Recycling Process PDF

1 Introduction  Recycling is processing used materials (waste) into new products  Recycling can help to prevent :  waste of potentially useful materials,  reduce the consumption of fresh raw materials,  reduce energy usage,  reduce air pollution (from incineration) and water...

1 Introduction  Recycling is processing used materials (waste) into new products  Recycling can help to prevent :  waste of potentially useful materials,  reduce the consumption of fresh raw materials,  reduce energy usage,  reduce air pollution (from incineration) and water pollution (from landfilling) by reducing the need for "conventional" waste disposal,  and lower greenhouse gas emissions as compared to virgin production 2 Introduction (cont) Concrete is humanity’s most consumed material after water, and its production contributes massive amounts of carbon dioxide to the atmosphere. And the production of every tonne of steel releases 1.83 tonnes of CO2. Recycling is a key component of modern waste reduction and is the third component of the "Reduce, Reuse, Recycle" waste hierarchy. 3 Introduction (cont)  In Malaysia we produce 45,000 tones of waste every day, and a majority of that ends up in landfills.  Malaysia currently has 230 landfill sights and 80% of them has reached its capacity, and with land for landfill sights being at a premium, there is soon going to be a big problem right on our doorsteps.  Our task now is to try and reduce the amount of rubbish going into these landfills. 4 5 Here are some ideas to get you started Paper  All the items below need to be separated bound and then can be recycled.  Newspapers  Manuals  School books  Computer paper  Leaflets and catalogues  Paper boxes. 6 Metals  The below items need to be drained of liquid, rinsed and placed in bags or boxes.  Aluminium cans/ drinks cans  Food and sauce cans  Tin containers of food beverages (milk & Milo etc)  Biscuit tins 7 Plastics  The items below need to be rinsed then stored separately in bags or boxes  Soft drinks and juice bottles  Mineral water bottles  Food and sauce containers  Liquid soap and detergent bottles  Shampoo and lotion bottles  Plastic bags 8 Glass  The items below have to be washed and stored separately in bags or boxes.  Soft drinks and juice bottles  Jams and food jars  Sauces and seasoning bottles  Vitamins and cosmetic bottles 9 Beverage Cartons  All tetra pack beverage and food cartons need to be rinsed and flattened as per the directions on the box. 10 Tetra Pak cartons  Aseptic cartons (~70% of tetra pak cartons) can be transported and stored without refrigaration – results in considerable amounts of energy saving  20% lighter today than they were 30 years ago!  Utilizing fewer resources  Less energy to produce  Less waste to dispose off 11 12 Recycling of Plastics 13  Recycling of plastics  Plastics cause serious environmental problems. Although they are not intrinsically dangerous, they take up a huge amount of space in landfills and they are made from a nonrenewable resource, namely fossil fuels. For these reasons it is important that, where possible, plastics are recycled.  The recycling of plastics is carried out in a five step process. 14  Recycling Process  Step 1 - Plastics collection  Plastics for recycling come from two main sources: post consumer plastics and post industrial plastics. Post consumer plastics are those which have already been used by people.  These are the plastics collected in plastics recycling bins and at domestic roadside collections.  Post industrial plastics, on the other hand, are rejects from industry — offcuts, damaged batches etc.  These plastics are collected either directly from the industry or collected by the local council, squashed into bales and sold to a recycler. 15  Recycling Process (cont)  Step 2 - Manual Sorting  In theory, every type of plastic can be recycled. In practise in New Zealand only codes 1 (PET) and 2 (HDPE) are recycled.  The incoming plastic is manually sorted into these two codes and 'other', and the three separate streams sent off to be chipped.  It is particularly important that all PVC is removed from the PET stream as the more sophisticated sorting used later on cannot differentiate between these two types of plastic. Any rocks, nails, metal etc. that is mixed in with the plastic is also manually removed at this stage. 16 Recycling Process (cont)  Step 3 – Chipping / Crushing  Each sorted stream of plastic is then sent separately to a chipper.  This is a cylinder of blades somewhat like an old- fashioned lawnmower in a vessel with a 10 mm grill floor.  