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Current Status of Containers & Packaging Plastics Recycling in - - PowerPoint PPT Presentation

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Asia Pacific Conference on Recycling of Plastics Current Status of Containers & Packaging Plastics Recycling in Japan February 2007 Yoshimi Ozaki General Manager, General Planning Dept. Plastic Waste Management Institute, Japan Email:

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SLIDE 1

Current Status of Containers & Packaging Plastics Recycling in Japan

Yoshimi Ozaki General Manager, General Planning Dept. Plastic Waste Management Institute, Japan Email:

  • zaki@pwmi.or.jp

Web site: http://www.pwmi.or.jp

February 2007

Asia Pacific Conference on Recycling of Plastics

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SLIDE 2

PWMI 2

Presentation Topics

1á. ALegislative & Voluntary Framework 2 . Flow of Plastic Products, Wastes and Recycling 3ñ. ñStatus of Recycling under C & P Recycling Law 4• . Summary

(5. Introduction of PWMI)

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SLIDE 3

3

Fundamental Law for Establishing a Sound Material-Cycle Society Containers & Packaging Recycling Law Home Appliance Recycling Law Construction Materials Recycling Law Food Recycling Law End of Life Vehicles Recycling Law Green Purchasing Law

(Full enforce.: Apr 2000) (Apr 2001) (May 2002) (Apr 2001) (Jan 2005) (Apr 2001) (Apr 2001) (Apr 2001) (Jan 2001) (Basic framework law)

Revised Waste Management Law Law for Promotion of Effective Utilization of Resources

(Proper waste management) (Promotion of recycling) (Individual product recycling law)

Source: Ministry of Economy, Trade and Industry

Legislative framework

Legislative Framework to Form Sustainable Development Society

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SLIDE 4

PWMI 4

I ndustrial Structure Council Guidelines for Waste and Recycling

The guidelines Indicate measures to be taken by businesses for waste treatment and recycling with aim of promoting voluntary actions, with respect to 35 product categories and 18 business sectors. <Example> Plastic product category: PET bottles Collection rate 80% (2014) EPS fish boxes and packaging for home appliance Recycling rate 75% (2010) PVC agriculture films Recycling rate 70% (2006) PVC pipes and fittings Recycling rate 70% (2010) Distribution business sector: Japan Franchise Association Reduction of shopping bag 35% (2010 vs 2000) Japan Department Stores Association Reduction of packaging materials 25% (2010 vs 2000)

Legislative framework

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SLIDE 5

5

Position of Guidelines in Legislative Framework

Municipal Solid Waste

Annual total: ca. 50 million t Annual total: ca. 400 million t

Others ( PC, etc.) Furniture Clothes Home appliance

Industrial Waste

Law for Promotion of Effective Utilization of Resources Product Related Measures

By-products (waste) Related Measures Reducing waste generation (‘Reduce’ p}

  • licy)

Reusing parts etc. (‘Reuse’ policy) Recycling as raw materials (‘Recycling’ policy) Containers and Packaging Recycling Law Industrial Structure Council Guidelines by Product Category ELV Recycling Law Home Appliance Recycling Law Food recycling Law Food Recycling Law Law for Management of Animal Excrement

Kitchen waste, (Business waste, Household waste):

  • ca. 30%

Containers/ Packaging:

  • ca. 25%

Paper:

  • ca. 25%

Automobiles:

  • ca. 10%

Industrial Structure Council Guidelines By Industry Sector

Construction: 18% Agriculture: 22% Food processors: 3% Electricity, gas, heat, water utilities: 22% Steel: 8% Others: 10% Chemical: 5% Pulp/paper: 9% Mining: 7%

Construction Materials Recycling Law

(business waste only) 2% 2% 2%

Green Purchasing Law

Effective use of resources

Source: METI

  • Prevent by- product generation
  • Promote recycling of by- products, etc.
  • Save resources
  • Design for environment
  • Selectively collect and recycle products, etc.

Legislative framework

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SLIDE 6

6

Resin Production

14,510

Domestic Consumption

11,590

Post-use Discharge

9,140

Processing waste

690

Production waste

230

Total Discharge

10,060

Municipal

5,200

Industrial

4,860

Mechanical Recycl.

