The Best Practice on the Reduction of Plastic Waste

Development of New Recycling System

for Used Plastics

Kazuyuki Hirabayashi

Showa Denko K.K. (Japan)

About Showa Denko K.K.

Showa Denko Group (at December 2005)• Number of Group Companies 155• Net Sales (Consolidated) 740.7 billions of yen• Operating Income (Consolidated) 52.1 billions of yen• Net Income (Consolidated) 7.6 billions of yen• Number of Employees (Consolidated) 11,166• Major products

Petrochemicals Sector (Olefins, Organic chemicals, Polyolefins, Plastic products)

Chemicals Sector (Chemicals, Gases and Specialty chemicals, Specialty resins)

Electronics Sector (Hard disks, Compound semiconductors, Rare earth magnetic alloys, Specialty gases for semiconductor processing, Electroceramic materials, Fine carbons and other electronic materials)

Inorganic Materials Sector (Ceramics and Carbons)Aluminum Sector (Aluminum metal, Sheets, Extruded products, Fabricated

products, building materials, engineering and others)

About Showa Denko K.K. Domestic Facilities

Oita Complex

Omachi Plant

Higashinagahara Plant

Chiba Plant

Kawasaki PlantYokohma Plant

Chichibu Plant

Tokuyama PlantOyama Plant

Hikone Plant

Sakai Plant

Kitakata PlantShiojiri Plant

About Showa Denko K.K.Global Subsidiaries

Overseas Production CompaniesP.T. Showa Esterindo IndonesiaTaiwan Showa Chemicals Manufacturing Co., LtdShowa Denko Carbon, Inc.Lianyungang Zaoling Abrasives Co.Ltd.SHOTIC Europa -Industria de Aluminio Lda.SHOTIC (Singapore) Pte. Ltd.Showa Aluminum Corporation of AmericaShowa Aluminium Czech s.r.o.Showa Aluminum (Thailand) Co., Ltd.P.T. Showa Aluminum IndonesiaShowa Aluminum Manufacturing Philippines CorporationBaotou Showa Rare Earth Hi-tech New Material Co., Ltd.Showa Denko (Dalian) Co., Ltd.Showa Denko HD (Malaysia) Sdn. Bhd.Showa Denko HD (Singapore) Sdn. Bhd.

Activity Guidelines regarding Responsible Care (Showa Denko, 1995)

(1) In the total life cycle of chemical substances, we should make our best effort to review and improve the business activities from the viewpoint of ensuring safety / health and protecting the environment.

(2) In the manufacturing activities, we should make best efforts to reduce the burden on the global environment not only by conventional approaches to environmental protection but also by promotion of raw material switching, energy conservation, wastes reduction and recycling, and reduction in the release of chemical substances.

(3) In new product development, new business development and establishment / increase / renewal of facilities, we should make our　 best effort to ensure safety / health and protect the environment.

(4) We should promote R & D and technology development which will contribute to the improvement of safety / health and　 protection of the environment. We should also promote marketing of alternative or new products.

(5) We should investigate the influences of the products and materials we handle on Safety / Health / Environment, and encourage our　 employees to have deep knowledge related to safe use and handling, and also provide our customers with such information.

(6) In overseas business activities, technology transfer and international trading of chemical products, we should give full　 consideration to ensuring safety / health and protecting the environment.

(7) We should comply with the international rules and domestic laws and regulations and make our best effort to cooperate with the　 relevant international organizations and foreign / domestic administrative agencies.

(8) We should positively participate in various activities related to environmental protection and make our best effort to　 communicate with society and communities for better understanding and trust.

