08a ppia styropor recycling technology

STYRO/PLASTIC RECYCLING TECHNOLOGY

Presented by :

ARACELI M. MONSADA, PhD Senior Science Research Specialist Materials Science Division (MSD)

“ Technical Briefing on Plastics and the Environment Organized by the Philippine Plastics Industry Association, Inc. (PPIA)

For the Multi S ectoral Committee on the Environment 25 July 2008, S heraton Park Hotel, Manila

The Solid Waste ScenarioThe Solid Waste Scenario Studies show that an average of Studies show that an average of 0.56 kg0.56 kg

of waste is produced per person per dayof waste is produced per person per day In Metro Manila, with a population of In Metro Manila, with a population of

about 12 M, about 6,700 tons of solid about 12 M, about 6,700 tons of solid wastes are generated per daywastes are generated per day

about 56% is biodegradableabout 56% is biodegradable and 44% is non-biodegradable and and 44% is non-biodegradable and

mostly, RECYCLABLEmostly, RECYCLABLE

Typical Waste Characterization Data

But...But... in reality recycling and composting in reality recycling and composting

accounts only to 720 tons per day, or only accounts only to 720 tons per day, or only 11% of post consumer solid waste 11% of post consumer solid waste generated in Metro Manila, because of generated in Metro Manila, because of non-segregationnon-segregation unavailable recycling technologiesunavailable recycling technologies no market for recyclablesno 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, 2001IRR Effectivity: January 06, 2002

ITDI has an Integrated Approach to Solid ITDI has an Integrated Approach to Solid Waste Management which includes Waste Management which includes

development of technologies on:development of technologies on:

BiodegradablesRecyclables

Special wastes Clay Lined Landfill

Bioreactor

Biogas digester

Recycling Technologies

4%

56%40%

Ecoshops/Buying Centers

POST-CONSUM ER WASTE PLASTIC BAGS (shopping bags, sando bags, etc.)

Our TARGET>>>>>>>>>……..

Municipal Solid Waste Transfer Station (Metro Manila)

Municipal Solid Waste Transfer Station (Metro Manila)

POST CONSUM ER WASTE STYRO

EXPANDED POLYSTYRENE (EPS)

Extruded Foamed Polystyrene (FPS)

“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 Packaging Products

✽ Most common plastic material used for disposable food packaging by almost all “ fast food chains” like McDonalds, Jollibee, Wendy’s, etc.

✽ About 200 tons of “waste styrofoam” is 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 Polystyrene (FPS)

✽ 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 The Styro/Plastic Melting Densifier Melting DensifierFEATURES :FEATURES :

Steel casserole with cover, double jacketed body with a Steel casserole with cover, double jacketed body with a melting capacity of 50 kgs per batchmelting capacity of 50 kgs per batch

A motorized blunger for homogeneous mixing.A motorized blunger for homogeneous mixing.

A cylindrical steel downspout - to facilitate the discharge of A cylindrical steel downspout - to facilitate the discharge of melted plastic during casting into the metal molds. melted plastic during casting into the metal molds.

The exhaust/chimney is installed with a charcoal stack to The exhaust/chimney is installed with a charcoal stack to absorb smoke emission during melting. absorb smoke emission during melting.

The temperature recorder measures the melting The temperature recorder measures the melting temperature temperature

LPG fired with three-line burner. LPG fired with three-line burner.

Recycling ProcessRecycling Process

Waste FPS/EPS

Melting/Densification

Densified Products (functional, novelty)

Size Reduction

RAW MATERIALSRAW MATERIALS The technology mainly involves densification of “waste Styro” or “plastic bags” by melting them in a vegetable cooking oil at a controlled heating temperature; converting the waste styro/plastic bags into rigid functional products. ✽ Post Consumer “Waste Styro” ✽ Waste plastic bags (PE, PP)✽ 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/GrindingShredding/Grinding

• plastic sando bags (PE, PP, PVC)

• styropor/styrofoam ( FPS, EPS)

• HDPE, PET bottles trays and containers

• Aluminum foil packs ( sachet, pouch)

• PE, PP household plastic wares • other commodity plastics

Can GRIND:

Weighing and ChargingWeighing and Charging

Melting/DensificationMelting/Densification

Molded functional products are produced Molded functional products are produced by melting the ground post consumer by melting the ground post consumer waste styrofoam or plastic sandobags in a waste styrofoam or plastic sandobags in a preheated used cooking oil at 150 upto preheated used cooking oil at 150 upto 200200ooC for about two(2) hours using the C for about two(2) hours using the ITDI fabricated portable melting densifier. ITDI fabricated portable melting densifier.

