarity in storage characteristics.     

Integrating waste,manufacturing and industrial symbiosis: an analysis of recycling,remanufacturing and waste treatment firms in Texas

The continually increasing volume of the waste stream has led to numerous calls for strategies to close the loop on material use through industrial symbiosis strategies which direct used material and products (wastes) back to production processes. By use of a survey of recycling, remanufacturing and waste treatment firms in Texas, this paper asks if these firms can operate as a bridge between production and consumption/waste to efficiently increase the flow of used materials and products back to production processes at the local level. The results suggest that while most materials and used products are collected locally, only some can be re(consumed) locally. Moreover, the firms face negative perceptions about their activities from industry and the public at large that likely slow both the rate of entry of new firms into these markets and the expansion possibilities of existing firms. In addition, the types of conventions that characterize the interactions of more successful firms are not well developed in this sector(s). It is unlikely that recycling, remanufacturing and waste treatment firms can become central players in the production, consumption and waste cycle loop until society develops production design, marketing and consumption philosophies that include recycling and remanufacturing at a fundamental level.     

Assessing the potential of yield improvements, through process scrap reduction, for energy and CO2 abatement in the steel and aluminium sectors

Targets to cut 2050 CO₂ emissions in the steel and aluminium sectors by 50%, whilst demand is expected to double, cannot be met by energy efficiency measures alone, so options that reduce total demand for liquid metal production must also be considered. Such reductions could occur through reduced demand for final goods (for instance by life extension), reduced demand for material use in each product (for instance by lightweight design) or reduced demand for material to make existing products. The last option, improving the yield of manufacturing processes from liquid metal to final product, is attractive in being invisible to the final customer, but has had little attention to date. Accordingly this paper aims to provide an estimate of the potential to make existing products with less liquid metal production.Yield ratios have been measured for five case study products, through a series of detailed factory visits, along each supply chain. The results of these studies, presented on graphs of cumulative energy against yield, demonstrate how the embodied energy in final products may be up to 15 times greater than the energy required to make liquid metal, due to yield losses. A top-down evaluation of the global flows of steel and aluminium showed that 26% of liquid steel and 41% of liquid aluminium produced does not make it into final products, but is diverted as process scrap and recycled. Reducing scrap substitutes production by recycling and could reduce total energy use by 17% and 6% and total CO₂ emissions by 16% and 7% for the steel and aluminium industries respectively, using forming and fabrication energy values from the case studies. The abatement potential of process scrap elimination is similar in magnitude to worldwide implementation of best available standards of energy efficiency and demonstrates how decreasing the recycled content may sometimes result in emission reductions.Evidence from the case studies suggests that whilst most companies are aware of their own yield ratios, few, if any, are fully aware of cumulative losses along their whole supply chain. Addressing yield losses requires this awareness to motivate collaborative approaches to improvement.     

Characterization of a limestone in a batch fluidized bed reactor for sulfur retention under oxy-fuel operating conditions

CO₂ and SO₂ are some of the main polluting gases emitted into atmosphere in combustion processes using fossil fuel for energy production. The former is one of the major contributors to build-up the greenhouse effect implicated in global climate change and the latter produces acid rain. Oxy-fuel combustion is a technology, which consists in burning the fuel with a mix of pure O₂ and recirculated CO₂. With this technology the CO₂ concentration in the flue gas may be enriched up to 95%, becoming possible an easy CO₂ recovery. In addition, oxy-fuel combustion in fluidized beds allows in situ desulfurization of combustion gases by supplying calcium based sorbent.In this work, the effect of the principal operation variables affecting the sulfation reaction rate in fluidized bed reactors (temperature, CO₂ partial pressure, SO₂ concentration and particle size) under typical oxy-fuel combustion conditions have been analyzed in a batch fluidized bed reactor using a limestone as sorbent. It has been observed that sulfur retention can be carried out by direct sulfation of the CaCO₃ or by sulfation of the CaO (indirect sulfation) formed by CaCO₃ calcination. Direct sulfation and indirect sulfation operating conditions depended on the temperature and CO₂ partial pressure. The rate of direct sulfation rose with temperature and the rate of indirect sulfation for long reaction times decreased with temperature. An increase in the CO₂ partial pressure had a negative influence on the sulfation conversion reached by the limestone due to a higher temperature was needed to work in conditions of indirect sulfation. Thus, it is expected that the optimum temperature for sulfur retention in oxy-fuel combustion in fluidized bed reactors be about 925–950 °C. Sulfation reaction rate rose with decreasing sorbent particle size and increasing SO₂ concentration.     

E‐waste in the world today: An overview of problems and a proposal for improvement in Brazil

Environmental issues have been at the center of society's concerns for a long time. Recently, this kind of concern is growing even more due to the damage caused to the environment by electrical and electronic product waste. Based on this same concern, this work aimed to analyze, through a literature review, the production and treatment of electronic waste in today's world, with an emphasis on Brazil and China. The articles reviewed point to an increase in the production of this type of waste, in both Brazil and China, and reveal that the current processes of treatment of electronic waste mostly aim to obtain profit through the recovery of precious metals such as copper. This paper concluded that although Brazil is one of the major producers of e‐waste, more than 90% of its e‐waste has not had a proper final destination. This deficiency in e‐waste treatment in Brazil is mainly due to financial factors and the lack of a robust educational policy focused on the environment. Thus, this work suggests the implementation of an effective educational policy aimed at environmental conservation, as well as investments in research on recycling methods in Brazil, especially on the use of e‐waste as an aggregate in the manufacture of concrete.     

