STYRO/PLASTIC RECYCLING TECHNOLOGY Presented by : ARACELI M. MONSADA, PhD Senior Science Research Specialist Materials Science Division (MSD)
“ Tec Technical hnical Br B rief iefiing on P las tics and a nd the the E nvir nvironm onment ent O rga gani nized zed by the the P hi hillippi ppine ne P las tics Indus try As A s s ociat ociatiion, Inc. Inc. (P (PP P IA IA)) F or the the M ult ultii S ect ectoral oral Comm C ommiittee on o n the the E nvir nvironme onment nt 25 July 2008 herat ark Hotel Hotel anil
The Solid Waste Scenario
Studies show that an average of 0.56 kg of waste is produced per person per day In Metro Manila, with a population of about 12 M, about 6,700 tons of solid wastes are generated per day about 56% is biodegradable and 44% is non-biodegradable and mostly, RECYCLABLE
Typical Waste Characterization Data
But...
in reality recycling and composting accounts only to 720 tons per day, or only 11% of post consumer solid waste generated in Metro Manila, because of
non-segregation unavailable recycling technologies no market for recyclables
Thus….
We see solid wastes in …..
River Channels
We see solid wastes in …..
Bays
We see solid wastes in …..
Canals
We see solid wastes in …..
Streets
Some are openly burned adding to the heavily polluted air shed.
ECOLOGICAL SOLID WASTE MANAGEMENT ACT of 2000 •
NO TO OPEN DUMPSITES
•
SEGREGATION AT SOURCE
•
RECYCLING – PACKAGING MATERIALS ARE RECYCLABLE
•
MATERIALS RECOVERY FACILITY (MRF)
•
SANITARY LANDFILL
RA 9003 Approval : January 26, 2001 IRR Effectivity: January 06, 2002
ITDI has an Integrated Approach to Solid Waste Management which includes development of technologies on: Special wastes 4% Recycling Recyclables Technologies 40%
Clay Lined Landfill
Biodegradables 56% Bioreactor Biogas digester
Our TARGET>>>>>>>>>……..
POSTOST-CONSUM CONSUM ER W ASTE PL PL ASTIC BAG S (shopping bags, sando bags, etc.)
Municipal Solid Waste Transfer Station (Metro Manila)
Municipal Solid Waste Transfer Station (Metro Manila)
POST CONSU CONSUM M ER WASTE STYR STYR O
EXPANDED POLYSTYRENE (EPS)
“Recycling/Processing of Waste Styro/Sandobags using the Styro/Plastic Melting Densifier ”
Primary Objective of the Project:
Introduce a plastics recycling technology that is simple, affordable, environmental friendly and able to generate livelihood; decentralizing plastics recycling (community level).
Polystyrene Foam Food Polystyrene Packaging Products
V
Most common plastic material used for disposable food packaging by almost all “ fast food chains” like McDonalds, Jollibee, Wendy’s, etc.
V V
About 200 tons of “waste styrofoam” styrofoam” is generated generated per month in the country; 70% of which, accounting to 140 tons per month, is in Metro Manila. “Styro” disposable packages are usually made up of 95% air and 5% PS resin
Extruded Foamed Polysty Polystyrene rene (FPS) V V V
V V V
commonly called, “Styrofoam”; Styropor Polystyrene (PS)- a commodity plastic material Thermoplastic” – remelts / reprocessed by heat;
Unique characteristics: inert, lightweight, versatile and cheap. “Non- biodegradable; Single Plastic material – “RECYCLABLE”
The Styro/Plastic Melting Densifier FEATURES :
Steel casserole with cover, double jacketed body with a melting capacity of 50 kgs per batch
A motorized blunger for homogeneous mixing.
A cylindrical steel downspout - to facilitate the discharge of melted plastic during casting into the metal molds.
The exhaust/chimney exhaus t/chimney is installed with a charcoal charcoal stack to exhaust/chimney absorb smoke emission during melting.
The temperature recorder measures the melting temperature
LPG fired with three-line burner.
Recycling Process Waste FPS/EPS
Size Reduction
Melting/Densification
Densified Products (functional, novelty)
RAW MATERIALS The technology mainly involves densification of “waste Styro” or Styro” or “plastic bags ” by melting them in a vegetable cooking oil at oil at a controlled heating temperature; converting the waste waste styro/plastic bags into rigid functional functional products. products. V
Post Consumer “Waste Styro” V Waste plastic bags (PE, PP) V Cooking oil ( e.g., “used cooking oil” from fast foods and restaurants ) The waste Styro or plastic bags must be ground/shredded or broken into small pieces.
Shredding/Grinding Can GRIND: • plastic sando bags (PE, PP, PVC)
• PE, PP household plastic wares
• styropor/styrofoam ( FPS, EPS)
• other commodity plastics
• HDPE, PET bottles trays and containers • Aluminum foil packs ( sachet, pouch)
Weighing and Charging
Melting/Densification
Molded functional products are produced by melting the ground post consumer waste styrofoam or plastic sandobags in a preheated used cooking oil at 150 upto 200oC for about two(2) hours using the ITDI fabricated portable melting densifier.
Melting Process
THE PRODUCT
The resulting molten waste plastic is easily molded by casting and converted into the metal molds which displayed potential uses for tabletops, planters and other valuable functional products.