1,850 (18%) Liquefaction/Blast Furnace 290 (3%) Solid Fuel 620 (6%)

  • Incinerat. with Power
  • Gen. 2,310(23%)
  • Incinerat. with Heat

Utilization 1,210

(12%) Incineration only 1,230 (12%) Landfill 2,550 (26%)

Reclaimed Products

960 Export Import Unutilized: 3,780 (38%) Utilized: 6,280 (62%)

Flow of Plastic Products, Wastes, and Recycling (2005)

Unit: 1000t Plastics Flow

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SLIDE 7

PWMI 7

Breakdown of Plastics Waste Discharge (2005)

25% 23% 15% 7% 4% 3% 4% 19%

Elect ric & Machinery Cont ainers & Packaging Building Transport at ion Agricult ure Household Ot hers Product ion loss

Municipal Plastics Waste (5,200 Kt)

20% 3% 6% 71%

Containers & Pac kaging Household

  • Elect. & Machinery

Others

Industrial Plastics Waste (4,860 Kt)

Containers & packaging accounts for 71% Electric & machinery and containers & packaging account for 25%, and 23% each.

Plastics Flow

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SLIDE 8

8

Containers and Packaging Recycling Law

Paper C&P, Plastic C&P Glass bottles, PET bottles Large sized company Paper C&P, Plastic C&P Glass bottles, PET bottles Medium sized company Not applied Small sized company 1997 2000 June 1995 Promulgation April 1997 Partial Enforcement (Glass bottles, PET bottles) April 2000 Full Enforcement (Glass bottles, PET bottles, Paper C&P, Plastic C&P) ê

Source: METI

(Driver: Concern about remaining space of disposal sites)

Recycling under C&P Recycling Law

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SLIDE 9

9

Containers and Package Recycling Law

Consumers Municipalities Recyclers

Sorted discharge Transportation and recycling

  • f “items to meet sorting criteria”

Sorted collection Payment of recycling costs Declaration for amount of sorting plastic waste Bidding price Payment of recycling costs

Designated manufactures/users

Business entities utilizing recycled products

The Japan C&P Recycling Association

Supply Supply

Recycling under C&P Recycling Law

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SLIDE 10

10

Method of Plastics Recycling

Solid Fuel (RPF, RDF) Incineration with power generation

Not specified as recycling method.

(Cement kiln and, RPF are included as an emergent and supplementary method in the amendment made recently.)

Cement kiln Fuel Energy recovery Chemical feedstock Gasification, Liquefaction Coke oven

Blast furnace (as reducing agent)

Degradation to monomer Chemical recycling (Feedstock recycling)

Prevail over chemical recycling

Recycling to make

  • Plastic raw material
  • Plastic product

Mechanical recycling

Positioning under law Method of recycling Category

Recycling under C&P Recycling Law

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SLIDE 11

PWMI 11 6 17 25 38 49 59 57 64 64 1 5 12 23 46 50 55 59 11 23 12 4 5 5 4 4 6 2 38 3 1 1 3 2 2 2 3

20 40 60 80 100 120 140 160 1997 1998 1999 2000 2001 2002 2003 2004 2005

Ot hers Molded produc t Bot t les Sheet Fiber

Source: Japan Containers and Packaging Recycling Association

× 1000t

Recycling of PET Bottles

PET bottles are mostly recycled to make Fibers, Sheets, and recently PET bottles as well.

Recycling under C&P Recycling Law

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SLIDE 12

PWMI 12

Monomerization Process

Process outline

PET bottle flakes Methanol Ester exchange DMT

separation/ refinement

PTA production BHET

refinement (decoloration/ distillation, etc.)

Hopper Liquid-state polymerization Solid-state polymerization Resin for PET bottles Depolymerization

Reference: Teijin and Aies pamphlets Recycling under C&P Recycling Law

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SLIDE 13

PWMI 13 2 12 24 47 86 95 66 11 58 103 140 197 181 34 59 65 83 76 47 53 12 12 13 8 23 52 86 113 176 287 160 15 18 7 12

100 200 300 400 500 600 700 2000 2001 2002 2003 2004 2005 2006

Mec hanic al rec yc ling Liquefac t ion Blast furnac e Coke oven Gasific at ion

Currently mechanical recycling shows a big increase. As a result, chemical recycling is being depressed.