Taking advantage of storm and waste water retention basins as part of water use minimization in industrial sites

A methodology for water use minimization has been developed by the Clean Technology Network of Bahia over a 10 year period in joint cooperative programs with the chemical, petrochemical and copper metallurgy industries located in the largest Industrial Complex in Latin America, in Camaçari, Bahia, Brazil. The methodology comprises a set of tools including reconciled aqueous stream balances, database of aqueous streams; large scale training leading to the identification of water minimization alternatives in the processes, water reuse optimization approaches; geographical information systems as well as, consideration of the region's hydro and hydro-geological characteristics. The results of a study carried out to assess the possibility of using storm and wastewaters for industrial use is presented in this paper. The inorganic system is composed by three water reservoirs (basins) receiving stormwater contaminated with inorganic effluents, and occasionally with organics. These basins have been operated to control water flow inputs according to the capacity of the pumping outlet systems before their discharge to a submarine outfall. A mass balance was performed with historical updated data to assess water availability from the basins based on the daily volume variation and flow rate of inorganic effluent from 2001 to 2007. The study identified the possibility of recovering about 1140 m³/h of the overall 5400 m³/h consumed by the Industrial Complex at the moment. Organizational changes in the present effluent disposal and stormwater harvest systems will be required in order to maximize water recovery for industrial use.     

Significance of iron compounds in chemical and electro‐oxidation treatment of sugar industry wastewater: Batch reaction

Industrialization plays a major role in a nation's growth. However, with an increase in industrial activities, pollution levels are also increasing. Among all industries, the sugar‐processing industry is one that requires large amounts of water to process the sugar, and, consequently, it discharges large amounts of water as effluent. Highly polluted wastewater brings changes to the physicochemical characteristics of the surrounding environment. Iron compounds have had a significant impact when they are used in wastewater treatment in various applications, including when they are used to minimize the pollution levels in sugar industry wastewater (SIWW). To minimize the pollutant levels from SIWW, iron compounds have been key for uses in treatments involving chemical and electro‐oxidation. Two different methodologies of electrocoagulation and chemical coagulation have been used to treat SIWW. In electrocoagulation, an iron plate is used as an electrode material under specific operating conditions. Ferrous sulfate and ferric chloride have been used as chemical coagulants at various pH and mass loading levels. The use of iron metals shows an 82% reduction in chemical oxygen demand (COD) and an 84% reduction in color at the optimum condition of pH 6, an electrode distance of 20 millimeters, and a current density of 156 square centimeters. As a chemical coagulant, iron salt (ferrous sulfate) provides a reduction of 77% COD and a 91% reduction of color at pH 6 and a 40‐millimole mass loading. Electrochemical treatment using iron was found to be suitable to treat SIWW. The sludge generated after treatment can be burned or composted with the possible recovery of some of the treatment costs.     

Integration of counter-current relative permeability in the simulation of CO2 injection into saline aquifers

Carbon dioxide (CO₂) injection into saline aquifers is one of the promising options to sequester large amounts of CO₂ in geological formations. During as well as after injection of CO₂ into an aquifer, CO₂ migrates towards the top of the formation due to density differences between the formation brine and the injected CO₂. The time scales of CO₂ migration towards the top of an aquifer and the fraction of CO₂ that is trapped as residual gas depends strongly on the driving forces that are acting on the injected CO₂.When CO₂ migrates to the top of an aquifer, brine may be displaced downwards in a counter-current flow setting particularly during the injection period. A majority of the published work on counter-current flow settings have reported significant reductions in the associated relative permeability functions as compared to co-current measurements. However, this phenomenon has not yet been considered in the simulation of CO₂ storage into saline aquifers.In this paper we study the impact of changes in mobility for the two-phase brine/CO₂ system as a result of transitions between co- and counter-current flow settings. We have included this effect in a simulator and studied the impact of the related mobility reduction on the saturation distribution and residual saturation of CO₂ in aquifers over relevant time scales. We demonstrate that the reduction in relative permeability in the vertical direction changes the plume migration pattern and has an impact on the amount of gas that is trapped as a function of time. This is to our best knowledge the first attempt to integrate counter-current relative permeability into the simulation of injection and subsequent migration of CO₂ in aquifers. The results and analysis presented in this paper are directly relevant to all ongoing activities related to the design of large-scale CO₂ storage in saline aquifers.     

Environmental,economic and social costs and benefits of a packaging waste management system: A Portuguese case study

The impact of the management of packaging waste on the environment, economic growth and job creation is analyzed in this paper. This integrated assessment intends to cover a gap in the literature for this type of studies, using the specific case study of the Portuguese packaging waste management system (SIGRE).The net environmental benefits associated with the management of packaging waste, are calculated using the Life Cycle Assessment methodology. The results show that, for the categories studied, the impacts associated to SIGRE's various activities are surpassed by the benefits associated to material and energy recovery, with special focus on recycling. For example, in 2011 SIGRE avoided the emission of 116 kt CO₂ equiv. – the equivalent carbon emission of the electricity consumption of 124.000 households in Portugal.The economic impact of SIGRE is evaluated through Input–Output Analysis. It was found that SIGRE's activities also have a significant economic impact. For example, their added value are ranked amongst the upper third of the economic activities with highest multiplier effect at national level: this means that for each Euro of value added generated within SIGRE, 1.25 additional € are added to the rest of the economy (multiplier effect of 2.25).Regarding the social impacts of SIGRE, the number of direct jobs associated with the system is estimated to be more than two thousand and three hundred workers. Out of these, 83% are connected to the management of municipal waste packaging (selective collection and sorting), 15% are connected to the management of non-municipal packaging waste and only 2% are connected to the Sociedade Ponto Verde (SPV, green dot society in English) – the management entity responsible for SIGRE.In general terms, the results obtained provide quantitative support to the EEA (2011) suggestion that moving up the waste hierarchy – from landfilling to recycling – creates jobs and boosts the economy.