The blades cut the material until it is small enough to fall through the grill. 17 Recycling Process (cont)  Step 4 - Washing  The chips are then washed to remove glue, paper labels, dirt and any remnants of the product they once contained.  Both the "other" stream and the PET stream are washed at around 90ºC for at least twelve minutes, while the HDPE (which has a much lower melting point) must be washed below 40ºC to prevent discolouration. 18 Recycling Process (cont)  Step 5 - Pelleting  This is done by melting the chips and extruding them out first through a fine grill to remove any solid dirt or metal particles that have made it through the treatment thus far and then through a die of small holes.  If the plastic was simply allowed to extrude from these holes it would come out as spaghetti-like strings and quickly tangle together.  However, it is sprayed with water as it comes out (to prevent the plastic from sticking together) and cut off by rotating knives to give small, oval pellets. 19 How to Quickly Understand the Types of Plastic (Plastic Codes)  The plastic codes were introduced by SPI (Society of the Plastics Industry) in 1988 as a resin coding system for the purposes of more efficient recycling. Plastic In Action 20  Plastic Type of plastic Identification Properties Common Packaging Applications polymer Code Polyethylene Clarity, strength, Soft drink, water and salad dressing terephthalate toughness, barrier to bottles; peanut butter and jam jars (PET, PETE) gas and moisture. Stiffness, strength, Water pipes, Hula-Hoop (children's High-density toughness, game) rings, Milk, juice and water polyethylene resistance to bottles; the occasional shampoo / (HDPE) moisture, toiletry bottle permeability to gas. Blister packaging for non-food items; cling films for non-food use. Not used Versatility, ease of for food packaging as the plasticisers Polyvinyl blending, strength, needed to make natively rigid PVC chloride (PVC) toughness. flexible are usually toxic. Non- packaging uses are electrical cable insulation; rigid piping; vinyl records. Ease of processing, Low-density strength, toughness, Frozen food bags; squeezable bottles, polyethylene flexibility, ease of e.g. honey, mustard; cling films; (LDPE) sealing, barrier to flexible container lids. moisture. Strength, toughness, Reusable microwaveable ware; resistance to heat, kitchenware; yogurt containers; Polypropylene chemicals, grease margarine tubs; microwaveable (PP) and oil, versatile, disposable take-away containers; barrier to moisture. disposable cups; plates. Egg cartons; packing peanuts; Versatility, clarity, disposable cups, plates, trays and Polystyrene (PS) easily formed cutlery; disposable take-away containers; Dependent on Beverage bottles; baby milk bottles. Other (often polymers or Non-packaging uses for polycarbonate: polycarbonate or combination of compact discs; "unbreakable" glazing; ABS) polymers electronic apparatus housings. 21  Understanding the seven plastic codes will make it easier to choose plastics and to know which plastics to recycle. For example, water bottles that display a three or a five cannot be recycled in most jurisdictions in the US. A three indicates that the water bottle has been made from polyvinyl chloride, a five means that it’s been made of polypropylene, two materials that are not accepted by most public recycling centers. 22  #1 - PET (Polyethylene Terephthalate) PET is one of the most commonly used plastics in consumer products, and is found in most water and pop bottles, and some packaging. It is intended for single use applications; repeated use increases the risk of leaching and bacterial growth. PET plastic is difficult to decontaminate, and proper cleaning requires harmful chemicals. Polyethylene terephthalates may leach carcinogens. PET plastic is recyclable and about 25% of PET bottles in the US today are recycled. The plastic is crushed and then shredded into small flakes which are then reprocessed to make new PET bottles, or spun into polyester fiber. This recycled fiber is used to make textiles such as fleece garments, carpets, stuffing for pillows and life jackets, and similar products. Products made of #1 (PET) plastic should be recycled but not reused. 