Showa　 Denko　 Kawasaki　Plant

- a HFC-125ＨＦＣ １３４ ・

Civil EngineeringMaterials

Derivativematerials

by products

DMOD

Hospitane C

Alanine

GLDA

PAS

EDTA

Glycine

Terephthalonitrile

isophthalonitrile

Acrylonitrile

SHOPRENE

ELASLEN

Vapor Grown CarbonFiber

Special clean gas

Clean S

Pollution preventivecylinders/devices

6ＦＣー１４・ＦＣ－１１

Liquid Ammonia

Nitrous oxide

Ammonium thiosulfate

Liquefied sulfurous acid

Sodium bisulfite

Sodium hypochlorite

Hydrochloric aide

Epitaxial wafer

High purity gas for semi-conductor processing

High purity NH3 CH2 Hbr and BCL3 gas and clean cylinders for them

Surface treatment

Absorption decomposition and recycling

Column for high-speed liquidchromatography

Products flow in the KawasakiPlant

Keihin Industrial Complex

Independent power produce

common salt

Air

Air

Naphtha

Waste plastic

Town gas

Propylene

Special gases

D/L Cystine

HYD

BEH

BHD

APS

SHODEX

APM

Fluorine

Trichloroethylene/TetrachloroethyleneHydrogen Fluoride

Argon

Oxygen

Nitrogen

Caustic Soda

Chlorine

Hydrogen

Wire coating/PVC Rubber modifier

Agrichemical materials/Daconyl

Raw materials for agricultural chemicals

Fodder addotoves

Food additive/VB materials

Food additive

Chelating agent

Biodegradable chelating agent

Cataplasm

Food additives and Aspartame

Photographic chemicals

Photographic chemicals

Cosmetics and high grade permanent wave

Cosmetics and whitening agent

Cosmetics and whitening agent

Decomposed gas

Ammonia

Carbon dioxide

※

＊

＊

＊

※ ＊

Chloroprene rubber

Photographic chemicals

＊ ＊ ＊ ＊

Chemical　 Recycling　of　Waste　 Plastic　

for　 Ammonia　Production

Chemical recycling(3％ )

Liquefaction

Blast furnace feed

Coke oven feed

Recycling(55 ％ ）

Material recycling(15％ )

Thermal recycling(37％ )

Incineration without power generation(18％ )

Landfill(28％ )

<Showa Denko Planｔ >

Perfect Chemical recycling

Recycling as chemical raw materials

（ H2,CO,CO2,Cl,S, etc.）

Gasification

Waste Plastics

(10mil　ton/year)

Disposal(45 ％ )

Waste Plastics recycling and disposal 　 in 　 Japan

計画地

Location

凡　例Pre-treatment

gasification

Kawasaki　plant

Ｎ

Ammonia　plant

195T/D

175T/D

(1)　 Scale

(2)　 Plant plot

(1)Pre-treatment plant　　 Showa Denko K.K. kawasaki plant　　 Area ；　６ , ５９０ｍ２

(2)Gasification plant　 Showa Denko K.K. kawasaki plant　 Area 　；　７ , ４００ｍ２

SHOWA DENKO PLANT

・ Hydrogen 346,000Nm3/D

・Waste plastics

・ Ammonia

Waste Plastics treatment process flow

Recovered

Metal

Law-temperature

gasifier

Scrubber

Neutralization

Slag treatment

De-sulfur

CO shift

GasCompressor

High-temperature

gasifier

Construction

materials

Caustic sodaraw materials

Sodium sulfite(NaHSO3)

Dry iceLiquefied CO2

Ammonia

Waste PlasticsStorage

Crusher

Separator

Feeder

Extruder

Metal

RPF ( Recycle Plastic Fuel )

H2 business

Pre-treatment plant Gasification plant

RPF

Metal

Slag

NaCl

S

CO2

H2

WastePlastics

Pre-treatmentplant

Gasification Scrubber CO shift De-sulfur

H2CO2NaClSlag

RecoveredMetal

Boiler

Dry iceLiquefied CO2

Metal

Construction

materials

Slag treatment

CausticSoda

GasCompressor

195T/D

175T/D430T/D

Sodium sulfite(NaHSO3)

0.65 T/D8.2 T/D5.8 T/D5.8 T/D

NaOH

Law-temperatureHigh-temperature

Component of Waste Plastics (Example)C H O N Cl S Metal Slag Total

74.2 10.7 6.3 0.4 2.5 0.1 2.9 2.9 100wt%144.7 20.9 12.3 0.8 4.9 0.2 5.6 5.6 195T/D

Process 　 Flow　 to　 produce　 Ammonia　Gas　 from　Waste　 Plastic

AmmoniaH2 business

S

Japanese　 Containers　 and　Packaging　 Recycling　 System

Flow　 of　 Containers　 and　 Packaging　Recycling

Consumers

The　 Japan　 Containers　 and　 Packaging　

Recycling　 Association

Showa　 Denko

Recycler

Specified　 business　entities

Manufacturing　 orselling　 companies

Ｍｕｎｉｃｉｐａｐａｌｉｔｉｅｓ(pressing　and　 stock)

Ｓｅｌｅｃｔｉｖｅ　ｄｉｓｃａｒｄ

Selective

　

collection

Selling　 container　 or　 packaging

Payment　 of　 recycling　 feePayment　 of　fees　 for　 recycling

Bidding

8% 92%

Payment　for　recycle　 fee

Transport

Plastic　 containers

Pre-Treatment　 process

Ｗａｓｔｅ　Ｐｌａｓｔｉｃ

Crasher

Extruder

RPF (Recycle Plastic Fuel　 for　Gasification)

Gasification　 Plant

Gasification　Plant

O2 + Steam

Metal

Law-temperature gasifier(fluidized-bed type)

High-temperature gasifier(swirling type)

Slag

ScrubberCO shiftDe-sulfur

H2

CO2

RPF

Caustic sodaraw material

Gasification plant outline

Silo

Perfect Chemical Recycling (zero-emission)

From Pre-treatment plant

O2 + Steam

Quench

Sodium sulfiteraw material

Thank　 You