Molding/Forming Technique
Molten Plastic casting/pouring into the metal molders
Molded Products
Functional Products Table tops
School chair
Cat walk blocks
Table Tops
Cat Walk
Other Products
Boards
Bricks
Synthetic timber plank
PS MELTING UNIT Design Fabrication
Melting Unit Transformations Transformations… …
2nd Generation
Steel vessel with steel cover LPG Fired 50 kgs capacity per batch With downspout for pouring molten products Manual charging of materials and mixing of molten plastic
Melting Unit Transformations (b)
1st Generation
1st Generation w/ make over
Temperature Gauge
2nd Generation after a make-over by PPCP
3rd Generation Styro-Oven Fabricated in ITDI
3r d Generation Styro-oven
Exhaust Chimney Suction Blower Condenser for liquid/gas liquid/ga s collection
Motorized Blunger Melting Chamber cover
Hopper
Activated Charcoal Chamber
Improved Feeding/charging of plastic materials
Ease in monitoring the working temperature Temperature Recorder
Spout
Improved Paddle for Mixing
Improved Pouring/casting
Newer Products Produced
Plastic Planters
Comparative Modulus of Rupture of Different Construction Materials
Cleaner Gas Emission
Smoke/Gas Emission Smoke/Gas Analysis
Environmental Impact Smoke Emission/Gas Analysis
Vacuum pump for gas collection
Liquified Gas Collected by the Condenser
Gas Emission Tests Conducted Gas Chromatography (ITDI)
GC-MS Spectra (Ateneo)
fatty acids
Gas Collected during the melting of PS in oil at 200C
30
composition of PS + oil before charcoal column 25
composition compositi on of PS + oil oi l after charcoal column column
Styrene
% , 20 t n u o m15 A e v i t a 10 l e R
benzene
5
0
1
3
5
7
9
11
13
15
17
19
21
23
25
27
29
31
Chemical Identity No.
33
36
38
40
42
44
46
48
50
Analysis of Airborne Contaminants, as per ASTM D4490*
* Tested by the Environmental Division, ITDI-DOST
Project/Business Highlights 250 kg/day Waste Styropor Recycling Facility (w/o land)
PRODUCT: Annual Plant Capacity : Technology Source : Total Project Cost: Unit Cost of Production/kg: Proposed Selling Price/pc. : Internal Rate of Return (equity): Internal Rate of Return (Investment): Payback Period: Net Profit before TAX
Zigzag Tiles/Blocks 71,100 pcs. ITDI-DOST P469,000 P 9.39 P11.50 35% 35% 2.4 years P226,045
Basic Needs to start the business Melting unit and fuel (LPG ) Metal molds and accessories raw materials: waste styropor/plastic bags and used oil appropriate working space with shade (min.50m2 proper exhaust system
Socio Economic Impact Employment generation Low investment good profitability Cleaner environment Part Solution to solid wastes problem Functional products and lumber substitute
Technology Adaptors 1. Local Government Unit a. Los Banos, Laguna: June 2005 b. Municipality of Enrique B. Magalona Negros Occidental: December 01, 2005 c. Davao City: June 2006 d. Cebu City : July 2006 e. Lapu-lapu City Ci ty : July 2006 City f. Boracay, Aklan : August 2006 g. San Fernando, Pampanga – October 2006 h. Anilao, Batangas – January 2007 i. Tanay, Rizal - November 2007 j. j. Sta. Cruz, Laguna – July 2008 k. Lipa, Batangas l. Bantayan, Bantayan Island, Cebu – July 2008
Technology Adaptors…….
2. Non-Government Organizations a. ZKK Corporation Taytay, Rizal March 2005 b. Mirriam College Quezon City August 2006 3. Plastics Industry Philippine Plastic Industrial Association (PPIA) Polystyrene Packaging Council of the Philippines
Cost of the Technology Technology One(1) unit of Styro Oven/Plastic Densifier Features: Batch Type 50kg capacity Steel Casserole with cover Hopper Motorized blunger Temperature Gauge Exhaust system packed with activated carbon/charcoal Price: P150,000.00 (excluding shipment/freight cost) Training chargeable against: Proponent of the Technology
ITDI-DOST Accredited Fabricators (As of October 2007) NCR • Asia Asia Environcon, Inc. Quezon City, Metro Manila Tel.: (02) 932-4758 / 932-4756 •Dragon Construction, Inc. Quezon City, Metro Manila Tel: (02) 371-5082 / 361-4627 •I.M. Bongar & Co., Inc. Las Pinas City, Metro Manila Tel: (02) 801-3943 / 801-3341 •Raymac, Inc. Caloocan City, Metro Manila Tel.: (02) 366-7342
Region 4 Region L. Angeles Machineries Corp. (LAMACO) Bacoor, Cavite Tel.: (02) 887-6596 / (046) 970-5672 Region Reg ion 11 Davao NCG Services, Inc. Davao City Tel.: (082) 227-4462 Region 7 Suki Trading Center Pajac, Lapu-Lapu City Cebu Tel. no. 341-5760; 341-2151 (accreditation (accreditati on in process)
PS BLOCKS ON PATHWAYS IN Bgy. Balabag, Boracay
PS BLOCKS FLOORINGS In Barangay Hall, Bgy. Balabag, Boracay
Blocks from waste Styrofoam
Blocks from waste plastic sando bags
PPIA’s Pilot Project on Mobile Plastic Collection and Recycling of Post Consumer Plastic Bags and Styropor in Metro Manila
Source: PPIA
LIKHA AWARD, 2
ND
Place
Outstanding Creative Research National Inventors Week
“ Plastic Sando Bags Recycling” 1st Place Likha Award (Outstanding Creative Research) National Inventors Week November 2006, PTTC, Pasay
For more details, please contact: Dr. Nuna E. Almanzor Director Industrial Technology Development Institute Department of f S Science & Technology
Tel.: (02) 837-2071 local 2182, 2215 Fax: (02) 837-3167 Email:
[email protected]