23 #2 - HDPE (High-Density Polyethylene) HDPE plastic is the stiff plastic used to make milk jugs, detergent and oil bottles, toys, and some plastic bags. HDPE is the most commonly recycled plastic and is considered one of the safest forms of plastic. It is a relatively simple and cost- effective process to recycle HDPE plastic for secondary use. HDPE plastic is very hard-wearing and does not break down under exposure to sunlight or extremes of heating or freezing. For this reason, HDPE is used to make picnic tables, plastic lumber, waste bins, park benches, bed liners for trucks and other products which require durability and weather- resistance. Products made of HDPE are reusable and recyclable. 24  #3 – PVC (Polyvinyl Chloride) PVC is a soft, flexible plastic used to make clear plastic food wrapping, cooking oil bottles, teething rings, children’s and pets’ toys, and blister packaging for myriad consumer products. It is commonly used as the sheathing material for computer cables, and to make plastic pipes and parts for plumbing. Because PVC is relatively impervious to sunlight and weather, it is used to make window frames, garden hoses, arbors, raised beds and trellises. PVC is dubbed the “poison plastic” because it contains numerous toxins which it can leach throughout its entire life cycle. Almost all products using PVC require virgin material for their construction; less than 1% of PVC material is recycled. Products made using PVC plastic are not recyclable. While some PCV products can be repurposed, PVC products should not be reused for applications with food or for children’s use. 25  #4 – LDPE (Low-Density Polyethylene) LDPE is often found in shrink wraps, dry cleaner garment bags, squeezable bottles, and the type of plastic bags used to package bread. The plastic grocery bags used in most stores today are made using LDPE plastic. Some clothing and furniture also uses this type of plastic. LDPE is considered less toxic than other plastics, and relatively safe for use. It is not commonly recycled, however, although this is changing in many communities today as more recycling programs gear up to handle this material. When recycled, LDPE plastic is used for plastic lumber, landscaping boards, garbage can liners and floor tiles. Products made using recycled LDPE are not as hard or rigid as those made using recycled HDPE plastic. Products made using LDPE plastic are reusable, but not always recyclable. You need to check with your local collection service to see if they are accepting LDPE plastic items for recycling. 26  #5 – PP (Polypropylene) Polypropylene plastic is tough and lightweight, and has excellent heat- resistance qualities. It serves as a barrier against moisture, grease and chemicals. When you try to open the thin plastic liner in a cereal box, it is polypropylene. This keeps your cereal dry and fresh. PP is also commonly used for disposable diapers, pails, plastic bottle tops, margarine and yogurt containers, potato chip bags, straws, packing tape and rope. Polypropylene is recyclable through some curbside recycling programs, but only about 3% of PP products are currently being recycled in the US. Recycled PP is used to make landscaping border stripping, battery cases, brooms, bins and trays. However, #5 plastic is today becoming more accepted by recyclers. PP is considered safe for reuse. To recycle products made from PP, check with your local curbside program to see if they are now accepting this material. 27  #6 – PS (Polystyrene) Polystyrene is an inexpensive, lightweight and easily-formed plastic with a wide variety of uses; disposable styrofoam drinking cups, take-out “clamshell” food containers, egg cartons, plastic picnic cutlery and foam packaging, rigid foam insulation and underlay sheeting for laminate flooring used in home construction. Because polystyrene is structurally weak and ultra-lightweight, it breaks up easily and is dispersed readily throughout the natural environment. Beaches all over the world have bits of polystyrene lapping at the shores, and an untold number of marine species have ingested this plastic with immeasurable consequences to their health. Polystyrene may leach styrene, a possible human carcinogen, into food products (especially when heated in a microwave). Chemicals present in polystyrene have been linked with human health and reproductive system dysfunction. Recycling is not widely available for polystyrene products. Most curbside collection services will not accept polystyrene, which is why this material accounts for about 35% of landfill material. While the technology for recycling polystyrene is available, the market for recycling is small. 28 Polystyrene should be avoided where possible.  #7 – Other (BPA, Polycarbonate and LEXAN) The #7 category was designed as a catch-all for polycarbonate (PC) and “other” plastics, so reuse and recycling protocols are not standardized within this category. #7 plastics is the potential for chemical leaching into food or drink products packaged in polycarbonate containers made using BPA (Bisphenol A). BPA is a xenoestrogen, a known endocrine disruptor. # 7 plastics are used to make baby bottles, sippy cups, water cooler bottles and car parts. BPA is found in polycarbonate plastic food containers often marked on the bottom with the letters “PC” by the recycling label #7. Some polycarbonate water bottles are marketed as ‘non- leaching’ for minimizing plastic taste or odor, however there is still a possibility that trace amounts of BPA will migrate from these containers, particularly if used to heat liquids. A new generation of compostable plastics, made from bio-based polymers like corn starch, is being developed to replace polycarbonates. These are also included in category #7, which can be confusing to the consumer. These compostable plastics have the initials “PLA” on the bottom near the recycling symbol. Some may also say “Compostable.” #7 plastics are not for reuse, unless they have the PLA compostable coding. When possible it is best to avoid #7 plastics, especially for children’s food. Plastics with the recycling labels #1, #2 and #4 on the bottom are safer choices and do not contain BPA. PLA coded plastics should be thrown in the compost and not the recycle bin since PLA compostable plastics are not recyclable. The plastics industry has conformed to regulations by applying the required codes to consumer products, but it is up to individuals to read and understand the codes. By understanding these simple classifications, we can best use plastics to our advantage while minimizing the health and disposal issues that may otherwise arise. 29  ENVIRONMENTAL IMPLICATIONS  Plastic recycling prevents damage to the environment via excessive landfilling and use of non-renewable resources.  The process is also largely environmentally safe, with the only effluent being from the washwater.  This is recycled in the plant as much as possible to minimise water use and when it is finished with it is still sufficiently clean to be dumped into the sewers. 30  FINANCIAL ASPECTS  Plastic recycling is an expensive business. The process uses huge amounts of electricity, particularly during the extruding step, and the equipment used is also expensive leading to high overheads.  In addition, sale prices are variable: people prefer to buy virgin plastic if it is available, thus prices fluctuate with the availability of virgin plastic. 31 Uses of recycled plastic  Recycled plastic can be used for anything that virgin plastic is used for except the packaging of food.  In general, the pelletised plastic is sold by the recycling company to other companies for moulding into a wide variety of products.  Some of it is used locally and the remainder is exported to Asia and the United States.  PET is often made into fibres to make carpet and clothing, while the "other" stream is usually used to make a wood substitute. 32 Recycled plastics 33 A report on the production of carrier bags made from recycled rather than virgin polythene concluded that the use of recycled plastic resulted in the following environmental benefits: reduction of energy consumption by two-thirds production of only a third of the sulphur dioxide and half of the nitrous oxide reduction of water usage by nearly 90% reduction of carbon dioxide generation by two-and-a- half times A different study concluded that 1.8 tonnes of oil are saved for every tonne of recycled polythene produced. 34 Reusing of plastics  Reusing plastic is preferable to recycling as it uses less energy and fewer resources. Long life, multi-trip plastics packaging has become more widespread in recent years, replacing less durable and single-trip alternatives, so reducing waste.  For example, the major supermarkets have increased their use of returnable plastic crates for transport and display purposes four-fold from 8.5 million in 1992 to an estimated 35.8 million in 2002. They usually last up to 20 years and can be recycled at the end of their useful life. 35 Reusing of plastics  According to a 2001 Environment Agency report, 80% of post-consumer plastic waste is sent to landfill, 8% is incinerated and only 7% is recycled. In addition to reducing the amount of plastics waste requiring disposal, recycling plastic can have several other advantages:  Conservation of non-renewable fossil fuels - Plastic production uses 8% of the world's oil production, 4% as feedstock and 4% during manufacture.  Reduced consumption of energy.  Reduced amounts of solid waste going to landfill.  