(594) (447) (368) (260) (67)

Recycling of Plastic C&P by Method

Chemical Recycling

(529) (169)

( ðplan ) ‰ Source: Japan Containers and Packaging Recycling Association

Take back volume by JCPRA for Recycling (x1000t)

Recycling under C&P Recycling Law

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SLIDE 14

PWMI 14

Kobe Steel (Kakogawa) Blast furnace: 10,000t Nihon Steel (Yahata) Coke Oven: 20,000t Nihon Steel (Oita) Cokes Oven: 25,000t Teijin Fiber (Tokuyama) Monomer B to B: 62,000t Nihon Steel (Nagoya) Coke Oven: 50,000t JFE Steel (Chiba) Gasification: 20,000t Nippon Steel (Kimitsu) Coke Oven: 20,000t Sapporo Plastic Recycling Liquefaction: 12,000t Nihon Steel (Muroran) Coke Oven: 20,000t Rekisei Oils (Niigata) Liquefaction: 6,000t JFE Steel (Fukuyama) Blast furnace/Coke Oven : 40,000t Ube( _Ube) Gasification: 30,000t PET Reverse(Kawasaki) Monomer B to B: 22,000t Showa Denko( Kawasaki) Gasification: 60,000t JFE Steel (Kawasaki) 40,000t/30,000t Blast furnace/Coke Oven

Large Scaled Chemical Recycling Facilities

( ácomplied with C&P recycling law, 2005)

15 Facilities:

Monomer 2 Blast furnace 3 Coke oven 5 Gasification 3 Liquefaction 2 (Total 470 Kt/y) Recycling under C&P Recycling Law

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SLIDE 15

PWMI 15

Breakdown of Usage of Recycled Product by Mechanical Recycling

Industrial parts 1% Miscellaneous daily goods & Others 6% Gardening & Agriculture 2%

Source: õJapan Container and Package Recycling Association

Electricity/ Communication 8% Building & Construction 7% Bar, Survey & Boundary Marker/ Imitation wood post 12%

Pallet 31% Plastic board 20% Resin 13%

Recycling under C&P Recycling Law

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SLIDE 16

PWMI 16

Plastic waste (PE, PP, PVC, PS, ABS) Wooden waste

Crushing

Compounding

+

Molding

+

Additives

Applications: Exteriors with resistance to decay, weathering, and termite attack

Source: HP of Ecowood Co., Ltd. HP of Misawa Homes Co., Ltd.

Wood Plastic Recycled Composites

JIS (Japanese Industrial Standards) for WPRC was set in April 2006 (JIS A5741:2006). Accelerated growth of application/demand is expected.

Recycling under C&P Recycling Law

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SLIDE 17

PWMI 17

Demand for RPF 2006 1,050 Kt 2008 1,310 Kt Production 2006 700 Kt

RPF (Refuse Paper & Plastic Fuel)

Appearance of RPF RPF Production process

Source: Japan RPF Association, The Recycling Economy Times

Diameter: 6 – 50 mm Calorie: 5,000 – 10,000 kcal/kg (Can be adjusted by varying paper content.) Ash content: 7 % max. Application: Boiler fuel, RPF power generator, etc.

Recycling under C&P Recycling Law

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SLIDE 18

PWMI 18 50 51 51 51 51 52 51 52 52 52 52 1,103 1,106 1,105 1,114 1,112 1,118 1,111 1,132 1,124 1,111 1,106 40 45 50 55 60

1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003

800 900 1,000 1,100 1,200

Tot al Discharge Discharge per capit a Source: Ministry of the Environment

Priority order: Reduction, Reuse, Recycling Waste discharge volume has not been decreasing. The law is working for the promotion of recycling, but not working well for the reduction of waste discharge volume of citizens.

g/day/person Million ton

Total Discharge Discharge per Capita

Reduction of Waste Discharge

Enforcement of C&P Recycling Law Glass & PET bottles Paper & Plastics

Recycling under C&P Recycling Law

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SLIDE 19

PWMI 19

High Costs in Recycling and Sorted Collection

  • Recycling costs borne by businesses continue to increase,

due to the drastic increase of plastic C&P recycling cost.

