TOHOKU UNIVERSITY
Yoshioka Lab., Graduate School of Environmental Studies, Tohoku University
6th Regional 3R Forum in Asia and the Pacific
The use of waste plastics as
chemicals and fuel
Tohoku University, Japan
Prof. Toshiaki Yoshioka
Mechanical recycling of PET bottles
1:solution of bags 2:compression
3:separation by hand 4:crushing
Mechanical recycling of PET bottles
5.washing 6.Wind sorting
Recycled PET flakes
Recycle Products from waste PET bottle
PEPP PS
PVC PET
Plastics
Additives
The kinds of Resins and Additives in Plastic
Materials (2013)Resins
Thermoplastics resin 85
Thermosetting resin 37
natural macromolecule, others 35
Total 153
Additives
Plasticizer 46
Stabilizer 39
Oxidation inhibitor 30
Ultraviolet absorbing agent 42
Antistatic 18
Flame retardant 24
Organic blowing agent 5
Lubricant 7
Antifungal 17
Crystalline nucleus agent 2
Total 230
Feedstock Recycling Facilities ( -2013)
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 Refine Technology (Kawasaki)
Monomer B to B: 22,000t
Showa Denko(Kawasaki)
Gasification: 60,000t
JFE Steel (Kawasaki)
40,000t/30,000t
Blast furnace/Coke Oven
(complied with C&P recycling law, 2005)
11 Facilities:
Monomer 1
Blast furnace 3
Coke oven 5
Gasification 3
Liquefaction 0
(Total 357 Kt/y)
Amount of contract for each recycling method in 2013
CategoriesAmount
(tons)
Share for total
(%)
Share for FR
(%)
Feedstock
Coke oven 192,503 29 61
Blast furnace 38,232 6 12
Gasification 85,463 13 27
Liquefaction 0 0 0
Total 316,198 47 100
Mechanical 356,626 53
Total of CP-P 672,824 100
Outline of Steel Making Process
Sintering machine
Molten iron
Slag
Coking coal
Iron Ore
Steam coal
(pulverized coal < 200mesh, 80%)
Pig iron making process Steel making process
converter
continuous
caster
Rolling process
Steel products
Slabs/Billet
Converter gas
Blast furnace gas
Coke oven gasTar
Coke oven
Coke
Coal
Sintered ore
--1000 C
--1200 C
Blast furnace
--2000 C
--1500 C
Usage of waste plastics in blast furnace
Sintering machine
Molten iron
Slag
Coking coal
Iron Ore
Pig iron making process Steel making process
converter
continuous
caster
Rolling process
Steel products
Slabs/Billet
Converter gas
Blast furnace gas
Coke oven gasTar
Coke oven
Coke
Coal
Sintered ore
--1000 C
--1200 C
Blast furnace
--2000 C
--1500 CWaste Plastics
Steam coal
(pulverized coal < 200mesh, 80%)
Usage of waste plastics in cake oven
Sintering machine
Molten iron
Slag
Coking coal
Iron Ore
Steam coal
(pulverized coal < 200mesh, 80%)
Pig iron making process Steel making process
converter
continuous
caster
Rolling process
Steel products
Slabs/Billet
Converter gas
Blast furnace gas
Coke oven gasTar
Coke oven
Coke
Coal
Sintered ore
--1000 C
--1200 C
Blast furnace
--2000 C
--1500 C
Waste Plastics
Gasification (KPR process)
O2 +
Steam
Law-temperature
gasification furnace(fluidized-bed type)
600℃
High-temperature
gasification furnace(swirling type)
1400℃
Scrubber
CO shift
De-sulfur
H2
CO2
Caustic soda
raw material
Silo
O2 +
Steam
Quench Sodium sulfite
raw material
RPF
Outline of Gasification (KPR process)
Waste
Plastics
Pre-treatment
plantGasification Scrubber CO shift De-sulfur
H2CO2NaClSlag
Metal
recoveryDry ice
Liquefied CO2
Metal
Building
materials
Slag
treatment
Caustic
Soda
Compressor
195T/D
175T/D
Sodium sulfite
(NaHSO3)
NaOH
Law-temperature
High-temperature
NH3H2 business
S
*future*future
Outline of liquefaction process flow
M
A
A
M
MM
M
M
残渣
残渣冷却コンベア
溶融槽
熱分解装置
脱塩装置
脱塩装置ホッパー
造粒物サイロ
乾燥機
造粒機
磁選
風選
破砕機廃プラスチック(ベール状に減容 されたもので搬入)
油化工程
前処理工程 脱塩化水素・分解工程
乾燥機サイクロン脱塩ガス 燃焼炉
塩化水素吸収塔
塩酸タンク
分解油ドラム 重質油タンク
軽質油タンク
生成油回収塔
排ガス燃焼装置
生成油回収工程
塩酸処理工程 排ガス処理工程
中質油タンク
A
A
M
M
Cost estimation in the liquefaction of packaging waste plastics
Sales of Waste Plastics Amount of
treatment
Unit price JPY Total/1000
JPY
ratio/%
Amount of treatment 14000 t 68,000/t 952,000 94.8%
Product oil Total sales 51,800 5.2%
light oil (sale) 1106 KL 20/L 22,120 2.2%
middle oil (sale) 420 KL 50/L 21,000 2.1%
heavy oil (sale) 434 KL 20/L 8,680 0.9%
Total sales 1,003,800 100.0%
Running cost Amount of
treatment
Transport unit
price/JPY
Total/1000
JPY
ratio/%
light-oil (shipment) 1106 KL 16.3/L 18,028 1.8%
middle-oil (shipment) 420 KL 2/L 840 0.1%
heavy-oil (shipment) 434 KL 2/L 868 0.1%
Expenses 896,375 86.7%
Total running cost 916,111 91.3%
Gasins 87,689 8.7%
Comparison of the composition of residues with ilmenite
0 20 40 60 80 100
800
900
1000
1100
Ilmenite ore 50.0
62.0
59.7
56.8
61.8
31.0
31.0
30.2
29.8
43.5 6.5
9.9
11.0
7.2
6.7
0.2
2.4
carbon
Content (%)
Tem
pera
ture
(oC
)OthersFe2O3TiO2
↓residues
↓
Energy capacity of fuel, materials, and resources
LP
G
Kero
sen
e
City
gas
Heavy o
il
coal
woo
d
coke
PV
C
PS
PP
PE
PET
In
cin
eratio
nw
aste
Natu
ral g
as
fiber
pap
er
gla
ss
garb
ag
e
0
2,000
4,000
6,000
8,000
10,000
12,000
Kcal/kg
Reduction of CO2 emissions in key industries
by waste plastic use
Coal
consumption (t)CO2
emission(t)
CO2
reduction(t)Reduction
ratio(%)
5,54 million
6.32 million
3.0
4.256.92
→42.85 million
149.35
→143.03 million
Power
generation
Steel
industry
Cement
industry
80.04
→ 64.39 million
184.72
→179.18 million
3.46 million 15.39.50 million
→0
21.92
→18.56 million
Paper/pulp
industry 1.27 million 16.45.11million
→012.73
→10.64 million
Circles of 50km and 100km radius around the
each basic industry plants in Japan
Steel industry
Power plant
Petroleum industry
Cement industry
Paper & Pulp industry
50km radius
100km radius
Transfer Technology (TransTech)
Present society suffering from some issues
Ideal future society
Selection of Tech.
TransTech
TransTech
TransTech
New Tech.
Selection of Tech.
Selection of Tech.
New Tech.
New Tech.
Thank you for your attention!
23