Reduced emissions of carbon-dioxide (CO2), nitrogen-oxide (NO) and sulphur- dioxide (SO2). 36 Items made from recycled materials 37 Recycling plastics  When plastics are recycled, they are usually used to make a lower quality form of plastic.  For example, plastic water bottles cannot be recycled into new plastic water bottles but the resins from them can be used to make fibers for pillows or tote bags.  Other common products that are made from recycled plastics include toys, drainage pipes, tables, car parts, etc. A majority of these items cannot be recycled, thus making plastics a dead- end waste stream. 38 EDIBLE CUTLERY  Researcher Narayana Peesapaty (2010)-Hyderabad  Spoons made from carrot, beetroot, spinach  Chopsticks and bowls which are edible  Edible and biodegradable plates 39  How fibreglass is recycled The production of cement is dependent on large quantities of sand. And sand is also the main constituent of glass, and thus also of fibreglass. Fibreglass additionally contains polyester which can be used as an energy source in cement production, thereby replacing the use of fossil fuels. The recycling process: Fiberline sends the fibreglass waste to Zajons in Germany Zajons consolidates the fibreglass in a giant crusher and adjusts the calorific value by adding other types of recycling materials The waste is sent to the cement manufacturer Holcim feeds the waste to the huge kilns that produce the finished cement. Recycling 1000 tonnes of Fiberline profiles in cement manufacture saves up to: 450 tonnes of coal, 200 tonnes of chalk, 200 tonnes of sand and 150 tonnes of aluminium oxide (Source: Holcim, 2010). And the recycling process produces no dust, ash or other residues. 40  The Circular Economy Package was created to help businesses and consumers make the transition to a stronger and more circular economy where resources are used in a more sustainable way. The proposed actions contribute to 'closing the loop' of product lifecycles through greater recycling and re-use, and bring benefits for both the environment and the economy. Examples: – using kenaf, rice husk, coconut fiber, palm husk, mud, mango seed, etc.. 41 5R’s for a greener world 1. Reduce 2. Reuse 3. Recycle 4. Renew 5. Respect 42  5R’s for a greener world  REDUCE  Reduce your stuff. Commercialization has resulted in an overabundance of stuff in many homes and businesses across the world. Take a look around you – how much of that stuff do you really need? Before you purchase another item – ask yourself – do I really need this?  Reduce the amount of driving you do. If you can walk to work, work from home or telecommute, then do it and do it as much as you can. Rather than jumping in the car to run to town for an item here or there, plan your outings to incorporate the most logical flow for your errands and save them for one or two days at a time.  Reduce your energy consumption. Replace light bulbs with high efficiency ones as they burn out. Replace appliances with Energy Saving models as it becomes necessary and lower your thermostat a degree or two and throw on a sweater instead.  Reduce your subscriptions to newspapers or magazines – its all online anyhow!!  Reduce the number of cleaning supplies in your house. 43 5R’s for a greener world  REUSE  In my office alone, there are so many items that can be reused – from manila folders and envelopes (reuse for scratch paper), to printer paper.  Around the house, think before you toss. Can this item be used again (safe and sanitary, of course)?  Take your own shopping bags to the market or any store for that matter.  Pass on outgrown clothing to a sibling or donate to charity 44 5R’s for a greener world  RECYCLE  Recycling is not just separating your green glass from your brown or collecting newspapers. Send your ink jet and laser printer cartridges back for recycling – many cartridge companies will even provide you with postage free return shipping.  You can recycle car batteries, tires, and motor oil. 45 5R’s for a greener world  RENEW  Renewable resources that is! Always choose paper over plastic when given the choice. Paper is a renewable resource. We can plant more trees. Petroleum used for making plastic is not. When it is gone, its gone.  What about solar power and wind generated power? These are viable energy sources but we need to educate the masses – increase the numbers of stations 46 5R’s for a greener world  RESPECT  We only have one Earth and we all have to live on it together. Respect your environment and try to leave the smallest footprint possible. 47 8R 48 THE END video on recycling 49