Source: Japan Containers and Packaging Recycling Association

40 69 91 91 84 75 33 65 145 215 290 352 423

100 200 300 400 500 600 1997 1998 1999 2000 2001 2002 2003 2004 2005 Paper Plast ic C&P PET bot t le Glass bot t le

Recycling cost (100 mill. Yen)

164 269 334 399 451 478

  • Additionally nominal cost borne by municipalities in sorted

collection, rough selection & storage of C&P waste : I

  • ca. 300 Billion Yen (Estimated by Ministry of Environment)

Recycling under C&P Recycling Law

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SLIDE 20

PWMI 20

Reason of High Recycling Cost

Source: ( Japan Container and Package Recycling Association

  • Average contract recycling

price of plastic C&P stays high, due to high price of mechanical recycling arising from its priority

  • ver other recycling methods.
  • Increase of collection volume

continues.

  • Balance in recycling capacity /

collection volume is tight.

  • 20

20 40 60 80 100 120 1997 1999 2001 2003 2005

PET Bottle Plastic C&P (Average) Plastic Mechanical Recycling Plastic Chemical Recycling

Contract Price for Recycling

1,000\/t Recycling under C&P Recycling Law

Plastics PET bottles

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SLIDE 21

PWMI 21

10 17 23 35 40 46 49 46 45

50 100 150 200 250 300 350 400 450 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 10 20 30 40 50 60

Recycling Capacit y Collect ed Volume Recycled Volume Collect ion Rat e

  • Burden of collection cost on municipalities and strong demand for PET in China

caused some municipalities’ movement to export collected PET bottles in order to recover a cost in their sorted collection.

  • Consequently the decrease of domestic recycling quantity is taking place.

Export of collected PET Bottles

[K tons] [%]

(Plan)

(Source: The council for PET bottle recycling) Recycling under C&P Recycling Law

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SLIDE 22

PWMI 22

  • Introduction of measures to reduce waste generation:
  • Measures to appoint 3R Meisters who promote nationwide minimization of

waste generation.

  • Measures to promote voluntary reduction planed by businesses.

(Reduction of delivery of shopping bags at supermarkets is to be implemented under this voluntary reduction program.)

  • Creation of a system in which designated businesses

provide funds to municipalities. (Details under discussion)

  • Introduction of measures to lead municipalities to stop

export of their collected PET bottles, and to recycle them in accordance with the law.

  • Addition of energy recover method to the recycling methods.

(Emergent and supplementary positioning)

Amendment of C & P Recycling Law

Recycling under C&P Recycling Law

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SLIDE 23

PWMI 23

  • Legislative framework to form a sustainable development

society has been built and has been being revised.

  • Various recycling methods have been developed for

recycling of plastics waste and have been being commercially operated under the C&P recycling law.

  • However, the recycling under the C&P recycling law is

facing challenges such as unchanged waste generation levels, high recycling costs of plastics and export of collected PET bottles.

  • Accordingly, last year were made some amendments of

the C&P recycling law, that put more stress on reduction of waste generation, in accordance with Basic Framework Law for Sustainable Development Society.

Summary

Summary

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SLIDE 24

PWMI 24

  • Foundation:

1971

  • Present Members:

18 corporations (resin manufactures), 3 organization, 4 supporting members

  • Mission:

To research and develop systems for optimal processing of plastic waste and effective use of processed waste as a resource, and to promote the use of these systems.

  • Examples of recent activities:
  • Development of recycling technologies for plastics waste.

* Recycling of PC resin of CDs (2004). * Liquefaction by catalytic cracking using waste FCC catalyst (2005 ~ ). * Recycling of agriculture PO films by dry washing process (2006).

  • LCA based study.

* Benefit of usage of plastic products (2003). * Eco-efficiency of plastics recycling methods under the C&P recycling law (2004, 2006).

I ntroduction on Plastic Waste Management I nstitute, Japan

Introduction on PWMI