Melting ProcessMelting Process

THE PRODUCTTHE PRODUCT The resulting molten waste plastic is easily The resulting molten waste plastic is easily

molded by casting and converted into the molded by casting and converted into the metal molds which displayed potential uses metal molds which displayed potential uses for tabletops, planters and other valuable for tabletops, planters and other valuable functional products.functional products.

Molten Plastic casting/pouring Molten Plastic casting/pouring into the metal moldersinto the metal molders

Molding/Forming Technique

Molded ProductsMolded Products

Functional Products

Table tops

School chair

Cat walk blocks

Table Tops

Cat WalkCat Walk

Synthetic Synthetic timber planktimber plank

Other Products

Bricks

Boards

PS MELTING UNIT Design Fabrication

Melting Unit Transformations…Melting Unit Transformations…

Steel vessel with steel Steel vessel with steel covercover

LPG FiredLPG Fired 50 kgs capacity per 50 kgs capacity per

batchbatch With downspout for With downspout for

pouring molten pouring molten productsproducts

Manual charging of Manual charging of materials and mixing materials and mixing of molten plasticof molten plastic

2nd Generation

Melting Unit Transformations (b)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

3rd Generation Styro-oven

Motorized Blunger

Activated Charcoal Chamber

Hopper

Suction Blower

Exhaust Chimney

Condenser for liquid/gas collection

Melting Chamber cover

Improved Feeding/charging of Improved Feeding/charging of plastic materialsplastic materials

Temperature Recorder

Spout

Ease in monitoring the working temperature

Improved Paddle for MixingImproved Paddle for Mixing

Improved Pouring/casting

Newer Products ProducedNewer Products Produced

Plastic Planters

Comparative Modulus of Rupture of Comparative Modulus of Rupture of Different Construction MaterialsDifferent Construction Materials

Cleaner Gas EmissionCleaner Gas Emission

Smoke/Gas Emission Analysis

Smoke Emission/Gas AnalysisSmoke Emission/Gas Analysis

Environmental Impact

Vacuum pump for gas collectionVacuum pump for gas collection

Liquified Gas Collected by the Liquified Gas Collected by the CondenserCondenser

Gas ChromatographyGas Chromatography

fatty acids

GC-MS Spectra

Gas Emission Tests Conducted

(ITDI)

(Ateneo)

0

5

10

15

20

25

30

1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 36 38 40 42 44 46 48 50

Chemical Identity No.

Rel

ativ

e A

mou

nt, %

composition of PS + oil before charcoal column

composition of PS + oil after charcoal columnStyrene

Gas Collected during the melting of PS in oil at 200C

benzene

Analysis of Airborne Contaminants, as Analysis of Airborne Contaminants, as per ASTM D4490*per ASTM D4490*

* Tested by the Environmental Division, ITDI-DOST

Project/Business HighlightsProject/Business Highlights 250 kg/day Waste Styropor Recycling Facility (w/o land) 250 kg/day Waste Styropor Recycling Facility (w/o land)

PRODUCT: Zigzag Tiles/BlocksPRODUCT: Zigzag Tiles/Blocks Annual Plant Capacity : 71,100 pcs.Annual Plant Capacity : 71,100 pcs. Technology Source : ITDI-DOSTTechnology Source : ITDI-DOST Total Project Cost: P469,000Total Project Cost: P469,000

Unit Cost of Production/kg: P 9.39Unit Cost of Production/kg: P 9.39Proposed Selling Price/pc. : P11.50Proposed Selling Price/pc. : P11.50

Internal Rate of Return (equity): 35%Internal Rate of Return (equity): 35% Internal Rate of Return 35%Internal Rate of Return 35% (Investment):(Investment): Payback Period: 2.4 yearsPayback Period: 2.4 years Net Profit before TAX P226,045Net Profit before TAX P226,045 Gross Profit on Sales P398,345Gross Profit on Sales P398,345

Basic Needs to start the Basic Needs to start the businessbusiness

Melting unit and fuel (LPG ) Melting unit and fuel (LPG ) Metal molds and accessoriesMetal molds and accessories raw materials: waste styropor/plastic raw materials: waste styropor/plastic bags and used oilbags and used oil appropriate working space with shade (min.50mappropriate working space with shade (min.50m22

proper exhaust systemproper exhaust system

Socio Economic Socio Economic ImpactImpact

Employment generationEmployment generation Low investment Low investment good profitabilitygood profitability

