Current Recycling Technologies for Plastic Waste in Japan
June 15 2009 in Osaka
Yamawaki Takashi
Plastic Waste Management Institute
Contents
1. Law for recycling of containers and packaging
2. Recycling technologies
3. New recycling technologies
4. Waste to energy
5. Conclusion
1 1.Law for Recycling of Containers and Package Figure1
Designated Business entities utilizing manufactures/users recycled products
Payment of recycling costs The Japan C&P Recycling Association
Payment of recycling costs Supply Supply Declaration for amount of sorting Bidding plastic waste Consumers price Recyclers
Municipalities
Sorted collection
Sorted discharge Transportation and recycling of “items to meet sorting criteria”
Figure2 Actual performance related to plastics other than PET bottles
2 Figure3 Trends in bidding for the various recycling methods for plastics other than PET bottles
Figure4 Large Scaled Chemical Recycling Facilities （complied with C&P recycling law, 2009) 19 Facilities: Mogami Kiko (Sinjyo) Monomer 2 Liquefaction: 3t/d Sapporo Plastic Recycling Blast furnace 3 Liquefaction: 14,800t Coke oven 6 Orix Resource Recycling Service Gasification 6 (Yoroi) Gasification: 450t/d Nihon Steel (Muroran) Liquefaction 2 Mizushima Eco-Works（Kurashiki) Coke Oven: 20,000t Gasification: 555t/d JFE Steel (Chiba) JFE Steel (Fukuyama) Gasification: 20,000t Blast furnace : 40,000t Nippon Steel (Kimitsu) （ Ube Ube) Coke Oven: 50,000t Gasification: 30,000t JFE Steel (Kawasaki) Kyoei Steel（Onoda) 40,000t/30,000t Gasification: 25,000t Blast furnace/Coke Oven
Nihon Steel (Yahata) Showa Denko（Kawasaki) Coke Oven: 20,000t Gasification: 60,000t
Nihon Steel (Oita) PET Refine Technology (Kawasaki) Cokes Oven: 25,000t Monomer B to B: 22,000t
Teijin Fiber (Tokuyama) Kobe Steel (Kakogawa) Nihon Steel (Nagoya) Monomer B to F: 62,000t Blast furnace: 10,000t Coke Oven: 50,000t Withdraw from B to B (F: Fiber)
3 2. Recycling technologies
Figure5 The flow seat of utilization for blast furnace reducing agents
Source: JFE Steel Co.
Figure6 The flow seat of utilization for coke oven fuels
Source: Nippon Steel Co.
4 Figure7 Carbonization room
Source: Nippon Steel Co.
Figure8
Source: Ube Industries Ltd.
5 Figure9
Figure10
Source: Sapporo Plastic Recycling
6 Figure11
Figure12 Cement Kiln
Source: Japan Cement Association
7 3. New recycling technologies
Figure13 Liquefaction by Catalyst Cracking using Spent FCC Catalyst
Waste Plastic, Spent Catalyst, Slaked Lime
Fixed Spent Catalyst
Cool Rotational Dram Fuel gas Fixed er
Heater
Oil/Gas Separator Fuel Heating Air Furnace Waste Catalyst
Dechlorination Agent
Residual Substance Source: The University of Kitakyusyu
Table1 Table2
Paraffin[vol%] 19.3
Olefin[vol%] 24.7
1ring-aromatic[vol%] 41.8
2rings-aromatic[vol%] 6.6
3rings-aromatic[vol%] 7.8
Source: The University of Kitakyusyu
8 Figure14
4500 4047 4000 3500 Start up feed Ca(OH) 3000 2 2500
2000 Feed continuously 1500 1000 500 39 210 176 189 128 Residual Chlorine[ppm] 47 47 0 1 4 6 8 12 13 16 20 Number of run [-] Source: The University of Kitakyusyu
Figure15
Source: National Inst. for Adv. Ind. Sci. & Tech. (AIST)
9 Table3
Source: AIST
Figure16 Tomakomai Thermal Power Station:Facility Flow for Generation of Electric Power Boiler Stack
Fuel Preparation and Plastic Fuel Processing Plant Plastic Supply Bag Filter Fuel Facility
Chipping Device Pneumatic transportation Steam
Air Cooled Condenser Transmission Line TG・Central Control Room Turbine
Generator Transformer
10 Figure17 Tomakomai Thermal Power Station:Schematic Diagram Plant Capacity Flow Fluid １，Output：74MW Steam (at Generator Terminal) Water Steam Turbine ２，Fuel Consumption Exhaust Gas Generator ：７05ｔ／day Air 66ｋV”Hokkaido ３，Steam Condition Fuel/Chemicals/Ash Electric Power”Line ：Temperature ４００℃ :Pressure 6.08 MPa ４，Thermal Efficiency No2 Boiler ２７．１％ Emissions : (gross) Deaerator ５，Boiler：Two(２) １，ＮＯｘ ：<200ppm ２，ＳＯｘ ： <50ppm ６，Turbine：One(１) ACC ３，Particulates ７，Ambient Condition (Design Base) ：<0.04g/m3N 1)Dry Bulb Temp：１５℃ ４，Dioxins Ｐ 2)Relative Humidity：７５％ ：<0.1ng-TEQ/Nm3 3)Barometric Pressure ：760mmHｇ Ｐ Boiler Feed Water Pump Plastic Fuel Silica No.1 Circulating Fluidized Bed Boiler Condensate Pump Slaked Lime Dolomite Activated Carbon
“A”Heavy Oil IDF for Start Up Gas Air Bag Filter Heater Induced Draft Fan FDF Stack Forced Draft Fan Bottom Ash Fly Ash
Picture1
Source: Sanix Inc.
11 4. Waste to Energy
Table4
Figure18 Gasification process for ELV Gas reforming Cleaning Cleaning
Power generation Gas
Gasification furnace (Thermal cracking kiln type)
Residue Char, Metal Raw material
Source: Toyota Motor Co.
12 Summary of Waste to Energy
1. Trend of waste plastic treatment in Japan ・Material recycling and energy recovery are increasing rapidly. ・Ministry of the environment and Tokyo metropolitan make a policy that waste plastic treatment should be changed from landfill to energy recovery.
2. Relation of energy recovery to recycling laws ・Home appliance recycling law excluding (now) ・End of Life Vehicles recycling law including (main technology) ・Containers and Packaging recycling law including (liquefaction, gasification, RPF)
Thinking that best available waste plastics treatment is energy recovery is expanding.
5. Conclusion ・Over 500 thousands tons waste plastics were recycled and 19 large size chemical recycling plants were operated under the Containers and Packaging Recycling Law.
・ Several kind of technologies were developed such as, blast furnace reducing agent, coke oven fuels, gasification, liquefaction.
・New technologies are developing such as, liquefaction by catalyst cracking using spent FCC Catalyst, fuel oil production using a moving-bed reactor, new technology of energy recovery process for waste plastics using circulated fluid bed boiler, next generation stoker furnaces for municipal waste and so on.
・Material recycling, energy recovery as RDF including RPF and waste power generation is prospected to increase rapidly.
・Thinking that best available waste plastics treatment is energy recovery is now expanding in Japan, and all kind of recycling laws except Home Appliance recycling law are permitted to utilize energy recovery technologies.
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