Cleaner environmentCleaner environment Part Solution to solid wastes problemPart Solution to solid wastes problem

Functional products and lumber substituteFunctional products and lumber substitute

Technology AdaptorsTechnology Adaptors 1. 1. Local Government UnitLocal Government Unit a. Los Banos, Laguna: June 2005a. Los Banos, Laguna: June 2005

b. Municipality of Enrique B. Magalona b. Municipality of Enrique B. Magalona Negros Occidental: December 01, 2005Negros Occidental: December 01, 2005

c. Davao City: June 2006c. Davao City: June 2006 d. Cebu City : July 2006d. Cebu City : July 2006 e. Lapu-lapu City : July 2006e. Lapu-lapu City : July 2006 f. Boracay, Aklan : August 2006f. Boracay, Aklan : August 2006 g. San Fernando, Pampanga – October 2006g. San Fernando, Pampanga – October 2006 h. Anilao, Batangas – January 2007h. Anilao, Batangas – January 2007 i. Tanay, Rizal - November 2007i. Tanay, Rizal - November 2007 j. Sta. Cruz, Laguna – July 2008j. Sta. Cruz, Laguna – July 2008 k. Lipa, Batangas k. Lipa, Batangas l. Bantayan, Bantayan Island, Cebu – July 2008l. Bantayan, Bantayan Island, Cebu – July 2008 m. Canaman, Camarines Sur, Bicol - June 2008 m. Canaman, Camarines Sur, Bicol - June 2008

Technology Adaptors…….Technology Adaptors…….

2.2. Non-Government OrganizationsNon-Government Organizations a.a. ZKK Corporation ZKK Corporation Taytay, Rizal Taytay, Rizal March 2005March 2005 b. Mirriam College b. Mirriam College Quezon City Quezon City August 2006August 20063. Plastics Industry3. Plastics Industry Philippine Plastic Industrial Association (PPIA)Philippine Plastic Industrial Association (PPIA) Polystyrene Packaging Council of the Polystyrene Packaging Council of the

Philippines Philippines

Cost of the TechnologyCost of the Technology One(1) unit of Styro Oven/Plastic DensifierOne(1) unit of Styro Oven/Plastic Densifier Features: Batch Type Features: Batch Type 50kg capacity 50kg capacity Steel Casserole with coverSteel Casserole with cover Hopper Hopper Motorized blunger Motorized blunger Temperature Gauge Temperature Gauge Exhaust system packed with activated Exhaust system packed with activated carbon/charcoal carbon/charcoal Price:Price: P150,000.00 (excluding P150,000.00 (excluding shipment/freight cost)shipment/freight cost)

Training chargeable against: Proponent of the Training chargeable against: Proponent of the TechnologyTechnology

NCRNCR•Asia Environcon, Inc. Quezon City, Metro ManilaTel.: (02) 932-4758 / 932-4756

•Dragon Construction, Inc.Quezon City, Metro ManilaTel: (02) 371-5082 / 361-4627

•I.M. Bongar & Co., Inc. Las Pinas City, Metro ManilaTel: (02) 801-3943 / 801-3341

•Raymac, Inc.Caloocan City, Metro ManilaTel.: (02) 366-7342

Region 4Region 4L. Angeles Machineries Corp. (LAMACO) Bacoor, CaviteTel.: (02) 887-6596 / (046) 970-5672Region 11Region 11Davao NCG Services, Inc. Davao CityTel.: (082) 227-4462

Region 7 Suki Trading Center Pajac, Lapu-Lapu City Cebu Tel. no. 341-5760; 341-2151(accreditation in process)

ITDI-DOST Accredited Fabricators(As of October 2007)

PS BLOCKS ON PATHWAYS IN Bgy. Balabag, Boracay

PS BLOCKS FLOORINGSIn 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, 2ND Place Outstanding Creative Research

National Inventors Week November 17-21, 2005, PTTC

1st Place Likha Award (Outstanding Creative Research) National Inventors Week November 2006, PTTC, Pasay

“ Plastic Sando Bags Recycling”

For more details, please contact:

Dr. Nuna E. AlmanzorDirector

Industrial Technology Development InstituteDepartment of Science & Technology

Tel.: (02) 837-2071 local 2182, 2215 Fax: (02) 837-3167

Email: nea@dost.gov.ph